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NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER INTERNATIONAL.
Chrysler International reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.
FOREWORD
The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Owners Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual. Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed. Chrysler International reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
0 2 5 6 7 8A 8B 8E 8H 8K 8L 8Q 8U 8W 9 13 14 19 21 23 24 25
Lubrication and Maintenance Suspension Brakes Clutch Cooling System Battery Starting System Instrument Panel and Systems Vehicle Speed Control System Wiper and Washer Systems Lamps Vehicle Theft/Security Systems Chime Warning/Reminder System Wiring Diagrams Engine Frame and Bumpers Fuel System2.5L Diesel Engine/2.0L Gas Engine Steering A598 Manual Transaxle Body Heating and Air Conditioning Emission Control System
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INTRODUCTION
INTRODUCTION
CONTENTS
page GENERAL INFORMATION BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . . 1 FASTENER IDENTIFICATION . . . . . . . . . . . . . . . . 4 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . . . . . 4 METRIC SYSTEM . . . . . . . . . . . . . . . . . . . TORQUE REFERENCES . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER . . . . . VEHICLE SAFETY CERTIFICATION LABEL VIN CHECK DIGIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . . . . . . 7 7 1 1 1
INTRODUCTION
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GENERAL INFORMATION (Continued)
DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space
INTRODUCTION
DIGITS 20, 21, AND 22 Engine Code EDZ = 2.4L 4 cyl. DOHC Gasoline EFA = 3.0L 6 cyl. Gasoline EGA = 3.3L 6 cyl. Gasoline EGH = 3.8L 6 cyl. Gasoline
IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will indicate (CTD) When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.
INTRODUCTION
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Fig. 4
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS
The graphic symbols illustrated in the following chart (Fig. 4) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.
FASTENER IDENTIFICATION
FASTENER IDENTIFICATION
THREAD IDENTIFICATION SAE and metric bolt/nut threads are not the same. The difference is described in the Thread Notation chart (Fig. 5). GRADE/CLASS IDENTIFICATION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual
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GENERAL INFORMATION (Continued)
FASTENER IDENTIFICATION
INTRODUCTION
INTRODUCTION
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GENERAL INFORMATION (Continued)
INTRODUCTION
METRIC SYSTEM
WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage metric fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification should be used. The metric system is based on quantities of one, ten, one hundred, one thousand and one million (Fig. 6). The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. Refer to the Conversion Chart to convert torque values listed in metric Newton- meters (Nm). Also, use the chart to convert between millimeters (mm) and inches (in.)
TORQUE REFERENCES
Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifications Chart for torque references not listed in the individual torque charts.
INTRODUCTION
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METRIC CONVERSION
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GENERAL INFORMATION (Continued)
INTRODUCTION
TORQUE SPECIFICATIONS
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INTRODUCTION
INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . . 1 E-MARK LABEL . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL INFORMATION E-MARK LABEL
An E-mark Label (Fig. 1) is located on the rear shut face of the drivers door. The label contains the following information: Date of Manufacture Month-Day-Hour (MDH) Vehicle Identification Number (VIN) Country Codes Regulation Number Regulation Amendment Number Approval Number
INTRODUCTION
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DIGITS 16, 17, AND 18 Vehicle Shell Car Line GSYH = Voyager/Grand Voyager SE FWD GSYP = Voyager/Grand Voyager LE FWD GSYS = Voyager LX FWD GSCP = Voyager/Grand Voyager LE AWD GSCS = Voyager LX AWD DIGIT 19 Price Class H = High Line P = Premium S = Special/Sport
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GENERAL INFORMATION (Continued)
DIGIT 4 Open Space DIGIT 5 Market Code B = International M = Mexico DIGIT 6 Open Space
INTRODUCTION
DIGITS 7 THROUGH 23 Vehicle Identification Number (VIN) Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will indicate continued (CTD). When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.
MANUFACTURER PLATE
The Manufacturer Plate (Fig. 4) is located in the engine compartment on the radiator closure panel crossmember adjacent to the Body Code Plate. The plate contains five lines of information: 1. Vehicle Identification Number (VIN) 2. Gross Vehicle Mass (GVM) 3. Gross Train Mass (GTM) 4. Gross Front Axle Rating (GFAR) 5. Gross Rear Axle Rating (GRAR)
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MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INDEX
page GENERAL INFORMATION CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 1 FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 2 INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1 page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 PARTS AND LUBRICANT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).
CLASSIFICATION OF LUBRICANTS
Only lubricants that are endorsed by the following organization should be used to service a Chrysler Corporation vehicle. Society of Automotive Engineers (SAE) American Petroleum Institute (API) (Fig. 2) National Lubricating Grease Institute (NLGI) (Fig. 3)
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FLUID CAPACITIES
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . .76 L (20 Engine Oil, With Filter . . . . . . . . . . . .4.3 L (4.5 Engine Oil, W/O Filter. . . . . . . . . . . . .3.8 L (4.0 Cooling System 2.4L Engine . . . . . . . .9.0 L (9.5 Cooling System 3.OL Engine . . . . . . .9.5 L (10.5 Cooling System 3.3 or 3.8L Engine . .9.5 L (10.5 Automatic Transaxle Service Fill. . . . .3.8 L (4.0 Automatic Transaxle 31TH/O-haul Fill . . . . . . . . . . . . . . .8.0 L (8.5 Automatic Transaxle 41TE/O-haul Fill . . . . . . . . . . . . . . .8.6 L (9.1 Power Steering . . . . . . . . . . . . . . . . .0.81 L (1.7 gal.) qts.) qts.) qts.) qts.) qts.) qts.) qts.) qts.) pts.)
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MAINTENANCE SCHEDULES
INDEX
page GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 3 SCHEDULE A . . . . . . . . . . . . . . . . . . . . . . . . . . 3 page SCHEDULE B . . . . . . . . . . . . . . . . . . . . . . . . . . 4 UNSCHEDULED INSPECTION . . . . . . . . . . . . . . . 3
At Each Oil Change Inspect exhaust system. Inspect brake hoses Inspect the CV joints and front suspension components Rotate the tires at each oil change interval shown on Schedule A (7,500 miles) or every other interval shown on Schedule B (6,000 miles). Check the coolant level, hoses, and clamps. If your mileage is less than 7,500 miles (12 000 km) yearly, replace the engine oil filter at each oil change. Replace engine oil filter on 2.4L engines.
SCHEDULE A
7,500 Miles (12 000 km) or at 6 months Change engine oil. 15,000 Miles (24 000 km) or at 12 months Change engine oil. Replace engine oil filter. 22,500 Miles (36 000 km) or at 18 months Change engine oil. Inspect brake linings. 30,000 Miles (48 000 km) or at 24 months Change engine oil. Change automatic transmission fluid. Replace engine oil filter. Replace air cleaner element. Inspect tie rod ends and boot seals. 37,500 Miles (60 000 km) or at 30 months Change engine oil. 45,000 Miles (72 000 km) or at 36 months Change engine oil. Replace engine oil filter. Inspect brake linings. Flush and replace engine coolant at 36 months, regardless of mileage.
UNSCHEDULED INSPECTION
At Each Stop for Fuel Check engine oil level, add as required. Check windshield washer solvent and add if required. Once a Month Check tire pressure and look for unusual wear or damage. Inspect battery and clean and tighten terminals as required. Check fluid levels of coolant reservoir, brake master cylinder, power steering and transaxle and add as needed. Check all lights and all other electrical items for correct operation. Check rubber seals on each side of the radiator for proper fit.
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SCHEDULE B
3,000 Miles (5 000 km) Change engine oil. 6,000 Miles (10 000 km) Change engine oil. Replace engine oil filter. 9,000 Miles (14 000 km) Change engine oil. Inspect brake linings. 12,000 Miles (19 000 km) Change engine oil. Replace engine oil filter. 15,000 Miles (24 000 km) Change engine oil. Inspect air cleaner element. Replace as necessary.
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GENERAL INFORMATION (Continued)
Drain and refill automatic transmission fluid and replace filter. Adjust bands, if so equipped. (See note) Change AWD powertransfer fluid unit.
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18,000 Miles (29 000 km) Change engine oil. Replace engine oil filter. Inspect brake linings. 21,000 Miles (34 000 km) Change engine oil. Check AWD overrunning clutch and rear carrier fluid. 24,000 Miles (38 000 km) Change engine oil. Replace engine oil filter. 27,000 Miles (43 000 km) Change engine oil. Inspect brake linings. 30,000 Miles (48 000 km) Change engine oil. Replace engine oil filter. Replace air cleaner element. Inspect PCV valve. Replace as necessary. * Drain and refill automatic transmission fluid and replace filter. Adjust bands, if so equipped. (See note) Change AWD power transfer unit fluid. Inspect tie rod ends and boot seals. 33,000 Miles (53 000 km) Change engine oil. 36,000 Miles (58 000 km) Change engine oil. Replace engine oil filter. Inspect brake linings. 39,000 Miles (62 000 km) Change engine oil. 42,000 Miles (67 000 km) Change engine oil. Replace engine oil filter. Change AWD overrunning clutch and rear carrier fluid. 45,000 Miles (72 000 km) Change engine oil. Inspect air cleaner element. Replace as necessary.
Drain and refill automatic transmission fluid and replace filter. Adjust bands, if so equipped. (See note) Inspect brake linings. Change AWD power transfer unit fluid.
48,000 Miles (77 000 km) Change engine oil. Replace engine oil filter. 51,000 Miles (82 000 km) Change engine oil. Flush and replace engine coolant. 54,000 Miles (86 000 km) Change engine oil. Replace engine oil filter. Inspect brake linings. 57,000 Miles (91 000 km) Change engine oil. 60,000 Miles (96 000 km) Change engine oil. Replace engine oil filter. Replace air cleaner element. Inspect PCV valve, replace if necessary. * Inspect serpentine drive belt, replace if necessary. Drain and refill automatic transmission fluid and replace filter. Adjust bands, if so equipped. (See note) Change AWD power transfer unit fluid. Inspect tie rod ends and boot seals. 63,000 Miles (101 000 km) Change engine oil. Change AWD overrunning clutch and rear carrier fluid. Inspect brake linings. 66,000 Miles (106 000 km) Change engine oil. Replace engine oil filter. 69,000 Miles (110 000 km) Change engine oil. 72,000 Miles (115 000 km) Change engine oil. Replace engine oil filter. Inspect brake linings. 75,000 Miles (120 000 km) Change engine oil. Inspect air cleaner element. Replace as necessary.
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78,000 Miles (125 000 km) Change engine oil. Replace engine oil filter. 81,000 Miles (130 000 km) Change engine oil. Inspect brake linings. Flush and replace engine coolant. 84,000 Miles (134 000 km) Change engine oil. Replace engine oil filter. Change AWD overrunning clutch and rear carrier fluid. 87,000 Miles (139 000 km) Change engine oil. 90,000 Miles (144 000 km) Change engine oil. Replace engine oil filter. Replace air cleaner element. Check PCV valve and replace if necessary. Not required if previously changed. * Inspect serpentine drive belt, replace if necessary. This maintenance is not required if belt was previously replaced. Drain and refill automatic transmission fluid and replace filter. Adjust bands, if so equipped. (See note) Change AWD power transfer unit fluid. Inspect tie rod ends and boot seals. Inspect brake linings. 93,000 Miles (149 000 km) Change engine oil. 96,000 Miles (154 000 km) Change engine oil. Replace engine oil filter. 99,000 Miles (158 000 km) Change engine oil. Inspect brake linings. 102,000 Miles (163 000 km) Change engine oil. Replace engine oil filter.
105,000 Miles (168 000 km) Change engine oil. Inspect air cleaner element. Replace as necessary. Inspect serpentine drive belt, replace if necessary. This maintenance is not required if belt was previously replaced. Drain and refill automatic transmission fluid and filter. Adjust bands, if so equipped. (See note) Change AWD power transfer unit fluid. Change AWD overrunning clutch and rear carrier fluid. 108,000 Miles (173 000 km) Change engine oil. Replace engine oil filter. Inspect brake linings. 111,000 Miles (178 000 km) Change engine oil. Flush and replace engine coolant. 114,000 Miles (182 000 km) Change engine oil. Replace engine oil filter. 117,000 Miles (187 000 km) Change engine oil. Inspect brake linings. 120,000 Miles (192 000 km) Change engine oil. Replace engine oil filter. Replace air cleaner element. Inspect PCV valve. Replace as necessary. * Inspect serpentine drive belt. Not required if replaced at 75,000, 90,000 or 105,000 miles. Drain and refill automatic transmission fluid and replace filter. Adjust bands, if so equipped. Change AWD power transfer unit fluid. Inspect tie rod ends and boot seals. * This maintenance is recommended by Chrysler to the owner but is not required to maintain the warranty on the PCV valve. ** If California vehicle, this maintenance is recommended by Chrysler to the owner but is not required to maintain the warranty of the timing belt.
NOTE: Operating vehicle more than 50% in heavy traffic during hot weather, above 90F (32C), using vehicle for police, taxi, limousine type operation or trailer towing require the more frequent transaxle service noted in Schedule B. Perform these services if vehicle is usually operated under these conditions. Inspection and service should also be performed anytime a malfunction is observed or suspected.
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TO JUMP START A DISABLED VEHICLE: (1) Raise hood on disabled vehicle and visually inspect engine compartment for: Battery cable clamp condition, clean if necessary. Frozen battery. Yellow or bright color test indicator, if equipped. Low battery fluid level. Generator drive belt condition and tension. Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. (2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place
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TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR TOW VEHICLE BY FRONT OR REAR BUMPER, OR BUMPER ENERGY ABSORBER UNITS. DO NOT GO UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY ON SAFETY STANDS. DO NOT ALLOW PASSENGERS TO RIDE IN A TOWED VEHICLE. USE A SAFETY CHAIN THAT IS INDEPENDENT FROM THE TOWING ATTACHMENT DEVICE. CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle. Do not attach towing device to front or rear suspension components. Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers.
LOCKED VEHICLE TOWING When a locked vehicle must be towed with the front wheels on the ground, use a towing dolly or flat bed hauler. FLAT TOWING WITH TOW BAR 3-speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph) for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. 4-speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral. FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching chains or cables to suspension components or engine mounts, damage to vehicle can result. NS vehicles can be tied to a flat bed device using the reinforced loops located under the front and rear bumpers on the drivers side of the vehicle. There are also four reinforced elongated holes for T or R-hooks located on the bottom of the front frame rail torque
RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use of a flat bed towing device or wheel lift (Fig. 2) is recommended. When using a wheel lift towing device, be sure the disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees.
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SERVICE PROCEDURES (Continued)
boxes behind the front wheels and forward of the rear wheels inboard of the rocker panel weld seam.
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SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. CAUTION: Do not position hoisting device on suspension components or front crossmember, damage to vehicle can result. TO HOIST OR JACK VEHICLE SEE (Fig. 3). Vehicles with factory installed ground effects are equipped with front and rear hoisting pads. These pads are stamped, Hoist Point.
TOWINGFRONT WHEEL LIFT Chrysler Corporation recommends that a vehicle be towed with the front end lifted, whenever possible. A 90 cm (36 in.) length of 4x4 wood beam can be placed between the wheel lift device and the bottom of the fascia to prevent damage to vehicle during the lifting operation. The beam can removed after lifting the front of the vehicle. TOWINGREAR WHEEL LIFT If a vehicle cannot be towed with the front wheels lifted, the rear wheels can be lifted provided the following guide lines are observed.
CAUTION: Do not use steering column lock to secure steering wheel during towing operation. On AWD vehicles, all four wheels must be free to rotate. Use towing dollies at unlifted end of vehicle. Unlock steering column and secure steering wheel in straight ahead position with a clamp device designed for towing. 3-speed automatic transaxle vehicles can be flat towed at speeds not to exceed 40 km/h (25 mph) for not more than 25 km (15 miles). The steering column must be unlocked and gear selector in neutral. 4-speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral.
HOISTING RECOMMENDATIONS
Refer to Owners Manual provided with vehicle for proper emergency jacking procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN THE ENGINE OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
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MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INDEX
page GENERAL INFORMATION ENGINE OIL GASOLINE ENGINES . . . . . . . . 1 ENGINE OILDIESEL ENGINES . . . . . . . . . . . . 1 page FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 1 MANUAL TRANSMISSION FLUID (A-558 and A-598 Models) . . . . . . . . . . . . . . . . 1 To assure of properly formulated engine oils, it is recommended that SAE Grade 15W-40 engine oils that meet Chrysler material standard MS-6395, be used. European Grade 10W-40 oils are also acceptable. Oils of the SAE 5W-30 or 10W-30 grade number are preferred when minimum temperatures consistently fall below -12C.
SAE VISCOSITY GRADE To assure of properly formulated engine oils, it is recommended that SAE Grade 5W-30 engine oils that meet Chrysler material standard MS-6395, be used. SAE Grade 10W-30 oils are also acceptable when the temperatures do not fall below 0C. In areas where these grades are not generally available, higher SAE grades may be used. Lubricants which have both an SAE grade number and the proper API service classification shown on the container should be used.
FLUID CAPACITIES
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 L 2.0L Gasoline Engine Oil with Filter . . . . . . . . 4.3L 2.5L VM Diesel Engine Oil With Filter . . . . . . 6.5 L 2.0L Gasoline Engine Cooling System* . . . . . . . 6.0L 2.5L VM Diesel Engine Cooling System* . . . . 10.0 L Transmission5-Speed Manual . . . . . . . . . . . . 2.2 L * Includes heater and coolant recovery tank filled to Max level. Add 2.76L if equipped with Rear Heater.
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MAINTENANCE SCHEDULES
INDEX
page GENERAL INFORMATION MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . 2 MAINTENANCE SCHEDULE DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 2 page SCHEDULEA (DIESEL) . . . . . . . . . . . . . . . . . . 2 SCHEDULEB (DIESEL) . . . . . . . . . . . . . . . . . . 3 UNSCHEDULED INSPECTION . . . . . . . . . . . . . . 2
Check fluid levels of coolant reservoir, brake master cylinder, power steering and transaxle and add as needed. Check all lights and all other electrical items for correct operation. Check rubber seals on each side of the radiator for proper fit.
At Each Oil Change Inspect exhaust system. Inspect brake hoses Inspect the CV joints and front suspension components Rotate the tires at each oil change interval shown on ScheduleA (7,500 miles) or every other interval shown on Schedule B (6,000 miles). Check the coolant level, hoses, and clamps. If your mileage is less than 7,500 miles (12 000 km) yearly, replace the engine oil filter at each oil change. Replace engine oil filter.
SCHEDULEA (DIESEL)
1 000 KM Change engine oil. Change engine oil filter. Check all fluid levels. Check correct torque, intake manifold mounting nuts. Check correct torque, exhaust manifold mounting nuts. Check correct torque, turbocharger mounting nuts. Check correct torque, water manifold bolts. 10 000 KM Change engine oil. Change engine oil filter. 20 000 KM Change engine oil. Change engine oil filter. Replace air filter element.
UNSCHEDULED INSPECTION
At Each Stop for Fuel Check engine oil level, add as required. Check windshield washer solvent and add if required. Once a Month Check tire pressure and look for unusual wear or damage. Inspect battery and clean and tighten terminals as required.
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GENERAL INFORMATION (Continued)
Check drive belt tension. Check glow plug operation.
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30 000 KM Change engine oil. Change engine oil filter. 40 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. Replace fuel filter/water separator element.** 50 000 KM Change engine oil. Change engine oil filter. 60 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check glow plug operation. Replace drive belt. Check engine smoke. Replace engine coolant. 70 000 KM Change engine oil. Change engine oil filter. 80 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. Replace fuel filter/water separator element.** 90 000 KM Change engine oil. Change engine oil filter. 100 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation.
EVERY 10 000 KM AFTER 100 000 KM Change engine oil. Change engine oil filter. EVERY 20 000 KM AFTER 100 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation.
SCHEDULEB (DIESEL)
500 KM Check nuts. Check ing nuts. Check nuts. Check
correct torque, intake manifold mounting correct torque, exhaust manifold mountcorrect torque, turbocharger mounting correct torque, water manifold bolts.
1 000 KM Change engine oil. Change engine oil filter. Check all fluid levels. 5 000 KM Change engine oil. Change engine oil filter. 10 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. 15 000 KM Change engine oil. Change engine oil filter. 20 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. 25 000 KM Change engine oil. Change engine oil filter. 30 000 KM Change engine oil. Change engine oil filter. Replace air filter element.
EVERY 40 000 KM AFTER 80 000 KM Replace fuel filter/water separator element.** **The fuel filter/water separator element should be replaced once a year if the vehicle is driven less than 40 000 km annually or if power loss from fuel starvation is detected.
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75 000 KM Change engine oil. Change engine oil filter. 80 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check glow plug operation. Replace drive belt. Check engine smoke. Replace engine coolant. 85 000 KM Change engine oil. Change engine oil filter. 90 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. 95 000 KM Change engine oil. Change engine oil filter. 100 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. Diesel engines onlyReplace fuel filter/water separator element. Change MTX fluid EVERY 5 000 KM AFTER 100 000 KM Change engine oil. Change engine oil filter. EVERY 10 000 KM AFTER 100 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. EVERY 20 000 KM AFTER 100 000 KM Diesel engines onlyReplace fuel filter/water separator element. EVERY 35 000 KM AFTER 100 000 KM Change MTX fluid
35 000 KM Change engine oil. Change engine oil filter. Change MTX Fluid 40 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. Diesel engines onlyReplace fuel filter/water separator element. 45 000 KM Change engine oil. Change engine oil filter. 50 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. 55 000 KM Change engine oil. Change engine oil filter. 60 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. Diesel engines onlyReplace fuel filter/water separator element. 65 000 KM Change engine oil. Change engine oil filter. 70 000 KM Change engine oil. Change engine oil filter. Replace air filter element. Check drive belt tension. Check glow plug operation. Change MTX fluid
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LOCKED VEHICLE TOWING When a locked vehicle must be towed with the front wheels on the ground, use a towing dolly or flat bed hauler. FLAT TOWING WITH TOW BAR 4-speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral. FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching chains or cables to suspension components or engine mounts, damage to vehicle can result.
RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use of a flat bed towing device or wheel lift (Fig. 1) is recommended. When using a wheel lift towing device, be sure the disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees.
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TOWINGTOW HOOKS
TOWINGFRONT WHEEL LIFT Chrysler International recommends that a vehicle be towed with the front end lifted, whenever possible. A 90 cm (36 in.) length of 4x4 wood beam can be placed between the wheel lift device and the bottom of the fascia to prevent damage to vehicle during the lifting operation. The beam can removed after lifting the front of the vehicle. TOWINGREAR WHEEL LIFT If a vehicle cannot be towed with the front wheels lifted, the rear wheels can be lifted provided the following guide lines are observed.
CAUTION: Do not use steering column lock to secure steering wheel during towing operation. On AWD vehicles, all four wheels must be free to rotate. Use towing dollies at unlifted end of vehicle. Unlock steering column and secure steering wheel in straight ahead position with a clamp device designed for towing. 4-speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km/h (44 mph) for not more than 160 km (100 miles). The steering column must be unlocked and gear selector in neutral.
Fig. 2
WARNING: Do not use the tow hook to lift the vehicle off the ground. A tow-hook bolt, located in the rear interior trim storage compartment (with jack), is provided with your vehicle. The tow hook is used for towing the vehicle with all four wheels on the ground only. It can be attached to the vehicle through an opening in the lower front fascia. The tow hook must be fully seated to the attach bracket through the lower front fascia as shown. If the tow hook is not fully seated to the attach bracket the vehicle should not be towed. NOTE: The tow hook bolt protective plug must be removed from the tow hook bracket prior to bolt attachment. The tow hook is used ONLY for towing the vehicle with all four wheels on the ground.
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CONTENTS
page page
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1
WHEEL ALIGNMENT
INDEX
page DESCRIPTION AND OPERATION GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING PRE-WHEEL ALIGNMENT INSPECTION . . . . . . . 4 SUSPENSION AND STEERING DIAGNOSIS . . . . 3 page SERVICE PROCEDURES WHEEL ALIGNMENT CHECK AND ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . 4 SPECIFICATIONS ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . 7 cations recommended by Chrysler Corporation should always be used. The Chrysler Corporation recommended alignment specifications, are listed in Specifications at the end of this group in the service manual section. There are six basic factors which are the foundation to front wheel alignment. These are vehicle height, caster, camber, toe-in, steering axis inclination and toe-out on turns. Of the six basic factors only toe-in is normally mechanically adjustable on this vehicle (Fig. 1).
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POSSIBLE CAUSES
1. Defective wheel bearing 2. Incorrect wheel alignment 3. Worn tires 1. Defective wheel bearing 2. Engine mount grounding 3. 4. 5. 6. 7. Worn or broken C/V joint Loose wheel lug nuts Incorrect wheel alignment Worn tires Front strut pin in upper strut mount Loose lug nuts Worn or broken C/V joint Worn or loose tie rod Worn or loose ball joint Worn/loose control arm bushing Loose stabilizer bar.
CORRECTION
1. Replace wheel bearing 2. Check and reset wheel alignment 3. Replace tires 1. Replace wheel bearing 2. Check for motor mount hitting frame rail and reposition engine as required 3. Replace C/V joint 4. Verify wheel lug nut torque 5. Check and reset wheel alignment 6. Replace tires 7. Replace the front strut upper mount and bearing 1. Verify wheel lug nut torque 2. Replace C/V joint 3. Tighten or replace tie rod end 4. Tighten or replace ball joint 5. Replace control arm bushing 6. Tighten stabilizer bar to specified torque 7. Tighten strut attachment to specified torque 8. Tighten crossmember bolts to specified torque 1. Replace wheel bearing 2. Check and reset wheel alignment 3. Replace tires 4. Replace transaxle gears or bearings 1. Reposition engine as required 2. Replace C/V joint 1. Replace transaxle gears or bearings 1. Replace engine mount 2. Replace transaxle gears or bearings 3. Verify wheel lug nut torque 4. Replace C/V joint 5. Tighten or replace ball joint 6. Replace control arm bushing 7. Tighten crossmember bolts to specified torque 8. Replace tie rod end
1. 2. 3. 4. 5. 6.
7. Loose strut mount to body attachment 8. Loose crossmember bolts Front End Whine With Vehicle Going Straight At A Constant Speed 1. Defective wheel bearing 2. Incorrect wheel alignment 3. Worn tires 4. Worn or defective transaxle gears or bearings Front End Growl Or Grinding With Vehicle Going Straight At A Constant Speed Front End Whine When Accelerating Or Decelerating Front End Clunk When Accelerating Or Decelerating 1. Engine mount grounding 2. Worn or broken C/V joint 1. Worn or defective transaxle gears or bearings 1. Worn or broken engine mount 2. Worn or defective transaxle gears or bearings 3. Loose lug nuts 4. Worn or broken C/V joint 5. Worn or loose ball joint 6. Worn or loose control arm bushing 7. Loose crossmember bolts 8. Worn tie rod end
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POSSIBLE CAUSES
1. Incorrect tire pressure 2. Incorrect front or rear wheel toe 3. Worn wheel bearings 4. Worn control arm bushings 5. Excessive friction in steering gear 6. Excessive friction in steering shaft coupling 7. Excessive friction in strut upper bearing
CORRECTION
1. Inflate tires to recommended pressure 2. Check and reset wheel toe 3. Replace wheel bearing 4. Replace control arm bushing 5. Replace steering gear 6. Replace steering coupler 7. Replace strut bearing 1. Inflate all tires to recommended pressure 2. Perform lead correction procedure 3. Check and reset front wheel camber 4. Replace power steering gear 5. Correct braking condition causing lateral pull 1. Adjust Or Replace Steering Gear 2. Replace or tighten tie rod ends 3. Tighten steering gear bolts to specified torque 4. Replace steering shaft coupler 1. Inflate all tires to recommended pressure 2. Replace steering gear 3. Fill power steering fluid reservoir to correct level 4. Correctly adjust power steering pump drive belt 5. Lubricate or replace ball joints 6. Replace steering gear 7. Replace steering coupler
Lateral Pull
1. Unequal tire pressure 2. Radial tire lead 3. Incorrect front wheel camber 4. Power steering gear imbalance 5. Wheel braking
1. Incorrect Steering Gear Adjustment 2. Worn or loose tie rod ends 3. Loose steering gear mounting bolts 4. Loose or worn steering shaft coupler
1. Low tire pressure 2. Lack of lubricant in steering gear 3. Low power steering fluid level 4. Loose power steering pump drive belt 5. Lack of lubricant in ball joints 6. Steering gear malfunction 7. Lack of lubricant in steering coupler
(5) Check vehicle ride height to verify it is within specifications. (6) Alignment MUST only be checked after the vehicle has the following areas inspected and or adjusted. Recommended tire pressures, full tank of fuel, no passenger or luggage compartment load and is on a level floor or a properly calibrated alignment rack.
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SERVICE PROCEDURES (Continued)
mounting location of the vehicles suspension components throughout the design and assembly processes of the vehicle. This is called a Net Build vehicle and results in no normal requirement to adjustment the Caster and Camber after a vehicle is built or when servicing the suspension components. Thus Caster and Camber are not normally considered an adjustable specification when performing an alignment on this vehicle. Though Caster and Camber are not adjustable they should be checked during the alignment procedure to ensure they meet the manufacturers specifications. If front camber does not meet the vehicle alignment specifications, it can be adjusted using a Mopar Service Kit developed to allow for camber adjustment. If a vehicles front camber does not meet required specifications, the vehicles suspension components should be inspected for any signs of damage or bending and the vehicle ride height should be checked to verify it is within required specification. This inspection must be done before using the Mopar Service Kit for setting camber to the vehicle specification. CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating, bending or by performing any other modification to the vehicles front suspension components. (1) Correctly position the vehicle on the alignment rack. Then install all required alignment equipment on the vehicle, per the alignment equipment manufacturers specifications. NOTE: Prior to reading each alignment specification, front and rear of vehicle should be jounced an equal number of times. Induce jounce (rear first then front) by grasping center of bumper and jouncing each end of vehicle an equal number of times. Bumper should always be released when vehicle is at the bottom of the jounce cycle. (2) Correctly jounce vehicle and then read the vehicles current front and rear alignment settings. Compare the vehicles current alignment settings to the vehicle specifications for camber, caster and Toein. See Alignment Specifications in this group of the service manual for the required specifications. If front and rear camber readings are within required specifications proceed to step Step 3 for the Toe-in adjustment procedure if required. If Camber readings are not within specifications refer to step Step 1 in the front camber adjustment cam bolt adjustment procedure.
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CAMBER ADJUSTMENT CAM BOLT PACKAGE INSTALLATION PROCEDURE (1) If the front camber readings obtained are not within the vehicles specifications, use the following procedure and the Mopar Clevis Bolt Service Kit to provide camber adjustment. The kit contains 2 flange bolts, 2 cam bolts, and 2 dog bone washers. These components of the service kit are necessary to assemble the strut to the steering knuckle, after modification of the strut clevis bracket. (2) Verify that the strut and steering knuckle are not bent or otherwise damaged. If either component is bent or show other signs of damage, replace required component(s) and check the camber setting again. Refer to Strut Damper Assembly Service in this group of the service manual for the required strut replacement procedure. (3) If no component is bent or damaged, use the following procedure for modifying the strut clevis bracket and adjusting the camber setting. (4) Raise front of vehicle until tires are not supporting the weight of the vehicle. Then remove wheel and tire assembly from the location on the vehicle requiring the strut to be modified. CAUTION: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to support the steering knuckle assembly or if required remove the brake flex hose from the caliper assembly. CAUTION: The steering knuckle strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. (5) Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts (Fig. 2) and discard. Separate the steering knuckle from the strut clevis bracket and position steering knuckle so it is out of the way of the strut. CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the hole beyond the indentations (Fig. 3) on the sides of the strut clevis bracket.
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SERVICE PROCEDURES (Continued)
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(3) Loosen front inner to outer tie rod end jam nuts (Fig. 7). Grasp inner tie rods at serrations and rotate inner tie rods of steering gear (Fig. 7) to set front Toe to the preferred Toe specification. See Alignment Specifications in this group of the service manual for preferred specification.
FRONT TOE SETTING PROCEDURE (1) Prepare vehicle as described in the Pre-Alignment Vehicle Inspection procedure. (2) Center steering wheel and lock in place using a steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment.
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SPECIFICATIONS (Continued)
ALIGNMENT ANGLE TIRE SIZES
P205/75/R14 P215/65/R15 * FRONT INDIVIDUAL CAMBER IN +0.15 +or- 0.40 DEGREES............................................ Front Side To Side Camber Difference Not To Exceed................... 0.00 - 0.50 MAX
TIRE SIZES
P205/75/R15 P215/65/R16 +0.05 +or- 0.40 0.00 - 0.50 MAX +1.40 + or - 1.00 0.00 - 1.00 MAX
ALTERNATIVE FUELS
C.N.G. ELECTRIC +0.15 +or- 0.40 0.00 - 0.50 MAX +1.40 +or- 1.00 0.00 - 1.00 MAX
** FRONT INDIVIDUAL CASTER IN +1.40 + or - 1.00 DEGREES............................................ Front Side To Side Caster Difference Not To Exceed..................................... *** FRONT INDIVIDUAL TOE RIGHT/ LEFT......................................... FRONT TOTAL TOE.................................................... Specified In Degrees 0.00 - 1.00 MAX
+0.05+or- 0.10
FRONT SIDE TO SIDE TOE 0.00 - 0.06 MAX DIFFERENTIAL..................................... ****REAR INDIVIDUAL CAMBER IN +0.00 +or- 0.25 DEGREES............................................ REAR INDIVIDUAL TOE RIGHT/ LEFT........................................ **** REAR TOTAL TOE..................... Specified In Degrees TOE OUT: When Backed On Alignment Rack Is TOE In When Driving ****REAR THRUST ANGLE................ STEERING WHEEL ANGLE................ 0.00 +or- 0.40 0.00 +or- 0.40
0.00 - 0.06 MAX +0.00 +or- 0.25 0.00 +or- 0.40 0.00 +or- 0.40
0.00 - 0.06 MAX -0.10 +or- 0.25 0.00 +or- 0.40 0.00 +or- 0.40
FRONT RIDE HEIGHT (MEASURED 747.5 mm +or-10.0mm AT TOP OF FENDER WHEEL OPENING)............................................ FRONT RIDE HEIGHT SIDE TO 0.0 mm 12.5 mm MAX SIDE DIFFERENTIAL..................................... *****REAR RIDE HEIGHT 766.0 mm +or-10.0mm (MEASURED AT TOP OF FENDER WHEEL OPENING)............................................ *****REAR RIDE HEIGHT SIDE TO 0.0 mm 12.5 mm MAX SIDE DIFFERENTIAL.....................................
772.0 mm +or-10.0mm
802.5 mm +or-10.0mm
* Camber is adjustable using the Mopar Camber Adjustment Service Kit. Refer to the Mopar Parts Catalog for the required service kit part number. ** Caster is not adjustable. If found to be out of specification check for proper ride heights and damaged/worn out suspension components and replace as necessary. *** Toe-In is positive. **** Toe, Camber and thrust angle are not adjustable. If found to be out of specification check for proper ride heights and damaged/worn out suspension components and replace as necessary. ***** When Measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification check for damaged and/or worn out suspension components and replace as necessary.
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FRONT SUSPENSION
INDEX
page DESCRIPTION AND OPERATION BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 FRONT SUSPENSION DESCRIPTION . . . . . . . . . 9 HUB AND BEARING ASSEMBLY . . . . . . . . . . . . 10 LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . 10 Mc PHERSON STRUT ASSEMBLY . . . . . . . . . . . 10 STABILIZER BAR ATTACHING LINK . . . . . . . . . . 10 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 10 STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 10 SUSPENSION CRADLE (CROSSMEMBER) . . . . . 9 WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING BALL JOINT (LOWER) . . . . . . . . . . . . . . . . . . . . 12 HUB AND BEARING ASSEMBLY . . . . . . . . . . . . 12 LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . 12 Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . . . 11 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 12 STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 12 SERVICE PROCEDURES SUSPENSION CRADLE THREAD REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL MOUNTING STUDS . . . . . . . HUB AND BEARING ASSEMBLY . . . . . . . . . . LOWER CONTROL ARM . . . . . . . . . . . . . . . . Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . REAR WHEEL MOUNTING STUDS . . . . . . . . STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . STEERING KNUCKLE . . . . . . . . . . . . . . . . . . DISASSEMBLY AND ASSEMBLY BALL JOINT SEAL BOOT . . . . . . . . . . . . . . . . LOWER CONTROL ARM FRONT BUSHING . . LOWER CONTROL ARM REAR BUSHING . . . Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . STABILIZER BAR BUSHING . . . . . . . . . . . . . . SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUES SPECIAL TOOLS FRONT SUSPENSION . . . . . . . . . . . . . . . . . . page
. . 12 . . . . . . . . . . . . . . . . . . . . . . . . . . 22 28 25 19 13 29 23 14 33 34 35 30 35
. . 36 . . 37
attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has the power steering hoses and the chassis brake tubes attached to it. The cradle is mounted to the front frame rails at four points, two on each side of the vehicle. The cradle is isolated from the body of the vehicle using four isolators, one located at each mounting bolt location. WARNING: If a threaded hole in the suspension cradle needs to be repaired, only use the type of thread insert and installation procedure specified for this application. The threaded holes in the cradle that are used for attachment of the lower control arm rear bushing retainer, power steering hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil thread insert which has been specifically developed for this application. Refer to the Mopar Parts Catalog for the specified Heli-Coil thread insert to be used for this application. The procedure for installing the Heli-Coil thread insert is detailed in the Service Procedures section in this group of the service manual.
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using a pivot bolt through the center of the front pivot bushing, and a retainer which traps the rear bushing in the crossmember. The ball joint is pressed into the control arm and has a non-tapered stud with a notch for clamp bolt clearance. The stud is clamped and locked into the steering knuckle leg with a clamp bolt. The ball joint is lubricated for the life of the vehicle and does not require any periodic lubrication.
STABILIZER BAR
The stabilizer bar interconnects both Mc Pherson strut assemblies of the vehicle and is attached through rubber isolator bushings to the front suspension cradle Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel to stabilize body roll. Attachment of the stabilizer bar to the front suspension cradle is through 2 rubber-isolator bushings and bushing retainers. The stabilizer bar to Mc Pherson strut assembly attachment is done utilizing a sway bar attaching link. All parts of the stabilizer bar are serviceable, and the stabilizer bar to crossmember bushings are split for easy removal and installation. The split in the stabilizer bar to crossmember bushing should be positioned toward the rear of the vehicle, with the square corner down toward the ground, when the stabilizer bar is installed in the vehicle.
STEERING KNUCKLE
The steering knuckle (Fig. 1) is a single casting with legs machined for attachment of the strut damper, steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has the front hub/bearing assembly mounted to it. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub.
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DESCRIPTION AND OPERATION (Continued)
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COIL SPRING
Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. During service procedures when both springs are removed, mark springs to ensure installation in original position. Each coil spring comes with a plastic sleeve on the second coil of the spring. This plastic sleeve is a noise insulator for the coil spring. NOTE: If coil springs require replacement, be sure that the springs needing replacement, are replaced with springs meeting the correct load rating for the vehicle and its specific options.
knuckle to replace the wheel attaching studs in the hub and bearing assembly.
BALL JOINT
The ball joint (Fig. 2) is pressed into the lower control arm. The ball joint has a non-tapered stud with a notch (Fig. 2) to provide clearance for the steering knuckle clamp bolt and to provide retention of the ball stud in the steering knuckle. The ball joint stud is clamped and locked into the steering knuckle leg using a pinch bolt. The ball joint used on this vehicle is replaceable and if found defective can be serviced as a separate component of the lower control arm assembly.
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STEERING KNUCKLE
The front suspension knuckle is not a repairable component of the vehicles front suspension IT MUST BE REPLACED. If bent, broken or damaged in any way, do not attempt to straighten or repair the steering knuckle. Service replacement of the front hub/bearing assembly can be done with the front steering knuckle remaining on the vehicle.
STABILIZER BAR
Inspect for broken or distorted sway bar bushings, bushing retainers, and worn or damaged sway bar to strut attaching links. If sway bar to front suspension cradle bushing replacement is required, bushing can be removed from sway bar by opening slit and peeling bushing off sway bar.
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SERVICE PROCEDURES (Continued)
instructions included with the thread insert for the detailed procedure used for the installation of the thread insert. NOTE: The thread inserts for this application are for the repair of M8x1.25 and M10x1.5 threads. Be sure the correct tools are used for the required thread insert size.
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TOOL REQUIREMENT FOR M8x1.25 Thread 8.3mm (5/16 in.) Drill Bit 120 Countersink Heli-Coil Tap #4863-8 Heli-Coil Gage #4624-8 Heli-Coil Hand Inserting Tool 7751-8 Needle Nose Pliers For Removal Of Thread Insert Driving Tang TOOL REQUIREMENT FOR M10x1.5 Thread 10.5mm (25/64 in.) Drill Bit 120 Countersink Heli-Coil Tap #4863-10 Heli-Coil Gage #4624-10 Heli-Coil Hand Inserting Tool 7751-10 Needle Nose Pliers For Removal Of Thread Insert Driving Tang
INSTALLATION (1) Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in shock tower. Install the 3 upper strut mount attaching nut/washer assemblies (Fig. 9). Then using a crow foot. tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.).
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STEERING KNUCKLE
REMOVE (1) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication And Maintenance Section of this manual for the required lifting procedure to be used for this vehicle. (2) Remove the cotter pin and nut lock (Fig. 11) from the end of the stub axle. (3) Remove the wheel and tire assembly from the vehicle. (4) Remove the wave washer (Fig. 12) from the end of the stub axle
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(14) Remove the steering knuckle to ball joint stud, clamping nut and bolt (Fig. 21) from the steering knuckle.
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Fig. 23 Steering Knuckle Separation From Driveshaft Fig. 21 Control Arm To Steering Knuckle Attachment
(15) Using a pry bar, separate steering knuckle from ball joint stud (Fig. 22). Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. (17) Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts (Fig. 24).
INSTALL (1) Transfer, or install if necessary, a new hub/ bearing assembly into the steering knuckle. Refer to Hub And Bearing Assembly Service in this section of the service manual for the required removal and installation procedure for the front hub/bearing assembly.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles.
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REMOVAL AND INSTALLATION (Continued)
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NOTE: The attaching bolts for the cradle plate are of two different thread sizes. Nine of the bolts are a M-14 thread and one of the bolts is a M-12 thread. Refer to (Fig. 30) for the cradle plate attaching bolt locations. (5) Remove the 10 bolts (Fig. 30) attaching the cradle plate to the front suspension cradle. Then remove the cradle plate from the cradle.
(6) Using a pry bar, separate steering knuckle from ball joint stud (Fig. 31). Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut.
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Fig. 34 Suspension Cradle To Frame Rail Mounting Bolts Fig. 32 Lower Control Arm Bushing To Cradle Pivot Bolt
(8) Remove retainer (Fig. 33) attaching rear bushing of lower control arm to front suspension cradle. to be lowered for the pivot bolt to clear the transaxle. (10) Lower the left front corner of the suspension cradle until pivot bolt will clear end of transaxle (Fig. 35). Remove the pivot bolt and the lower control arm from the cradle.
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REMOVAL AND INSTALLATION (Continued)
suspension cradle (Fig. 36). Do not tighten or torque pivot bolt at this time.
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(5) Install lower control arm ball joint stud into steering knuckle. Then install the bolt and nut, clamping the steering knuckle to the ball joint stud (Fig. 29). Tighten the clamping bolt to a torque of 145 Nm (105 ft. lbs.). (6) Install the cradle plate on front suspension cradle and then install the 10 cradle plate to cradle attaching bolts (Fig. 30). Tighten the 9 M-14 attaching bolts (Fig. 30) to a torque of 165 Nm (123 ft. lbs.). Tighten the 1 M-12 attaching bolt (Fig. 30) to a torque of 108 Nm (80 ft. lbs.). CAUTION: When locating jack stands under lower control arm, do not place the jack stands under the ball joints (Fig. 38). (7) Position jack stands under the lower control arms as close to the ball joints as possible (Fig. 38). Lower the vehicle onto the jack stands, until the jack stands are supporting the total weight of the vehicle (Fig. 38).
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BALL JOINT
REMOVE (1) Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly (Fig. 39)
INSTALL
NOTE: When installing ball joint in lower control arm, position the ball joint in control arm so notch in ball joint stud is in the direction shown (Fig. 41). This will ease assembly of the ball joint to the steering when installing pinch bolt.
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REMOVAL AND INSTALLATION (Continued)
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STABILIZER BAR
REMOVE (1) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle.
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INSTALL (1) If the stabilizer bar to front suspension cradle bushings require replacement at time of inspection, install new bushings before installing stabilizer bar. Bushings are replaced by opening slit on bushings and peeling them off stabilizer bar. Install new bushings on stabilizer bar by spreading bushing at slit and forcing them on the stabilizer bar. Bushings must be installed on stabilizer bar so slit in bushing will be facing toward the rear of vehicle with the square corner toward the ground,
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REMOVAL AND INSTALLATION (Continued)
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(1) Remove the cotter pin, and nut lock from the stub axle (Fig. 52).
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Fig. 56 Supporting Brake Caliper Fig. 54 Front Disc Brake Caliper Mounting Bolts
(7) Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle, and then removing bottom of caliper out from under machined abutment. (Fig. 55) (8) Support disc brake caliper assembly using a wire hook, (Fig. 56) do not hang caliper assembly by hydraulic hose. (9) Remove the braking disc from the front hub/ bearing assembly. (10) Remove the retaining nut and the washer (Fig. 57) from the end of the stub axle. (11) Remove the four hub and bearing assembly mounting bolts from the rear of steering knuckle (Fig. 58). (12) Remove the hub and bearing assembly from the steering knuckle (Fig. 59).
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stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature hub and bearing failure. The following procedure and special tools shown MUST be used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the rear axle for replacement of the wheel attaching studs. (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this manual, for the required lifting procedure to be used for this vehicle. (2) Remove the rear wheel and tire assembly. (3) Remove the rear brake drum. (4) Install a lug nut on the wheel stud to be removed from the hub and bearing assembly (Fig. 66) so the threads on stud are even with end of lug nut. Install Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud (Fig. 66).
INSTALL (1) Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers (Fig. 67). (2) Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud.
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(8) Remove the dust shield and jounce bumper (Fig. 73) as an assembly from the strut shaft. The dust shield can not be removed from the jounce bumper until after it is removed from strut shaft.
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ASSEMBLY (1) Clamp strut in vise, with strut in vertical position. Do not clamp strut in vise by body of strut, only by the clevis bracket (Fig. 68). (2) Install the spring isolator on the strut lower spring seat (Fig. 74). When installing the spring isolator, be sure the 2 retaining tabs on the spring isolator (Fig. 74) are installed in the 2 holes in the spring seat. When properly installed, the oversize holes in the spring seat should line up with the holes in the spring isolator. (3) Install the jounce bumper (Fig. 75) on the strut shaft. Jounce bumper is to be installed with the small end of the jounce bumper pointing down (Fig. 75).
Fig. 77 Coil Spring And Spring Seat Correctly Installed Fig. 75 Correctly Installed Jounce Bumper
(4) Install dust shield (Fig. 76) on the strut. After dust shield is installed on strut, collapse dust shield down on top of jounce bumper until jounce bumper snaps into dust shield. Then return the dust shield to its fully extended length. (5) Install coil spring on strut. Spring is to be installed with the end of the bottom coil aligned with the clevis bracket on the strut assembly (Fig. 77). (6) Install the upper spring seat on the coil spring (Fig. 77). Spring seat must be installed with the notch in the spring seat (Fig. 77) aligned with the clevis bracket on the strut. WARNING: WHEN COMPRESSING THE COIL SPRING, THE COIL SPRING UPPER SEAT AND THE BOTTOM COIL OF THE SPRING MUST BE CAPTURED BY THE JAWS OF THE COIL SPRING COMPRESSOR. (7) Compress strut coil spring using Pentastar Service Equipment Spring Compressor, 7522A (Fig. 69). Be sure the top and bottom attachment shoe selected, (Fig. 69) properly fit the coil spring. (8) Install the pivot bearing on the top of the upper spring seat (Fig. 78). Bearing must be installed on spring seat with the smaller diameter side of the pivot bearing toward the spring seat (Fig. 78). Also, be sure the pivot bearing is sitting flat on the spring seat. (9) Install the strut mount on the upper spring seat of the strut. Loosely install the nut on strut shaft. WARNING: THE FOLLOWING 2 STEPS MUST BE COMPLETELY DONE BEFORE SPRING COMPRESSOR IS RELEASED FROM THE COIL SPRING.
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DISASSEMBLY AND ASSEMBLY (Continued)
INSTALL
SUSPENSION
2 - 33
CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield (Fig. 80) on the ball joint seal must be positioned as shown. (1) Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to be with the shield positioned as shown (Fig. 80).
2 - 34
SUSPENSION
NS
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DISASSEMBLY AND ASSEMBLY (Continued)
the Nut, Special Tool 69083 (Fig. 84). This will pull the front bushing into the lower control arm. (5) Continue pulling the bushing into the lower control arm until bushing is seated squarely against the lower control arm and there is no gap between the bushing and the lower control arm (Fig. 85).
SUSPENSION
2 - 35
2 - 36
SUSPENSION
NS
NS
SUSPENSION
2 - 37
Remover Tie Rod End MB991113 Wrench Strut Rod Nut 6864
2 - 38
SUSPENSION
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REAR SUSPENSION
INDEX
page GENERAL INFORMATION REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION REAR TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL ALIGNMENT . . . . . . . . . . . . . . . . SHOCK ABSORBERS (REAR LOAD LEVELING) . STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION JOUNCE BUMPER . . . . . . . . . . . . . . . . . . . . . . . LEAF SPRING FRONT MOUNT . . . . . . . . . . . . . LEAF SPRING REAR MOUNT . . . . . . . . . . . REAR SPRINGS (AWD) . . . . . . . . . . . . . . . . REAR SPRINGS (FWD) . . . . . . . . . . . . . . . . REAR TRACK BAR . . . . . . . . . . . . . . . . . . . . SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . TRACK BAR MOUNT . . . . . . . . . . . . . . . . . . SPECIFICATIONS REAR SUSPENSION FASTENER TORQUES . . . . . . . . . . . . . . page . . . . . . . 47 43 40 45 45 46 45
38 39 39 40 39 46 47
. . . 48
The rear axle used on front wheel drive applications of this vehicle is mounted to the rear leaf springs using isolator bushings at the axle mounting brackets. The rear axle used on all wheel drive applications of this vehicle is also mounted to the rear leaf springs but does not use isolator bushings between the rear axle and the leaf springs.
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GENERAL INFORMATION (Continued)
SUSPENSION
2 - 39
STABILIZER BAR
The stabilizer bar (Fig. 4) interconnects both sides of the rear axle and attaches to the rear frame rails using 2 rubber isolated link arms. Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel to reduce body roll.
2 - 40
SUSPENSION
NS
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REMOVAL AND INSTALLATION (Continued)
NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle).
SUSPENSION
2 - 41
2 - 42
SUSPENSION
NS
INSTALLATION (1) Assemble front spring mount to front of spring eye and install pivot bolt and nut. Do not tighten.
CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring. (2) Raise front of spring and install four hanger bolts, tighten to 61 Nm (45 ft. lbs.) torque. (3) Install rear of spring onto rear spring shackle. Install shackle plate. Do not tighten. (4) Verify lower leaf spring isolator is in position. (5) Raise axle into correct position on leaf spring with axle centered under spring locator post (Fig. 12).
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REMOVAL AND INSTALLATION (Continued)
SUSPENSION
2 - 43
2 - 44
SUSPENSION
NS
INSTALL
CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring. (1) Install the front of the rear leaf spring into the spring mount (Fig. 18). Install the pivot bolt and nut. Do not tighten the pivot bolt at this time. (2) Position the front spring mount for the rear leaf spring against the floor pan of the vehicle. Install the 4 mounting bolts for the spring mount. Tighten the 4 mounting bolts to a torque of 61 Nm (45 ft. lbs.). (3) Install the rear of the leaf spring onto the outer half of the rear hanger. Install the inner half of the rear hanger. Install the nut and bolts on the rear hanger but do not tighten at this time. (4) Raise axle assembly into correct position with axle centered under spring locator post. (5) Install axle plate bolts. Tighten bolts to 108 Nm (80 ft. lbs.) torque. (6) Install shock absorber bolts. Do not tighten. (7) Lower vehicle to floor and with full weight of vehicle on wheels. Tighten component fasteners as follows: CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque shown below. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the torque specification listed below. This sequence must be followed to properly seat the bushings into the springs and to avoid bending the spring hanger. Front pivot bolt-156 Nm (115 ft. lbs.) Rear spring hanger pin nuts-61 Nm (45 ft. lbs.) Rear spring hanger inner to outer half retaining bolts-61 Nm (45 ft. lbs.) Shock absorber upper mounting bolt-115 Nm (85 ft. lbs.) Shock absorber lower mounting bolt-108 Nm (80 ft. lbs.) (8) If the vehicle is not equipped with antilock brakes, raise vehicle and connect the actuator for the height sensing proportioning valve on the rear leaf spring. Adjust the height sensing proportioning valve. Refer to the Adjustment Section in this group of the service manual for the required adjustment procedure.
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REMOVAL AND INSTALLATION (Continued)
SUSPENSION
2 - 45
SHOCK ABSORBER
REMOVE/INSTALL (1) Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. See Hoisting in the Lubrication And Maintenance section of this service manual. (2) Support the rear axle of the vehicle using 2 jackstands positioned at the outer ends of the axle.
NOTE: If the shock absorber lower mounting bolt deflects upward during removal, raise axle by adjusting the support jack. If the lower shock absorber bolt deflects downward during removal, lower the axle by adjusting the support jack. (3) Remove the shock absorber lower mounting bolt. (4) While holding shock absorber, remove the shock absorber upper mounting bolt. (5) To install the shock absorber use the reverse sequence of its removal. (6) Lower the vehicle to the ground so the full weight of the vehicle is supported by the suspension. (7) Tighten the upper and lower shock absorber mounting bolt to their specified torques.
with the head of the bolt facing toward the rear of the vehicle (Fig. 21). Do not tighten.
REMOVE (1) Remove the track bar from the track bar mount. (2) Remove the three bolts attaching the track bar mount to the body (Fig. 22).
INSTALL (1) Install the track bar first into the body mount for the track bar (Fig. 20). Install the track bar bolt
2 - 46
SUSPENSION
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JOUNCE BUMPER
There are two types of jounce bumpers available depending on which suspension option the vehicle is equipped with.
STABILIZER BAR
REMOVAL (1) Raise vehicle. Vehicle is to be raised and supported on jack stands or on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this service manual. (2) Remove the 2 lower bolts which hold the stabilizer bar to the link arm on each side of the vehicle. (3) Loosen but do not fully remove the four bolts that attach the stabilizer bar bushing retainers to the rear axle brackets. (4) While holding the stabilizer bar in place. Fully remove the 4 bolts loosened in step 3. (5) Remove the stabilizer bar from the vehicle. (6) If the link arms need to be serviced, remove the upper link arm to bracket bolt. Then remove link arm from frame rail attaching bracket. INSPECTION Inspect for broken or distorted clamps, retainers, and bushings. If bushing replacement is required, the stabilizer bar to axle bushings can be removed from the stabilizer bar by opening the split. INSTALLATION (1) Install the link arms onto the frame rail brackets. DO NOT TIGHTEN. (2) Position the axle to stabilizer bar bushings on the stabilizer bar with the slit in the bushings facing up.
REMOVAL-STANDARD The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a weld nut located on the frame rail (Fig. 23). (1) Using the proper tool, remove the bolt attaching the jounce bumper to frame rail. (2) Remove the jounce bumper from the frame rail.
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REMOVAL AND INSTALLATION (Continued)
REMOVAL-HEAVY DUTY The jounce bumpers are serviced as an assembly. The jounce bumpers screw into a weld nut located in the frame rail (Fig. 24). (1) Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise (Fig. 25). (2) Remove the jounce bumper from the frame rail.
SUSPENSION
2 - 47
jackstand support the weight of the axle and leaf spring. (3) Remove the lower mounting bolt from the shock absorber. (4) Remove the bolts attaching the leaf spring front mount (Fig. 26) to the body of the vehicle. (5) Lower the leaf spring and remove the front mount from the spring.
2 - 48
SUSPENSION
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SPECIFICATIONS
Fig. 28 Leaf Spring Shackle Nuts/Bolts (AWD)
(2) Install a jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand, support the weight of the axle and leaf spring. (3) Remove the lower mounting bolt from the shock absorber. (4) Remove the bolts attaching the leaf spring rear mount to the body of the vehicle (Fig. 29).
INSTALL
CAUTION: The following sequence must be followed when tightening the pin nuts on the rear
NS/GS
SUSPENSION
2-1
SUSPENSION
CONTENTS
page
2-2
SUSPENSION
NS/GS
SPECIFICATIONS (Continued)
ALIGNMENT ANGLE TIRE SIZES P205/75/R14 P215/65/R15 * FRONT INDIVIDUAL CAMBER IN DEGREES............................................ Front Side To Side Camber Difference Not To Exceed................... ** FRONT INDIVIDUAL CASTER IN DEGREES............................................ Front Side To Side Caster Difference Not To Exceed..................................... *** FRONT INDIVIDUAL TOE RIGHT/ LEFT......................................... FRONT TOTAL TOE.................................................... Specified In Degrees FRONT SIDE TO SIDE TOE DIFFERENTIAL..................................... ****REAR INDIVIDUAL CAMBER IN DEGREES............................................ REAR INDIVIDUAL TOE RIGHT/ LEFT........................................ **** REAR TOTAL TOE..................... Specified In Degrees TOE OUT: When Backed On Alignment Rack Is TOE In When Driving ****REAR THRUST ANGLE................ STEERING WHEEL ANGLE................ FRONT RIDE HEIGHT (MEASURED AT TOP OF FENDER WHEEL OPENING)............................................ FRONT RIDE HEIGHT SIDE TO SIDE DIFFERENTIAL..................................... *****REAR RIDE HEIGHT (MEASURED AT TOP OF FENDER WHEEL OPENING)............................................ *****REAR RIDE HEIGHT SIDE TO SIDE DIFFERENTIAL..................................... +0.15 +or- 0.40 0.00 - 0.50 MAX +1.40 + or - 1.00 0.00 - 1.00 MAX +0.05+or- 0.10 +0.10 +or- 0.20 TIRE SIZES P205/75/R15 P215/65/R16 +0.05 +or- 0.40 0.00 - 0.50 MAX +1.40 + or - 1.00 0.00 - 1.00 MAX +0.05 +or- 0.10 +0.10 +or- 0.20 ALTERNATIVE FUELS C.N.G. ELECTRIC +0.15 +or- 0.40 0.00 - 0.50 MAX +1.40 +or- 1.00 0.00 - 1.00 MAX +0.05 +or- 0.10 +0.10 +or- 0.20
0.00 - 0.06 MAX +0.00 +or- 0.25 0.00 +or- 0.40 0.00 +or- 0.40
0.00 - 0.06 MAX +0.00 +or- 0.25 0.00 +or- 0.40 0.00 +or- 0.40
0.00 - 0.06 MAX -0.10 +or- 0.25 0.00 +or- 0.40 0.00 +or- 0.40
0.00 +or- 0.30 0.00 +or- 2.50 747.5 mm +or-10.0mm 0.0 mm 12.5 mm MAX 766.0 mm +or-10.0mm 0.0 mm 12.5 mm MAX
0.00 +or- 0.30 0.00 +or- 2.50 753.5 mm +or-10.0mm 0.0 mm 12.5 mm MAX 772.0 mm +or-10.0mm 0.0 mm 12.5 mm MAX
0.00 +or- 0.30 0.00 +or- 2.50 783.5 mm +or-10.0mm 0.0 mm 12.5 mm MAX 802.5 mm +or-10.0mm 0.0 mm 12.5 mm MAX
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BRAKES
5-1
BRAKES
CONTENTS
page page
GENERAL INFORMATION
INDEX
page GENERAL INFORMATION BASE BRAKE SYSTEM COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 page GENERAL VEHICLE SERVICE CAUTIONS . . . . . . 1
5-2
BRAKES
NS
Fig. 2 Non-Antilock Brakes Hydraulic Brake Tube Routing And Fitting Locations
Fig. 3 Antilock Brakes/Traction Control Hydraulic Brake Tube Routing And Fitting Locations
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BRAKES
5-3
. . . 60 . . . 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 33 39 28 31 34 66 69 47 49 52 27
. . . 71 . . . 71 . . . 71 . . . 70 . . . 69 . . . 76
. . . 78 . . . 76 . . . 76 . . . 77 . . . 78 . . . 78 . . . 81 . . . 79 . . . 81 . . . 79 . . . 78 . . . 83 . . . 83
5-4
BRAKES
NS
SPECIAL TOOLS BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 84
sleeves, and 2 caliper guide pin bolts which thread directly into the steering knuckle (Fig. 3).
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DESCRIPTION AND OPERATION (Continued)
The caliper is a one piece casting with the inboard side containing a single piston cylinder bore. The phenolic piston is 60 mm (2.36 inch) in diameter. A square cut rubber piston seal is located in a machined groove in the cylinder bore. It provides a hydraulic seal between the piston and the cylinder wall (Fig. 4). The molded rubber dust boot mounts in a counter bore of the cylinder bore opening and in a groove which is machined in the outer surface of the piston (Fig. 4). This prevents contamination of the piston and the bore area.
BRAKES
5-5
The disc brake caliper floats on rubber bushings using threaded guide pin bolts which are attached to the back side of the adapter. The adapter and rotor shield are mounted to the rear axle. The adapter is used to mount the brake shoes and actuating cables for the parking brake system. The adapter is also used to mount the rear caliper. The adapter has two machined abutments which are used to position and align the caliper and brake shoes for movement inboard and outboard (Fig. 5).
PROPORTIONING VALVES
FIXED PROPORTIONING VALVE The hydraulic brake system on all vehicles is diagonally split. This means that the left front and right rear brakes are on one hydraulic circuit with the right front and left rear brakes on the other hydraulic circuit. On vehicles equipped with ABS brakes, the brake systems hydraulic control unit (HCU) is mounted to the front suspension crossmember on the drivers side of the vehicle. The (HCU) acts as the hydraulic system junction block, diagonally splitting the brakes hydraulic system. All vehicles equipped with ABS brakes use 2 fixed proportioning valves. The fixed proportioning valves are mounted in a common bracket on the left frame rail at the rear of the vehicle (Fig. 6).
5-6
BRAKES
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DESCRIPTION AND OPERATION (Continued)
(Fig. 8). The actuator assembly is mounted between the height sensing proportioning valve and the actuator bracket on the left rear leaf spring (Fig. 8). As the rear height of the vehicle changes depending on the load the vehicle is carrying the height change is transferred to the height sensing proportioning valve. This change in vehicle height is transferred through the movement of the left rear leaf spring. As the position of the left rear leaf spring changes this movement is transferred through the actuator bracket (Fig. 8) to the actuator assembly (Fig. 8) and then to the proportioning valve. Thus, the height sensing proportioning valve allows the brake system to maintain the optimal front to rear brake balance regardless of the vehicle load condition. Under a light load condition, hydraulic pressure to the rear brakes is minimized. As the load condition of the vehicle increases, so does the hydraulic pressure to the rear brakes. The proportioning valve section of the valve operates by transmitting full input hydraulic pressure to the rear brakes up to a certain point, called the split point. Beyond the split point the proportioning valve reduces the amount of hydraulic pressure to the rear brakes according to a certain ratio. Thus, on light brake applications, approximately equal hydraulic pressure will be transmitted to the front and rear brakes. At heavier brake applications, the hydraulic pressure transmitted to the rear brakes will be lower then the front brakes. This will prevent premature rear wheel lock-up and skid. The height sensing section of the valve thus changes the split point of the proportioning valve, based on the rear suspension height of the vehicle. When the height of the rear suspension is low, the proportioning valve interprets this as extra load and the split point of the proportioning valve is raised to allow more rear braking. When the height of the rear suspension is high, the proportioning valve interprets this as a lightly loaded vehicle and the split point of the proportioning valve is lowered and rear braking is reduced.
BRAKES
5-7
an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and threaded ports with seats for the hydraulic brake line connections. The brake fluid reservoir of the master cylinder assembly is made of a see through polypropylene type plastic. A low fluid switch is also part of the reservoir assembly.
MASTER CYLINDER
The master cylinder (Fig. 9) consists of the following components. The body of the master cylinder is
5-8
BRAKES
NS
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DESCRIPTION AND OPERATION (Continued)
normal. This may indicate: (1) Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. (2) Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level sensor closes to ground the brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak.
BRAKES
5-9
with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and CHMSL lamp, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps.
5 - 10
BRAKES
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DIAGNOSIS AND TESTING (Continued)
RED BRAKE WARNING LAMP FUNCTION
BRAKES
5 - 11
5 - 12
BRAKES
NS
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DIAGNOSIS AND TESTING (Continued)
BRAKE NOISE
BRAKES
5 - 13
5 - 14
BRAKES
NS
Before refinishing or refacing a rotor, the rotor should be checked and inspected for the following conditions: Braking surface scoring, rust, impregnation of lining material and worn ridges. Excessive rotor lateral runout or wobble. Thickness variation in braking surface of the rotor (Parallelism). Dishing or distortion in braking surface of the rotor (Flatness). If a vehicle has not been driven for a period of time, the rotors will rust in the area not covered by the brake lining and cause noise and chatter when the brakes are applied. Excessive wear and scoring of the rotor can cause temporary improper lining contact if ridges are not removed from braking surface of rotor before installation of new brake shoe assemblies. Some discoloration and/or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This will also increase guide pin bushing wear due to the tendency of the caliper to follow rotor wobble. Thickness variation in a rotor can also result in pedal pulsation, chatter and surge due to variation in brake output. This can also be caused by excessive runout in the rotor and/or the hub. Dishing or distortion can be caused by extreme heat and abuse of the brakes.
BRAKE ROTOR
Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action.
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DIAGNOSIS AND TESTING (Continued)
BRAKES
5 - 15
5 - 16
BRAKES
NS
PROPORTIONING VALVES
FIXED PROPORTIONING VALVE TEST PROCEDURE On a vehicle equipped with ABS, premature or excessive rear wheel ABS cycling may be an indication that the brake fluid pressure to the rear brakes is above the desired output. Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also, ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify that the brakes shoe assemblies on a vehicle being tested, are either original equipment manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining material specification. The vehicles brake system is not balanced for after market brake shoe assembly lining material. If brake shoe assembly lining material is of satisfactory condition, and of the correct material specification, check for proper proportioning valve function using the following procedure. (1) Road test vehicle to be sure the vehicle is truly exhibiting a condition of excessive rear wheel ABS cycling. Since ABS cycles both rear brakes together both proportioning valves of the assembly (Fig. 19) must be tested. Use the following procedure to test the proportioning valve.
Fig. 19 Rear Brake Proportioning Valve And Brake Tube Locations Fig. 18 Checking Rotor For Thickness Variation
Light scoring and/or wear is acceptable. If heavy scoring or warping is evident, the rotor must be refinished or replaced (See Refinishing/Refacing (2) Remove one of the chassis brake lines (Fig. 19) coming from the ABS modulator, at (3) the proportioning valve assembly. Remove the hydraulic brake line going to one of the rear wheels of the vehicle from the proportioning valve (Fig. 19)
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DIAGNOSIS AND TESTING (Continued)
(4) Remove the 2 bolts (Fig. 19) attaching the proportioning valve to the frame rail. CAUTION: When lowering the proportioning valve, care must be taken not to kink any of the chassis brake lines. (5) Carefully lower the proportioning valve for clearance to install the proportioning valve test fittings. (6) Install the required fitting from Pressure Test Fittings, Special Tool 6833 (Fig. 20) into the inlet port of the proportioning valve assembly, from which the chassis brake line was removed. Install the removed chassis brake line into the Pressure Test Fitting (Fig. 20). Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the required outlet port of the proportioning valve. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the required outlet port of the proportioning valve (Fig. 20). Then install the removed chassis brake line into the Pressure Test Fitting (Fig. 20).
BRAKES
5 - 17
5 - 18
BRAKES
NS
Fig. 24 Proportioning Valve Test Fitting Installation Fig. 22 Actuator Assembly Adjustment Nut
(2) Remove the chassis brake tube coming from the junction block from the front of the height sensing proportioning valve (Fig. 23). Remove the chassis brake tube going to the rear brakes from the back of the height sensing proportioning valve (Fig. 23). (4) Install a pressure gauge from Gauge Set, Special Tool C-4007-A into each pressure test fitting (Fig. 25). Bleed air out of hose from pressure test fittings to pressure gauges, at the pressure gauges (Fig. 25). Then bleed air out of the brake line being tested, at that rear wheel cylinder.
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DIAGNOSIS AND TESTING (Continued)
(5) With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000 psi) is obtained on the proportioning valve inlet gauge. Then based on the type of brake system the vehicle is equipped with and the pressure specification shown on the following table, compare the pressure reading on the outlet gauge to the specification. If outlet pressure at the proportioning valve is not within specification when required inlet pressure is obtained, replace the proportioning valve. (6) Remove the pressure test fittings and pressure gauges from the proportioning valve. (7) Install the chassis brake lines in the correct ports of the proportioning valve. (8) Install the pressure test fittings and pressure gauges in the opposite inlet and outlet port of the height sensing proportioning valve. Repeat steps 4 and 5 for the other proportioning valve. (9) Remove the pressure test fittings and pressure gauges from the proportioning valve. (10) Install the chassis brake lines in the correct ports of the proportioning valve. (11) Install the actuator (Fig. 22) on the height sensing proportioning valve. Adjust the proportioning valve actuator. See Height Sensing Proportioning Valve in the Adjustment Section in this group of the service manual for the adjustment procedure. (12) Bleed both rear hydraulic circuits at the rear brakes. (13) Road test vehicle.
BRAKES
5 - 19
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses.
WHEEL BASE
SWB SWB LWB LWB SWB LWB
DRIVE TRAIN
FWD FWD FWD FWD AWD AWD
SALES CODE
BRAKE SYSTEM
14 DISC/DRUM W/O ANTILOCK 14 ,15 ,15 HD DISC/DRUM WITH ANTILOCK 14 DISC/DRUM W/O ANTILOCK 14 ,15 ,15 HD DISC/DRUM WITH ANTILOCK 15 DISC/DISC WITH ANTILOCK 15 DISC/DISC WITH ANTILOCK
SPLIT POINT
SLOPE
BRA+BGF BRA+BGF BRB+BGF BRV+BGF BRA+BGF BRA+BGF BRB+BGF BRV+BGF BRE+BGF BRE+BGF
5 - 20
BRAKES
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SERVICE PROCEDURES (Continued)
BRAKES
5 - 21
good bleed of the hydraulic system has been obtained. (6) Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. (7) Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid.
NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the rear brakes. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. Left Rear Wheel Right Front Wheel Right Rear Wheel Left Front Wheel (1) Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. (2) Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. (3) Release the brake pedal only after the bleeder screw is closed. (4) Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. (5) Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid.
5 - 22
BRAKES
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SERVICE PROCEDURES (Continued)
BRAKES
5 - 23
RESURFACNG BRAKE ROTOR This operation can be used when rotor surface is rusty, has lining deposits or excessive lateral runout or thickness variation is evident. A sanding rotor attachment (Fig. 33) will remove surface contamination without removing much rotor material. It will generally follow variations in thickness that are in the rotor.
5 - 24
BRAKES
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SERVICE PROCEDURES (Continued)
flared end tubing. PLACE TUBE NUT ON TUBING BEFORE FLARING THE TUBING.
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Place gauge (Form A) on edge over end of brake tubing. Push tubing through jaws until end of tubing contacts the recessed notch in gauge matching the tubing size. Squeeze handles of flaring tool and lock tubing in place. Place 3/16 inch plug of gauge (A) down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess of disc. Screw in until plug gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the tubing. Remove gauge and continue to screw down until tool is firmly seated in tubing. Remove tubing from flaring tool and inspect seat. Refer to tube routing diagrams for proper brake tube routing and clip locations. Replace any damaged tube routing clips.
To create a (metric) ISO style tubing flare, Use Snap-On Flaring Tool TFM-428, or equivalent. See (Fig. 41) and proceed with the steps listed below. Be sure to place the tubing nut on the tube before flaring the tubing. (1) Carefully prepare the end of the tubing to be flared. Be sure the end of the tubing to be flared is square and all burrs on the inside of the tubing are removed (Fig. 38). This preparation is essential to
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Fig. 40 Inverted Double Wall Flare And ISO Flare Tubing Connections
obtain the correct form of a (metric) ISO tubing flare. (2) Open jaws of the Flaring Tool. Align the mating size jaws of the flaring tool around the size of the tubing to be flared. Close the jaws of the Flaring Tool around the tubing to keep it from sliding out of the flaring tool, but do not lock the tubing in place. See (Fig. 41) (3) Position the tubing in the jaws of the Flaring Tool so that it is flush with the top surface of the flaring tool bar assembly. (Fig. 41) ) (4) Install the correct size adaptor for the brake tubing being flared, on the feed screw of the yoke assembly. Center the yoke and adapter over the end of the tubing. Apply lubricant to the adapter area that contacts brake tubing. Making sure the adapter pilot is fully inserted in the end of the brake tubing. Screw in the feed screw of the yoke assembly until the adaptor has seated squarely on the surface of the bar assembly (Fig. 41). This process has created the (metric) ISO tubing flare.
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SERVICE PROCEDURES (Continued)
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lug nuts in the proper sequence to half of the required torque. Finally tighten the lug nuts in the proper sequence to 129 Nm (95 ft. lbs.). Never use oil or grease on studs or nuts.
REMOVE (1) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication and Maintenance group of this service manual. (2) Remove front wheel and tire assemblies.
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Fig. 46 Storing Front Disc Brake Caliper Fig. 44 Removing Caliper Guide Pin Bolts
(4) Remove caliper from steering knuckle, by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle (Fig. 45). CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. (2) Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper end of caliper over the machined abutment on steering knuckle (Fig. 45). Then rotate caliper into position at the top of the steering knuckle (Fig. 45). Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. (3) Install the caliper guide pin bolts (Fig. 44) and tighten to a torque of 41 Nm (40 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. (4) Install the wheel and tire assembly. (5) Using a torque wrench, tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). (6) Remove jackstands or lower hoist. (7) Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal.
INSTALL (1) Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent.
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REMOVAL AND INSTALLATION (Continued)
REMOVE (1) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication and Maintenance section of this manual. (2) Remove rear wheel and tire assemblies from vehicle. (3) Remove the disc brake caliper to adapter guide pin bolts (Fig. 47).
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REMOVAL AND INSTALLATION (Continued)
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FREE MATERIALS, SOME AFTER MARKET BRAKELINING MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLES BRAKE SYSTEM, WHEN AFTERMARKET BRAKELININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKELINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIRTIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing assembly. Handling of the braking disc and caliper is to be done in such a way as to avoid deformation of the disc and scratching or nicking of brake linings. If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it MUST be replaced immediately. During removal and installation of a wheel and tire assembly, use care not to strike the caliper.
REMOVE (1) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication and Maintenance section of this manual. (2) Remove rear wheel and tire assemblies from vehicle. (3) Remove the caliper to adapter guide pin bolts (Fig. 55). (4) Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter (Fig. 56). (5) Support caliper to prevent the weight of the caliper from damaging the flexible brake hose (Fig. 57).
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REMOVAL AND INSTALLATION (Continued)
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cable equalizer (Fig. 60). This is required to gain access to the star wheel. If the cable is not removed from the equalizer, the cable and spring inside of the brake drum is in the way of the star wheel.
INSTALL (1) Adjust brake shoes assemblies so as not to interfere with brake drum installation. (2) Install the rear brake drums on the hubs. (3) Adjust rear brake shoes per Adjusting Rear Brakes procedure in the service adjustments section of the service manual. (4) Install the removed park brake cable back on the park brake cable equalizer (Fig. 60) (5) Install wheel and tire. (6) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 130 Nm (95 ft. lbs.).
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REMOVAL AND INSTALLATION (Continued)
(7) Remove the brake shoe to brake shoe lower return springs (Fig. 64) and (Fig. 65).
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Fig. 66 Tension Clip Attachment To Adjuster Fig. 64 Remove/Install Brake Shoe Lower Return Spring
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REMOVAL AND INSTALLATION (Continued)
CAUTION: When installing the tension clip on the automatic adjuster, it must be located on only the threaded area of the adjuster assembly (Fig. 66). If it is located on a non-threaded area of the adjuster, the function of the automatic adjuster will be affected. (7) Install the tension clip (Fig. 66) attaching the upper return spring to the automatic adjuster assembly. (8) Install the brake shoe to brake shoe lower return springs on the brake shoes (Fig. 64) and (Fig. 65). (9) Install automatic adjustment lever on the leading brake shoe of the rear brake assembly (Fig. 63). (10) Install the actuating spring on the automatic adjustment lever and leading brake shoe assembly (Fig. 62). (11) Verify that the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. (12) When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. (13) Adjust brake shoes assemblies so as not to interfere with brake drum installation. (14) Install the rear brake drums on the hubs. (15) Adjust rear brake shoes per Adjusting Rear Brakes procedure in the service adjustments section of the service manual. (16) Install the wheel and tire assembly. (17) Push the park brake pedal to the floor once and release pedal. This will automatically remove the slack from and correctly adjust the park brake cables. (18) Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 130 Nm (95 ft. lbs.). (19) Road test vehicle. The automatic adjuster will continue the brake adjustment during the road test of the vehicle.
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(5) Disconnect the park brake cable from the park brake actuation lever. (6) Remove the rear wheel speed sensor from the rear hub/bearing flange (Fig. 74). This will prevent damage to the speed sensor during removal and installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless the speed sensor is removed first.
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REMOVAL AND INSTALLATION (Continued)
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(5) Apply sealant such as Mopar Gasket-In-A-Tube or an equivalent around the wheel cylinder opening in the brake support plate. (6) Install wheel cylinder onto brake support and tighten the wheel cylinder to brake support plate attaching bolts (Fig. 79) to 8 Nm (75 in. lbs.). (7) Install brake tube (Fig. 79) on rear wheel cylinder. Tighten tube nut to a torque of 16 Nm (142 in. lbs.). (8) Install the rear wheel speed sensor on the rear hub/bearing flange (Fig. 74). Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 in. lbs.). (9) Install the rear park brake cable into its mounting hole in the rear brake support plate. (10) Install the park brake cable on the park brake actuation lever. (11) Install the rear brake shoes on the brake support plate. Refer to Brake Shoe Service in this section of the service manual for the proper brake shoe installation procedure. (12) Install brake drum onto hub/bearing. (13) Install wheel and tire. (14) Tighten wheel stud nuts to 129 Nm (95 ft. lbs.). (15) Adjust the rear brakes, (See Adjusting Service Brakes) in Service Adjustments section in this group of the service manual. (16) Bleed the entire brake system. See Bleeding Brake System in the Service Procedures section in this group of the service manual.
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INSTALL (1) Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in brake support plate. (2) Install wheel cylinder onto brake support, and tighten the wheel cylinder to brake support plate attaching bolts (Fig. 81) to 8 Nm (75 in. lbs.). (3) Attach hydraulic brake tube to wheel cylinder, (Fig. 81) and tighten tube to wheel cylinder fitting to 16 Nm (142 in. lbs.). (4) Install brake shoes on support plate. (5) Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). (6) Adjust the rear brakes, (See Adjusting Service Brakes) in Service Adjustments section in this group of the service manual. (7) Bleed the entire brake system. See (Bleeding Brake System) in Service Adjustments section in this group of the service manual.
HUB/BEARING
FRONT WHEEL DRIVE
REMOVE (1) Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this service manual for required lifting procedure. (2) Remove wheel and tire. (3) Remove brake drum from hub/bearing. (4) Remove rear wheel speed sensor from rear hub/ bearing (Fig. 82). This will prevent damage to the speed sensor during removal and installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless the speed sensor is removed first. CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on the tone wheel will result in false ABS cycling and corrosion of the tone wheel. (5) Remove the 4 bolts (Fig. 83) attaching the hub/ bearing to the rear axle. CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/ bearing will not come out of the axle by pulling on
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REMOVAL AND INSTALLATION (Continued)
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(5) Install the rear wheel speed sensor on the rear hub/bearing flange (Fig. 82). Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 in. lbs.). (6) Install brake drum on hub/bearing. (7) Install wheel and tire. (8) Tighten the wheel stud nuts in the proper sequence to a torque of 129 Nm (95 ft. lbs.). (9) Adjust the rear brakes, (See Adjusting Service Brakes) in Service Adjustments section in this group of the service manual.
Fig. 86 Cotter Pin And Nut Retainer Fig. 85 Removing Rear Hub/Bearing From Axle
INSTALL (1) Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. (2) Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. (3) Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. (4) Tighten the 4 hub/bearing mounting bolts (Fig. 83) to a torque of 129 Nm (95 ft. lbs.) (5) Remove the spring washer (Fig. 87) from the stub shaft of the outer C/V joint. (6) Remove the hub nut and washer (Fig. 88) from the stub shaft of the outer C/V joint. (7) Remove the 6 bolts (Fig. 89) mounting the driveshaft inner joint to the output shaft of the rear drive line module. (8) Remove the rear wheel speed sensor (Fig. 90) from the rear hub/bearing. (9) Release the parking brake. (10) Remove the disc brake caliper to adapter guide pin bolts (Fig. 91). (11) Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
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REMOVAL AND INSTALLATION (Continued)
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hub/bearing from the axle. The hub/bearing will then need to be removed from the caliper adapter. (16) Remove the hub/bearing from the axle. (Fig. 95).
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MASTER CYLINDER
CAUTION: Different types of master cylinders are used on this vehicle. Vehicles equipped with traction control use a center port master cylinder. Vehicles not equipped with traction control use a compensating port master cylinder. Be sure to verify if the vehicle is equipped with traction control and that the correct replacement master cylinder is used. Also, vehicles that are equipped with four wheel disc brakes have a master with a different size piston bore than the other master cylinders. If a new master cylinder is being installed, be sure the correct master cylinder is used for the type of brake system the vehicle is equipped with.
REMOVE
CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent the power brake booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicles engine not running, until a firm feeling brake pedal is achieved. (1) With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). CAUTION: Before removing the master cylinder filler tube from the brake fluid reservoir, the filler tube, brake fluid reservoir and master cylinder must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the brake fluid reservoir and entering the brakes hydraulic system. (2) Thoroughly clean all surfaces of the filler neck, brake fluid reservoir, and master cylinder. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. (3) Remove master cylinder filler tube from brake fluid reservoir by pushing down and rotating (Fig. 97). Then remove the cap from the removed filler tube and install it on the master cylinder reservoir. (4) Remove vehicle wiring harness connector, from the brake fluid level sensor, in master cylinder brake fluid reservoir (Fig. 98). (5) Disconnect the primary and secondary brake tubes from the master cylinder housing (Fig. 99). Install sealing plugs in the open brake tube outlets on master cylinder assembly.
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REMOVAL AND INSTALLATION (Continued)
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cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. (6) Clean the area where the master cylinder assembly attaches to the power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. (7) Remove the 2 nuts attaching the master cylinder assembly to the brake vacuum booster (Fig. 100).
(1) Clamp the master cylinder in a vise using only the mounting flange (Fig. 101).
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INSTALL
CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be installed on the master cylinder. Use only procedure detailed below for installing the vacuum seal onto the master cylinder. (1) Install a NEW vacuum seal on master cylinder making sure seal sits squarely in groove of master cylinder casting (Fig. 103).
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REMOVAL AND INSTALLATION (Continued)
CAUTION: When installing the primary and secondary brake tubes on master cylinder, be sure brake tubes do not contact any other components within the vehicle and that there is slack in the flexible sections of the tubes. This is required due to the movement between the ABS hydraulic control module (HCU) and the master cylinder, when the vehicle is in motion. (4) Connect the primary and secondary brake tubes to master cylinder primary and secondary ports (Fig. 99). Brake tubes must be held securely when tightened to control orientation of flex section. Then fully tighten the tube nuts to a torque of 17 Nm (145 in. lbs.). (5) Install the vehicle wiring harness connector, on the brake fluid level sensor in the master cylinder brake fluid reservoir (Fig. 98). (6) Install filler tube into the master cylinder fluid reservoir (Fig. 97).
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INSTALL
CAUTION: When installing the vacuum booster in the vehicle be sure the heater hoses do not become trapped between the booster and the dash panel of the vehicle. (1) Position vacuum booster onto dash panel using the reverse procedure for its removal. (2) Install the 4 mounting nuts for the vacuum booster. Tighten the 4 mounting nuts to a torque of 29 Nm (250 in. lbs.). (3) Using lubriplate, or an equivalent, coat the surface of the brake pedal pin where it contacts the vacuum booster input rod. CAUTION: When installing the brake pedal pin on the vacuum booster input rod, do not re-use the old retaining clip. (4) Connect the vacuum booster input rod on the brake pedal pin and install a NEW retaining clip (Fig. 109). (5) Connect the vacuum hose on the check valve in the vacuum booster. CAUTION: The master cylinder is used to create the seal for holding vacuum in the vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the vacuum booster. CAUTION: When removing the vacuum seal from the master cylinder do not use a sharp tool. (6) Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange.
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REMOVAL AND INSTALLATION (Continued)
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(13) If vehicle is equipped with speed control, install the speed control servo and bracket on the battery tray. Install and securely tighten bolt attaching bracket to battery tray. (14) If vehicle is equipped with speed control, install the wiring harness connector on the speed control servo. Then connect the vacuum lines onto the speed control servo and vacuum reservoir on battery tray. (15) Install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner housing (Fig. 104). Securely tighten the hose clamp at the air cleaner housing and throttle body. (16) Install the battery and the battery thermal guard. (17) Install the battery cables on the battery. (18) Check the operation of the stop lamp switch and adjust if necessary.
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REMOVAL AND INSTALLATION (Continued)
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INSTALL
CAUTION: When installing the power brake vacuum booster in the vehicle be sure the heater hoses do not become trapped between the booster and the dash panel of the vehicle. (1) Position power brake booster onto dash panel using the reverse procedure for its removal. (2) Install the 4 power brake vacuum booster mounting nuts. Tighten the 4 mounting nuts to a torque of 29 Nm (250 in. lbs.). (3) Using lubriplate, or an equivalent, coat the surface of the brake pedal pin where it contacts the brake vacuum booster input rod. CAUTION: When installing the brake pedal pin on the power brake vacuum booster input rod, do not re-use the old retaining clip. (4) Connect power brake vacuum booster input rod on the brake pedal pin and install a NEW retaining clip (Fig. 116). (5) Connect the vacuum hose on the check valve in the power brake vacuum booster. CAUTION: The master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the power brake vacuum booster.
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REMOVAL AND INSTALLATION (Continued)
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INSTALL
CAUTION: When installing the power brake vacuum booster in the vehicle be sure the heater hoses do not become trapped between the booster and the dash panel of the vehicle. (1) Position vacuum booster on dash panel using the reverse procedure of its removal. (2) Install the 4 nuts mounting the vacuum booster to the dash panel. Tighten the 4 mounting nuts to a torque of 29 Nm (250 in. lbs.). (3) Using lubriplate, or an equivalent, coat the surface of the brake pedal pin where it contacts the vacuum booster input rod. CAUTION: When installing the brake pedal pin on the power brake vacuum booster input rod, do not re-use the old retaining clip. (4) Install vacuum booster input rod on brake pedal pin and install a NEW retaining clip (Fig. 127).
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REMOVAL AND INSTALLATION (Continued)
CAUTION: The master cylinder is used to create the seal for holding vacuum in the vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the vacuum booster. CAUTION: When removing the vacuum seal from the master cylinder do not use a sharp tool. (7) Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. (8) Install a NEW vacuum seal on mounting flange of the master cylinder (Fig. 128).
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(15) Install the wiring harness connector (Fig. 120) on the EGR valve transducer. (16) Install the battery tray. Install the 2 bolts and the nut (Fig. 119) attaching the battery tray to the vehicle. Tighten the 2 bolts and the nut to a torque of 14 Nm (125 in lbs.). (17) If vehicle is equipped with speed control, install the speed control servo and bracket on the battery tray. Install and securely tighten bolt attaching bracket to battery tray. (18) If vehicle is equipped with speed control, install the wiring harness connector on the speed control servo. Then connect the vacuum lines onto the speed control servo and vacuum reservoir on battery tray. (19) Install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner housing (Fig. 118). Securely tighten hose clamp at air cleaner housing and throttle body. (20) Install the battery and the battery thermal guard. (21) Install the battery cables on the battery. (22) Check the operation of the stop lamp switch and adjust if necessary.
JUNCTION BLOCK
REMOVE (1) Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the junction block. (2) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication And Maintenance Group of this service manual.
CAUTION: Before removing the brake tubes from the junction block, the junction block and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the brake hudraulic system. (3) Remove the 6 chassis brake tubes (Fig. 129) from the junction block. (4) Remove the bolt (Fig. 130) attaching the junction block mounting braket to the front suspension cradle.
INSTALL (1) Install the junction block and mounting bracket (Fig. 130) on the front suspension cradle. Install the attaching bolt and tighten to a torque of 28 Nm (250 in. lbs.). (2) Install the 6 chassis brake tubes (Fig. 131) into the inlet and outlet ports of the junction block.
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REMOVE (1) Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve. (2) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication And Maintenance Group of this service manual.
CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the proportioning valve or the brake tubes. (3) Remove the 4 chassis brake lines from the inlet and outlet ports of the proportioning valve (Fig. 132).
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REMOVAL AND INSTALLATION (Continued)
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(2) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication And Maintenance Group of this service manual. CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the proportioning valve or the brake tubes. (3) Remove the 4 chassis brake tubes from the inlet and outlet ports of the proportioning valve (Fig. 134).
REMOVE (1) Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve.
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REMOVAL AND INSTALLATION (Continued)
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INSTALL (1) Install the ground switch for the red brake warning lamp on the park brake pedal mechanism (2) Install park brake cable end housing (Fig. 138) into park brake pedal mechanism. (3) Install cable retainer (Fig. 138) onto the park brake cable strand and then install retainer into pedal bracket.
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REMOVE (1) Set the parking brake. The parking brake is set to keep the hub/bearing and axle shaft from rotating when loosening the hub nut. (2) Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. See Hoisting in the Lubrication And Maintenance section of this service manual. (3) Remove the wheel/tire. (4) Remove the cotter pin and nut retainer (Fig. 139) from the stub shaft of the outer C/V joint.
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REMOVAL AND INSTALLATION (Continued)
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(12) Remove the rotor from the hub/bearing. (13) Remove the horseshoe clip (Fig. 146) from the retainer on the end of the park brake cable. (14) Remove the end of the park brake cable from the actuator lever on the adapter (Fig. 146).
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Fig. 153 Leading Brake Shoe Hold Down Pin And Spring
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REMOVAL AND INSTALLATION (Continued)
(23) Remove the adjuster (Fig. 154) from the leading and trailing park brake shoe.
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Fig. 156 Upper Return Springs Fig. 154 Brake Shoe Adjuster
(24) Remove the leading park brake shoe (Fig. 155) from the adapter. Leading brake shoe is removed by rotating the bottom of the brake shoe inward (Fig. 155) until the top of the brake shoe can be removed from the brake shoe anchor. Then remove the upper return springs (Fig. 155) from the leading brake shoe.
Fig. 157 Trailing Brake Shoe Hold Down Pin And Spring
INSTALL (1) Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter.
(2) Install the hold down spring and pin (Fig. 157) on the trailing park brake shoe. (3) Install the upper return springs (Fig. 156) on the trailing park brake shoe. (4) Install the upper return springs on the leading park brake shoe (Fig. 155). Then position the top of the leading park brake shoe at the upper anchor and rotate the bottom of the shoe outward until correctly installed on the adapter. (5) Install the adjuster (Fig. 154) between the leading and trailing park brake shoe.
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REMOVAL AND INSTALLATION (Continued)
(30) Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings.
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INSTALL (1) Install the ends of the park brake cables through the cable guides. (2) Install the intermediate park brake cable on the cable connector at the right rear park brake cable (Fig. 163). (3) Install the intermediate park brake cable on the cable equalizer (Fig. 162).
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REMOVAL AND INSTALLATION (Continued)
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(9) Remove the park brake cable housing retainer from the brake support plate using a 14mm wrench to compress the retaining fingers (Fig. 167).
Fig. 167 Removing Park Brake Cable From Brake Support Plate
INSTALL (1) Install the park brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. (2) Attach the park brake cable onto the park brake actuator lever. (3) Install the brake shoes on the rear brake support plate. Refer to Rear Brake Shoes in the Removal And Installation Section of this service manual for the required procedure. (4) Insert cable housing retainer into body bracket making certain that cable housing retainer fingers lock the housing firmly into place. (5) Connect the right rear park brake cable to the connector on the intermediate park brake cable (Fig. 165). (6) Install the brake drum, and the wheel and tire assembly. (7) Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. (8) Apply and release park brake pedal 1 time, this will seat the park brake cables.
Fig. 166 Right Park Brake Cable Removal From Body Bracket
(8) Disconnect park brake cable from park brake actuator lever.
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Fig. 171 Removing Park Brake Cable From Brake Support Plate
INSTALL (1) Install the park brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. (2) Attach the park brake cable onto the park brake actuator lever. (3) Install the brake shoes on the rear brake support plate. Refer to Rear Brake Shoes in the Removal And Installation Section of this service manual for the required procedure.
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REMOVAL AND INSTALLATION (Continued)
(4) Insert cable housing retainer into body outrigger bracket making certain that cable housing retainer fingers lock the housing firmly into place. (5) Connect rear park brake cable to the equalizer bracket (Fig. 169). (6) Install brake drum, and wheel and tire assembly. (7) Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. (8) Apply and release park brake pedal 1 time, this will seat the park brake cables.
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top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30 to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker (Fig. 172) can result. (4) Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position.
DISASSEMBLY AND ASSEMBLY MASTER CYLINDER TO POWER BRAKE BOOSTER VACUUM SEAL
(1) Remove the master cylinder from the power brake vacuum booster. Refer to Master Cylinder removal, for the required procedure to remove master cylinder from power brake vacuum booster. (2) Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. (3) Using Mopar Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master cylinder push rod. (4) Install new master cylinder to power brake booster vacuum seal on master cylinder. When installing new vacuum seal, be sure it is squarely seated against master cylinder mounting flange and in groove of push rod (Fig. 173). (5) Bleed the master cylinder assembly prior to
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DISASSEMBLY AND ASSEMBLY (Continued)
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REMOVE (1) Check brake fluid level in master cylinder fluid reservoir to be sure brake fluid is not in the filler neck. If brake fluid is in filler neck, lower fluid level before removing filler neck from fluid reservoir (2) Grasp filler neck at cap end (Fig. 177) and push straight down. This will cause the filler neck to pop out of the fluid reservoir.
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CALIPER GUIDE PIN BUSHING SERVICE The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this assembly can be serviced using the following procedure.
REMOVING CALIPER GUIDE PIN BUSHINGS (1) Remove caliper from brake rotor (See Brake Shoe Removal). Hang caliper assembly on a wire hook away from the brake rotor. (2) Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown in (Fig. 180).
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DISASSEMBLY AND ASSEMBLY (Continued)
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DISASSEMBLY AND ASSEMBLY (Continued)
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CALIPER ASSEMBLY
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. (1) Clamp caliper in a vise (with protective caps installed on jaws of vise). (2) Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove (Fig. 190), using only your fingers until properly seated. NEVER USE AN OLD PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled (Fig. 190). (3) Coat new piston boot with clean brake fluid leaving a generous amount inside boot. (4) Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. (5) Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 191). (6) Position dust boot into the counterbore of the caliper assembly piston bore. (7) Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool
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CLEANING AND INSPECTION (Continued)
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CALIPER INSPECTION Check for brake fluid leaks in and around boot area and inboard lining, and for any ruptures, brittleness or damage to the piston dust boot. If the boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new seal and boot, and piston if scored. Refer to Rear Disc Brake Caliper in the Disassembly And Assembly Section in this group of the service manual. Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Rear Disc Brake Caliper in the Disassembly And Assembly Section in this group of the service manual.
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ADJUSTMENTS (Continued)
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(3) Be sure parking brake lever is fully released. (4) Insert Brake Adjusting, Special Tool C-3784 or equivalent through the adjusting hole in support plate and against star wheel of adjusting screw. Move handle of tool upward until a slight drag is felt when road wheel is rotated. (5) Insert a thin screwdriver or piece of welding rod into brake adjusting hole. Push adjusting lever out of engagement with star wheel. Care should be taken so as not to bend adjusting lever or distort lever spring. While holding adjusting lever out of engagement, back off star wheel to ensure a free wheel with no brake shoe drag. (6) Repeat above adjustment at the other rear wheel. (7) Install adjusting hole rubber plug (Fig. 197) in rear brake support plates. (8) Install park brake cables on park brake cable equalizer (Fig. 196).
Fig. 198 Disc Brake Caliper Fig. 197 Brake Adjusting Hole Plug
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ADJUSTMENTS (Continued)
(4) Remove rotor from hub/bearing. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. (5) Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, accurately measure the inside diameter of the park brake drum portion of the rotor (Fig. 199).
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ADJUSTMENTS (Continued)
group of the service manual for the installation procedure. (13) Install wheel and tire. (14) Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). (15) Lower vehicle. (16) Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. (17) Road test the vehicle to ensure proper function of the vehicles brake system.
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(1) Raise vehicle. Vehicle is to be raised and supported on jackstands or with a frame contact type hoist so the rear suspension of the vehicle is hanging free. See hoisting in the Lubrication And Maintenance section of this service manual. (2) Remove rear wheels/tires. (3) Using an appropriate jack, support the rear axle prior to the removal of the track bar and shock absorber bolts from the rear axle. (4) Unbolt the track bar from the rear axle. (5) Unbolt both shock absorbers from the rear axle. (6) Loosen (do not remove) both of the leaf spring to front spring hanger pivot bolts. NOTE: When lowering the rear axle be sure that the leaf springs do not come in contact with the hoist limiting the downward movement of the axle. If this occurs an improper adjustment of the actuator may result. (7) Lower the rear axle so it is at its farthest point of downward movement. (8) Loosen the adjustment nut (Fig. 203) on the actuator. (9) Be sure the hooked end of the actuator is correctly (fully) seated in the clip on the proportioning valve lever and that the clip is correctly positioned on the lever of the proportioning valve. (10) Pull the housing of the proportioning valve actuator toward the spring hanger (Fig. 203) until the lever on the proportioning valve bottoms on the body of the proportioning valve. Hold the proportioning valve actuator in this position while tightening the adjustment nut (Fig. 203) to a torque of 5 Nm (45 in. lbs.). Proportioning valve adjustment is now complete.
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ADJUSTMENTS (Continued)
(13) Lower the vehicle to the ground. Be sure that the suspension is supporting the full weight of the vehicle. (14) Tighten the spring to front hanger pivot bolts to a torque of 156 Nm (115 ft. lbs.). (15) Tighten the shock absorber mounting bolts to a torque of 101 Nm (75 ft. lbs.). (16) Tighten the track bar mounting bolt to a torque of 95 Nm (70 ft. lbs.). (17) Road test vehicle to ensure that the premature rear wheel lockup condition has been corrected. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open container will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleumbased fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid ect.
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SPECIFICATIONS (Continued)
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. . . . 87 . . . . 85 . . . . 86 . . . . 89 . . . . 87 . . . . 89 . . . . 91 . . . . 85 . . . . 88 . . . . 90 . . . . 88 . . . . 89 . . . . . . . . . . . . . . . . . . . . . . . . 92 88 87 88 89 89
. . . . 96 . . . . 97 . . . . 96
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steering maneuvers at high speed or high speed cornering beyond the limits of tire adhesion to the road surface may cause vehicle skidding, independent of vehicle braking. For this reason, the ABS system is termed Antilock instead of Anti-Skid.
NORMAL BRAKING SYSTEM FUNCTION Under normal braking conditions, the ABS System functions the same as a standard brake system with a diagonally split master cylinder and conventional vacuum assist. ABS SYSTEM OPERATION If a wheel locking tendency is detected during a brake application, the brake system will enter the ABS mode. During ABS braking, hydraulic pressure in the four wheel circuits is modulated to prevent any wheel from locking. Each wheel circuit is designed with a set of electric solenoids to allow modulation, although for vehicle stability, both rear wheel solenoids receive the same electrical signal. During an ABS stop, the brakes hydraulic system is still diagonally split. However, the brake system pressure is further split into four control channels. During antilock operation of the vehicles brake system the front wheels are controlled independently and are on two separate control channels and the rear wheels of the vehicle are controlled together. The system can build and release pressure at each wheel, depending on signals generated by the wheel speed sensors (WSS) at each wheel and received at the Controller Antilock Brake (CAB). ABS operation is available at all vehicle speeds above 3 to 5 mph. Wheel lockup may be perceived at the very end of an ABS stop and is considered normal. VEHICLE HANDLING PERFORMANCE DURING ABS BRAKING It is important to remember that an antilock brake system does not shorten a vehicles stopping distance under all driving conditions, but does provide improved control of the vehicle while stopping. Vehicle stopping distance is still dependent on vehicle speed, weight, tires, road surfaces and other factors. Though ABS provides the driver with some steering control during hard braking, there are conditions however, where the system does not provide any benefit. In particular, hydroplaning is still possible when the tires ride on a film of water. This results in the vehicles tires leaving the road surface rendering the vehicle virtually uncontrollable. In addition, extreme
NOISE AND BRAKE PEDAL FEEL During ABS braking, some brake pedal movement may be felt. In addition, ABS braking will create ticking, popping and/or groaning noises heard by the driver. This is normal due to pressurized fluid being transferred between the master cylinder and the brakes. If ABS operation occurs during hard braking, some pulsation may be felt in the vehicle body due to fore and aft movement of the suspension as brake pressures are modulated. At the end of an ABS stop, ABS will be turned off when the vehicle is slowed to a speed of 34 mph. There may be a slight brake pedal drop anytime that the ABS is deactivated, such as at the end of the stop when the vehicle speed is less then 3 mph or during an ABS stop where ABS is no longer required. These conditions will exist when a vehicle is being stopped on a road surface with patches of ice, loose gravel or sand on it. Also stopping a vehicle on a bumpy road surface will activate ABS because of the wheel hop caused by the bumps. TIRE NOISE AND MARKS Although the ABS system prevents complete wheel lock-up, some wheel slip is desired in order to achieve optimum braking performance. Wheel slip is defined as follows, 0 percent slip means the wheel is rolling freely and 100 percent slip means the wheel is fully locked. During brake pressure modulation, wheel slip is allowed to reach up to 25 to30%. This means that the wheel rolling velocity is 25 to 30% less than that of a free rolling wheel at a given vehicle speed. This slip may result in some tire chirping, depending on the road surface. This sound should not be interpreted as total wheel lock-up. Complete wheel lock up normally leaves black tire marks on dry pavement. The ABS System will not leave dark black tire marks since the wheel never reaches a fully locked condition. Tire marks may however be noticeable as light patched marks. START UP CYCLE When the ignition is turned on, a popping sound and a slight brake pedal movement may be noticed. Additionally, when the vehicle is first driven off a humming may be heard and/or felt by the driver at approximately 20 to 40 kph (12 to 25 mph). The ABS warning lamp will also be on for up to 5 seconds after the ignition is turned on. All of these conditions are a normal function of ABS as the system is performing a diagnosis check.
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DESCRIPTION AND OPERATION (Continued)
PREMATURE ABS CYCLING
NOTE: When working on a vehicle which has a complaint of premature ABS cycling it may be necessary to use a DRB Scan Tool to detect and verify the condition. There is one complaint called Premature ABS Cycling in which neither the Red Brake Warning Lamp nor the Amber Antilock Lamp were illuminated and no fault codes were stored in the CAB. Symptoms of Premature ABS Cycling, include clicking sounds from the solenoids valves, pump motor running and pulsations in the brake pedal. This condition can occur at any braking rate of the vehicle and on any type of road surface. This creates an additional condition which needs to be correctly assessed when diagnosing problems with the antilock brake system. The following conditions are common causes that need to be checked when diagnosing a condition of Premature ABS Cycling. Damaged tone wheels, incorrect tone wheels, damage to a wheel speed sensor mounting boss on a steering knuckle, a loose wheel speed sensor mounting bolt, and excessive tone wheel runout. Also, an excessively large tone wheel to wheel speed sensor air gap can lead to the condition of Premature ABS Cycling. Special attention is to be given to these components when diagnosing a vehicle exhibiting the condition of Premature ABS Cycling. After diagnosing the defective component, repair or replace as required. When the component repair or replacement is completed, test drive the vehicle to verify the condition of Premature ABS Cycling has been corrected.
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A vehicle equipped with four wheel disc brakes (AWD applications) also have a unique master cylinder. The master cylinder used on these vehicles have a piston bore diameter which is larger then the master cylinder used on the other brake applications. The primary and secondary outlet ports on the master cylinder go directly to the hydraulic control unit HCU. Reference the appropriate section of this service manual for further information on the individual components.
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DESCRIPTION AND OPERATION (Continued)
fluid accumulators temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This stored brake fluid is then used by the pump in the HCU to provide build pressure for the brake hydraulic system. Additionally on vehicles that are equipped with only ABS (non-traction control vehicles) there is a mini brake fluid accumulator on the secondary hydraulic circuit which protects the master cylinders seals during an ABS stop. There is also a noise damping chamber on the primary hydraulic circuit. On ABS equipped vehicles with traction control, in addition to the brake fluid accumulators there are also two noise damping chambers in the HCU.
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The junction block is located on the left hand front cowl panel on the vehicle.
HCU PUMP/MOTOR
The HCU (Fig. 4) contains 2 pump assemblies, one for the primary and one for the secondary hydraulic circuit of the brake system. Both pumps are driven by a common electric motor (Fig. 4) which is part of the HCU. The pumps draw brake fluid from the fluid accumulators to supply build pressure to the brakes during an ABS stop. The pump motor runs during the drive-off cycle as a check and during an ABS stop and is controlled by the CAB. The Pump/Motor Assembly is not a serviceable item. If the pump/motor requires replacement the complete HCU (Fig. 4) (minus the CAB) must be replaced.
ABS RELAYS
On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will need to be replaced. Refer to Controller Antilock Brakes in the Removal And Installation Section in this group of the service manual for the procedure.
PROPORTIONING VALVES
One assembly containing two proportioning valves are used in the system, one for each rear brake hydraulic circuit. The proportioning valve is located on the frame rail next to the fuel tank, forward of the right rear shock absorber (Fig. 6). Be sure replacement proportioning valve assemblies have the same split point and slope as the proportioning valve being replaced.
ABS FUSES
The fuse for the ABS pump motor and the ABS system are located in the power distribution center (PDC) (Fig. 5). The PDC is located on the drivers side of the engine compartment forward of the strut tower. The fuse for the ABS warning lamp in the instrument panel message center is located in the junction block. On vehicles equipped with traction control, the fuse for the traction control switch is also located in the junction block.
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DESCRIPTION AND OPERATION (Continued)
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disable the ABS braking system. The normal base braking system will remain operational. The CAB contains a self-diagnostic program which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected. Faults are then stored in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB and displayed through the DRB Scan Tool. These fault messages will remain in the CAB memory even after the ignition has been turned off. The fault messages can be read and or cleared from the CAB memory by a technician using the DRB Scan Tool. The fault occurrence and the fault code will also be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3500 miles of vehicle operation. Mileage though of the last fault occurrence will not be automatically cleared.
CONTROLLER ANTILOCK BRAKE INPUTS Four wheel speed sensors. Stop lamp switch. Ignition switch. System relay voltage. Ground. Traction Control Switch (If Equipped). Diagnostics Communications (CCD) CONTROLLER ANTILOCK BRAKE OUTPUTS C2D Communication To Body Controller And Instrument Cluster ABS warning lamp actuation. Traction Control Light (If Equipped). Diagnostic communication. (CCD)
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TEVES MARK 20 ABS CIRCUIT AND SOLENOID VALVE FUNCTION This hydraulic circuit diagram (Fig. 12) shows the vehicle in the ABS braking mode. This hydraulic circuit (Fig. 12) shows a situation where one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than the surface the vehicles tires are on will allow. The normally open and normally closed valves modulate the brake hydraulic pressure as required. The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. The brake fluid will then be routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. TEVES MARK 20 SECONDARY ABS CIRCUIT AND SOLENOID VALVE FUNCTION This hydraulic circuit diagram (Fig. 13) shows the vehicle in the ABS braking mode. This hydraulic circuit (Fig. 13) shows a situation where one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than the surface the vehicles tires are on will allow. The normally open and normally closed valves modulate the brake hydraulic pressure as required. The pump/motor is switched on so that the brake fluid from the low pressure accu-
NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION This condition is the normal operation of the vehicles base brake hydraulic system. The hydraulic system circuit diagram (Fig. 11) shows a situation where no wheel spin or slip is occurring relative to the speed of the vehicle. The driver is applying the brake pedal to build pressure in the brake hydraulic system to apply the brakes and stop the vehicle.
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DESCRIPTION AND OPERATION (Continued)
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TEVES MARK 20 ABS WITH TRACTION CONTROL NORMAL BRAKING HYDRAULIC CIRCUIT SOLENOID AND SHUTTLE VALVE FUNCTION This condition is the normal operation of the vehicles base brake hydraulic system when the vehicle is equipped with ABS and traction control. The hydraulic system circuit diagram (Fig. 14) shows a situation where no wheel spin or slip is occurring relative to the speed of the vehicle. The driver is applying the brake pedal to build pressure in the brake hydraulic system to apply the brakes and stop the vehicle. The hydraulic shuttle valve (Fig. 14) closes with every brake pedal application so pressure is not created at the inlet to the pump.
TEVES MARK 20 ABS WITH TRACTION CONTROL ABS BRAKING HYDRAULIC CIRCUIT SOLENOID AND SHUTTLE VALVE FUNCTION This hydraulic circuit diagram (Fig. 15) shows a vehicle equipped with ABS and traction control in the ABS braking mode. This hydraulic circuit (Fig. 15) shows a situation where one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than the surface the vehicles tires are on will allow. The hydraulic shuttle valve (Fig. 15) closes upon brake application so that the pump can not suck brake fluid from the master cylinder. The normally open and normally closed valves modulate the brake hydraulic pressure as required. The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. The brake fluid will then be routed to either the master cylinder or the wheel brake depending on the position of the normally open valve.
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DESCRIPTION AND OPERATION (Continued)
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the powertrain control module and air bag electronic control module.
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DIAGNOSIS AND TESTING (Continued)
START-UP CYCLE The self diagnostic ABS start up cycle begins when the ignition switch is turned to the on position. Electrical checks are completed on ABS components, such as the Controller, solenoid continuity, and the system relay operation. During this check the Amber ABS Warning Light is turned on for approximately 4 seconds and the brake pedal may emit a popping sound and move slightly when the solenoid valves are checked. DRIVE-OFF CYCLE Further Functional testing is accomplished once the vehicle is set in motion and reaches a speed of about 20 kph (12 mph.). This cycle is performed only once after each ignition on/off cycle. The pump/motor is activated briefly to verify function. When the pump/motor is activated a whirling or buzzing sound may be heard by the driver, which is normal when the pump/motor is running. The wheel speed sensor output is verified to be within the correct operating range. ONGOING TESTS Other tests are performed on a continuous basis. These include checks for solenoid continuity, wheel speed sensor continuity and wheel speed sensor output.
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LATCHING VERSUS NON-LATCHING DIAGNOSTIC TROUBLE CODES Some DTCs detected by the CAB are latching; the DTC is latched and ABS braking is disabled until the ignition switch is reset. Thus ABS braking is non operational even if the original DTC has disappeared. Other DTCs are non-latching; any warning lights that are turned on, are only turned on as long as the DTC condition exists. As soon as the condition goes away, the ABS Warning Light is turned off, although a DTC will be set in most cases.
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PROPORTIONING VALVE
CAUTION: Proportioning valves (Fig. 18) should never be disassembled.
TONEWHEEL INSPECTION
CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tonewheels should show no evidence of contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive runout of the tonewheel can cause erratic wheel speed sensor signals. Refer to Tonewheel Runout in the Specification Section in this section of the service manual for the tonewheel runout specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect tonewheels for looseness on their mounting surfaces. Tonewheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. Refer to Wheel Speed Sensor Clearance in the Specification Section in this section of the service manual.
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DIAGNOSIS AND TESTING (Continued)
Before test driving a brake complaint vehicle, note whether the Red or Amber Brake Warning Lamp is turned on. If it is the Red Brake Warning Lamp, refer to the hydraulic system section in the brake group of this manual. If the ABS Warning lamp was/is on, test drive the vehicle as described below, to verify the complaint. While the ABS Warning Lamp is on, the ABS is not functional. The standard brake system and the ability to stop the car may not be affected if only the ABS Warning Lamp is on. Discuss with the owner of the vehicle or note any other electrical problems or conditions that may be occurring on the vehicle. They may have an effect on the antilock brake systems function. (1) Turn the key to the off position and then back to the on position. Note whether the ABS Warning Lamp continues to stay on. If it does, refer to the diagnostic manual covering the ITT Teves Mark 20 ABS system for the required test procedures. (2) If the ABS Warning Lamp goes out, shift into gear and drive the car to a speed of 20 kph (12 mph) to complete the ABS start up cycle. If at this time the ABS Warning Lamp goes on refer to the ITT Teves Mark 20 Diagnostic Manual. (3) If the ABS Warning Lamp remains OUT, drive the vehicle a short distance. During this test drive be sure that the vehicle achieves at least 40 mph. Brake to at least one complete stop in an ABS cycle, and again accelerate to 25 mph. (4) If a functional problem with the ABS system is determined while test driving a vehicle, refer to the diagnostic manual covering the ITT Teves Mark 20 ABS system for the required test procedures and proper use of the DRB diagnostic scan tool.
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with antilock brakes may affect the function of the antilock brake system.
ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure or standard pressure bleeding equipment.
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REMOVAL AND INSTALLATION (Continued)
hoist. See Hoisting in the Lubrication And Maintenance section of this service manual. (4) Remove the routing clip attaching the HCU wiring harness to the HCU mounting bracket (Fig. 19). CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected. (5) Remove the 25 way connector (Fig. 19) from the CAB. The 25 way connector is removed from the CAB using the following procedure. Grasp the lock on the 25 way connector (Fig. 19) and pull it as far out as possible (Fig. 20). This will raise and unlock the 25 way connector from the socket on the CAB.
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(6) Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. (7) Remove the brake tubes (6) from the inlet and outlet ports on the HCU. (Fig. 21).
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REMOVAL AND INSTALLATION (Continued)
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INSTALL (1) Install the CAB (Fig. 32) on the valve block of the HCU. (2) Install the 4 bolts mounting the CAB (Fig. 31) to the valve block of the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 in. lbs.). (3) Plug the pump/motor wiring harness into the CAB (Fig. 30).
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REMOVAL AND INSTALLATION (Continued)
CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to (Fig. 27) for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the HCU mounting bracket. (6) Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown in (Fig. 27). Tighten the tube nuts to a torque of 17 Nm (145 in. lbs.). NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector. (7) Install the 25 way connector on the CAB using the following procedure. Position the 25 way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock (Fig. 26). This will pull the connector into the socket of the CAB and lock it in the installed position. (8) Install the routing clips (Fig. 33) on the brake tubes.
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(9) Lower vehicle. (10) Connect negative cable back on negative post of the battery. (11) Bleed the base brakes and the ABS brakes hydraulic system. Refer to the Bleeding ABS System in this section of the manual for the proper bleeding procedure. (12) Road test vehicle to ensure proper operation of the base and ABS brake systems.
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INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. (1) Connect the front wheel speed sensor cable to the vehicle wiring harness connector (Fig. 35). Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut tower (Fig. 35). CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the channel bracket. (2) Install the channel bracket and grommet retainer on the frame rail (Fig. 34). (3) Install the 2 bolts (Fig. 34) attaching the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 in. lbs.). (4) Insert speed sensor cable grommets into intermediate bracket on strut (Fig. 37). Route cable from strut to steering knuckle on the rearward side of the stabilizer bar link. (5) Install the wheel speed sensor to steering knuckle attaching bolt (Fig. 36). Tighten the speed sensor attaching bolt to a torque of 12 Nm (105 in. lbs.) (6) Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (.047 in.). (7) Install the wheel and tire assembly on vehicle. (8) Road test vehicle to ensure proper operation of the base and ABS brake systems.
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REMOVAL AND INSTALLATION (Continued)
CAUTION: When unplugging speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also inspect connectors for any signs of previous damage. (3) Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from vehicle wiring harness (Fig. 38).
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axle flange, the brake tube clip and the routing clip from the track bar bracket on the axle (Fig. 40).
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REMOVAL AND INSTALLATION (Continued)
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Fig. 46 Speed Sensor Attaching Bolt Fig. 44 Speed Sensor Cable Attachment To Brake Flex Hose
(5) Remove the rear wheel speed sensor cable/ brake tube routing clips (Fig. 45). Then un-clip the speed sensor cable from the routing clips on rear brake tube (Fig. 45). CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor head in a attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the sensor from side to side until free. (6) Remove the wheel speed sensor attaching bolt (Fig. 46). If sensor head does not come loose, do not use pliers on the sensor head to loosen. Tap sensor head from side to side to loosen. (7) Remove the wheel speed sensor from the rear bearing assembly. (8) Remove the speed sensor assembly from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. (1) Install wheel speed sensor head. Note, the plastic anti rotation pin must be fully seated prior to installing the attaching bolt. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange.
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BRAKES
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REMOVAL AND INSTALLATION (Continued)
(7) Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage by the vise jaws. Mount the hub/bearing assembly in a vise (Fig. 50). Using Puller, Special Tool C-4693 installed as shown in (Fig. 50) remove the tone wheel from the hub/bearing assembly.
BRAKES
5 - 111
5 - 112
BRAKES
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REAR WHEEL Minimum Clearance .40mm (.016 in.) Maxamum Clearance 1.2 mm (.047 in.)
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BRAKES
5-1
BRAKES
CONTENTS
page page
GENERAL INFORMATION BASE BRAKE SYSTEM COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 1 DESCRIPTION AND OPERATION MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING MASTER CYLINDER FLUID LEVEL CHECK . . . 2 GENERAL INFORMATION BASE BRAKE SYSTEM COMPONENT DESCRIPTION
The standard brake system on this vehicle contains the same components as brake systems described in group 5 of the service manual, with the exception of the brake pedal system and master cylinder. These differences are mainly related to service procedures. The major differences are as follows: Use of a torque shaft assembly to transfer brake pedal travel to the power brake booster and master cylinder on the left side of the vehicle A unique power brake booster and master cylinder. Refer to the Base Brake System Component Description in the General Information section of group 5 for more information on components used in the base brake system.
REAR DRUM BRAKE ADJUSTMENT . . . . . . . . 1 REMOVAL AND INSTALLATION BRAKE PEDAL TORQUE SHAFT ASSEMBLY . . 4 FRONT PARK BRAKE CABLE AND LEVER ASSEMBLY-RHD&LHD VEHICLES . . . . . . . . 2
5-2
BRAKES
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REMOVAL AND INSTALLATION FRONT PARK BRAKE CABLE AND LEVER ASSEMBLY-RHD&LHD VEHICLES
REMOVE (1) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication and Maintenance group of this service manual. (2) Remove the intermediate and left rear park brake cable from the park brake cable equalizer (Fig. 2).
Fig. 4 Console and Gearshift boot Fig. 2 Park Brake Cable Attachment To Equalizer
(3) Remove the front park cable housing retainer from body outrigger bracket (Fig. 3). Cable is removable by sliding a 14 mm box wrench over cable retainer and compressing the three retaining fingers. Alternate method is to use an aircraft type hose clamp and screwdriver. (6) Carefully lift the base of the gearshift boot from the gearshift console to access the screws (Fig. 4).
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REMOVAL AND INSTALLATION (Continued)
BRAKES
5-3
INSTALL (1) Pass park brake cable assembly through hole in floor pan from the inside of the vehicle. (2) Pass cable strand button through the hole in the pedal assembly bracket. (3) Install parking brake cable to the brake/gearshift lever bracket by lifting the bracket and sliding the cable in. (4) Install the three (3) screws to the parking brake grommet on the floor pan of the passenger compartment. (5) Compress the parking brake cable retainer by sliding a 14 mm box wrench over the cable retainer and compress the three (3) retaining fingers. (6) Hook the loop on the end of the parking brake to the equalizer bar on the parking brake/gearshift lever bracket. (7) Attach the parking brake assembly and place assembly on the parking brake/gearshift lever bracket. (8) Install the three (3) nuts at the base of the parking brake assembly. (9) Pull the parking brake lever to the up position. (10) Place the console over the parking brake/gearshift lever and tilt the base of the gearshift boot and carefully pull it through the opening in the console. (11) Install the four (4) retaining screws (Fig. 5). (12) Carefully press the three (3) clips at the base of the gearshift boot into the slots on the gearshift console. (13) Raise the vehicle. (14) install the two (2) retaining nuts and (2) retaining bolts to the bottom of the parking brake/ gearshift lever bracket. (15) Install the front park cable housing retainer to the body outrigger bracket (Fig. 3). Cable is installed by sliding a 14 mm box wrench over cable retainer and compressing the three retaining fingers. Alternate method is to use an aircraft type hose clamp and screwdriver. (16) Install the intermediate and left rear park brake cable to the park brake cable equalizer (Fig. 2). (17) Lower the vehicle.
5-4
BRAKES
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INSTALL (1) Install torque shaft. Reconnect pedal arm, link and pedal bracket assembly to torque shaft as necessary. (2) Tighten the retaining nut (1) for the Brake Booster Bracket in the engine compartment. Tighten the four (4) Brake Booster retaining nuts from inside the passenger compartment. (3) Install new retaining clip on torque shaft. (4) Install steering column intermediate shaft. Install 72 and 36 way connector brackets. (5) Tighten the six (6) retaining nuts for the Brake Pedal Bracket assembly. (6) Connect the Brake Pedal Switch connector.
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CLUTCH
6-1
CLUTCH
CONTENTS
page page
GENERAL INFORMATION CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . CLUTCH DISC AND COVER APPLICATION . . . CLUTCH REPLACEMENT . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION CLUTCH PEDAL POSITION SWITCH . . . . . . . . CLUTCH RELEASE SYSTEM . . . . . . . . . . . . . . DIAGNOSIS AND TESTING CLASHINTOREVERSE COMPLAINTS . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH CHATTER COMPLAINTS . . . . . . . . . . CLUTCH COVER AND DISC RUNOUT . . . . . . . CLUTCH DIAGNOSIS . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL POSITION SWITCH . . . . . . . . DRIVE PLATE MISALIGNMENT . . . . . . . . . . . . REMOVAL AND INSTALLATION CLUTCH ASSEMBLY (2.5L DIESEL) . . . . . . . CLUTCH CABLE SYSTEM LHD . . . . . . . . . . CLUTCH PEDAL POSITION SWITCH . . . . . . . GENERAL INFORMATION CLUTCH COMPONENTS
1 3 3 4 4
8 8 8 6 4 7 13 8 10
CLUTCH RELEASE BEARING AND FORK . . . HYDRAULIC CLUTCH LINKAGE SYSTEM RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER SYSTEM RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODULAR CLUTCH ASSEMBLY (2.0L AND 2.4L GASOLINE) . . . . . . . . . . . . . . . . . . . . . QUICK CONNECT COUPLING RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLAVE CYLINDER ASSEMBLY RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING AND INSPECTION CLEANING PRECAUTIONS . . . . . . . . . . . . . . . CLUTCH CONTAMINATION . . . . . . . . . . . . . . ADJUSTMENTS CLUTCH CABLE LHD . . . . . . . . . . . . . . . . CLUTCH PEDAL POSITION SWITCH . . . . . . . SPECIFICATIONS CLUTCH TIGHTENING REFERENCE . . . . . . . .
14 11 12 13 12 12 15 15 16 16 16
The clutch used in the 2.0 liter and 2.4 liter gasoline engine is a single, dry-disc modular clutch assembly. The modular clutch assembly combines the pressure plate cover, pressure plate, disc, and flywheel into one unit. The unit rides on the input shaft of the transmission and is bolted to the drive plate mounted on the rear of the crankshaft. The clutch used in the 2.5 liter diesel engine is a conventional clutch and pressure plate arrangement.
The clutch pedal is connected to the cable through a plastic spacer (Fig. 1). The upper end of the clutch pedal pivots in the pedal bracket on two nylon bushings and a shaft (Fig. 2). These bushings are greased during assembly and do not require periodic lubrication.
CLUTCH CABLE AND PEDAL LHD The clutch cable has a unique self-adjuster mechanism built into the cable which compensates for clutch disc wear. The cable requires no maintenance or lubrication. There are no serviceable components on the cable assembly.
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CLUTCH
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HYDRAULIC LINKAGE AND COMPONENTS RHD The hydraulic clutch linkage is a prefilled system free of air, contamination, and leaks. There is no routine maintenance required. The hydraulic clutch linkage is serviced as an assembly and the individual components cannot be overhauled or serviced separately. The hydraulic linkage consists of a clutch master cylinder with integral reservoir, a clutch slave cylinder and an interconnecting fluid line with quick disconnect coupling (Fig. 5). The clutch master cylinder push rod is connected to the clutch pedal (Fig. 6). The clutch pedal is fitted with a return spring. The spring hook that attaches to the pedal is coated with nylon. No service lubrication is necessary. The slave cylinder push rod is connected to the clutch release fork (Fig. 5).
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GENERAL INFORMATION (Continued)
CLUTCH
6-3
CLUTCH REPLACEMENT
The transaxle must be removed to service the clutch assembly, fork, or bearing.
6-4
CLUTCH
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Slave cylinder force causes the release lever to move the release bearing into contact with the diaphragm spring. As additional force is applied, the bearing presses the diaphragm spring fingers inward on the fulcrums. This action moves the pressure plate rearward relieving clamp force on the disc. The clutch disc is disengaged and not driven at this point. The process of clutch engagement is simply the reverse of what occurs during disengagement. Releasing pedal pressure removes clutch linkage pressure. The release bearing moves away from the diaphragm spring which allows the pressure plate to exert clamping force on the clutch disc.
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DIAGNOSIS AND TESTING (Continued)
the switch is in its normal (fully extended) position. When the switch is depressed more than 1.25 mm (0.050), the ohmmeter should show continuity (zero ohms). If ohmmeter readings do not fall within these ranges, the switch is defective, and must be replaced.
CLUTCH
6-5
CLUTCH PEDAL POSITION SWITCHMECHANICAL TEST With the park brake set and the vehicle IN NEUTRAL, turn the key to the start position. The vehicle should not crank. If the vehicle cranks, the switch is defective (shorted out) and must be replaced. If the vehicle does not crank proceed to the next step.
WARNING: BEFORE PERFORMING THIS STEP, BE SURE THAT THE AREA IN FRONT OF THE VEHICLE IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHICLE MAY MOVE WHEN PERFORMING THIS TEST.
With the park brake set and the vehicle IN GEAR, turn the key to the start position and hold it there. Slowly depress the clutch pedal and feel for any vehicle motion when the starter is energized. If there is no motion the switch is working properly. If motion is felt, check to see if the switch is making contact when the pedal is between 25 mm (1.0 in.) and 6 mm (0.25 in.) from the floor. If this condition is met, then the problem is either the clutch or the clutch actuation system (See Clutch Will Not Disengage Properly). If this condition is not met, then the switch mounting tab on the brake bracket is bent, and the brake bracket must be replaced. If vehicle will not crank, even with clutch pedal pressed to the floor, refer to Service DiagnosisClutch Pedal Position Switch chart in this section.
Floor mat interferes with clutch pedal movement. Move floor mat out of the way. Switch mounting bracket is bent. Replace brake bracket assembly
Check other components in the starting circuit. Refer to Section 8A, Battery/Starting/Charging System.
6-6
CLUTCH
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CLUTCH DIAGNOSIS
Problem diagnosis will generally require a road test to determine the type of fault. Component inspection will then determine the problem after road testing. Drive the vehicle at normal speeds during road test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or improper release is experienced, remove and inspect the clutch components. If the problem is noise or hard shifting, further diagnosis may be needed. The transaxle or other driveline components may actually be at fault.
Further diagnosis required. Check engine/transmission mounts, suspension attaching parts and other driveline components as needed. Check EFI and ignition systems Replace clutch assembly
Engine related problems PARTIAL ENGAGEMENT OF CLUTCH DISC Clutch cover, spring, or release fingers bent, distorted (rough handling, improper assembly) Clutch disc damaged or distorted Clutch misalignment
Replace clutch assembly Check alignment and runout of flywheel, disc, or cover. Check clutch housing to engine dowels and dowel holes for damage. Correct as necessary.
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DIAGNOSIS AND TESTING (Continued)
SERVICE DIAGNOSISIMPROPER CLUTCH RELEASE
CONDITION CLUTCH DISC BINDS ON INPUT SHAFT SPLINES POSSIBLE CAUSES Clutch disc hub splines damaged during installation
CLUTCH
6-7
CORRECTION Clean, smooth, and lubricate disc and shaft splines. Replace clutch assembly and/or input shaft if splines are severely damaged. Clean input shaft splines. Then lube. Clean input shaft splines and disc splines, then lube Replace clutch assembly
Input shaft splines rough, damaged. Corrosion or rust formations on splines of input shaft and disc CLUTCH DISC RUSTED TO FLYWHEEL AND/OR PRESSURE PLATE CLUTCH WILL NOT DISENGAGE PROPERLY Occurs in vehicles stored or not driven for extended period of time. Also occurs after steam cleaning if vehicle is not used for extended period. Disc bent, distorted during transaxle installation Clutch cover diaphragm spring damaged during transaxle installation Release fork and (or) bushings damaged Clutch cable binding or routed incorrectly Self-adjuster in cable not functioning properly, resulting in excess cable slack Clutch pedal travel restricted
Replace clutch assembly Replace clutch assembly Replace fork and (or) bushings if worn or damaged Check and correct cable routing Pull on cable conduit at transaxle (as if disconnecting cable) to check adjuster operation Verify clutch pedal can travel all the way to the downstop on the bracket
Pedal bushings worn out or inadequate lubrication Clutch pedal assist spring fittings worn out Clutch release shaft bushings in the bellhousing are worn out
Clean the crankshaft flange before mounting the drive plate. Dirt and grease on the flange surface may misalign the flywheel, causing excessive runout. Use new bolts when mounting drive plate to crankshaft. Tighten drive plate bolts to specified torque only. Over-tightening can distort the drive plate hub causing excessive runout.
6-8
CLUTCH
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(4) Check to see if the clutch disc hub splines are damaged, and replace with new clutch assembly if required. (5) Check the input shaft for damaged splines. Replace as necessary. (6) Check for broken clutch cover diaphragm spring fingers. (7) Install clutch assembly and transaxle.
CLASHINTOREVERSE COMPLAINTS
(1) Depress clutch pedal to floor and hold. After three seconds, shift to reverse. If clash is present, clutch has excessive spin time. NOTE: Verify that nothing is obstructing pedal travel. Floormats or other articles located underneath the clutch pedal could prevent the clutch from disengaging fully. (2) Remove transaxle. See Group 21, Manual Transaxle for procedure. (3) Check the input shaft spline, clutch disc splines, and release bearing for dry rust. If present, clean rust off and apply a light coat of bearing grease to the input shaft splines. Apply grease on the input shaft splines only where the clutch disc slides. Verify that the clutch disc slides freely along the input shaft spline.
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REMOVAL AND INSTALLATION (Continued)
CLUTCH
6-9
6 - 10
CLUTCH
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INSTALLATION (1) Using a slight twisting motion, insert the selfadjuster mechanism end of the clutch cable through the dash panel hole and into the bracket.
NOTE: It may be helpful to lubricate the dash panel grommet using Mopar Door-Ease or equivalent to aid installation. (2) Seat the cylindrical part of the cable grommet in the dash panel. Be sure the selfadjuster is firmly seated against the clutch bracket to ensure proper adjuster mechanism function. (3) Connect the clutch cable to the upstop/spacer. (4) Connect the upstop/spacer to the clutch pedal. (5) Replace the upstop/spacer retainer clip. (6) Lift the clutch pedal and perform the Adjuster Mechanism Function Check before finishing installation. NOTE: If the adjuster mechanism does not function properly, the most likely cause is that the cable is not properly seated in the bracket. ADJUSTER MECHANISM FUNCTION CHECK LHD (1) With slight pressure, pull the clutch release lever end of the cable to draw the cable taut. Push the clutch cable housing toward the dash panel (With less than 20 lbs. of effort, the cable housing should move 30-50mm.). This indicates proper adjuster mechanism function. If the cable does not adjust, determine if the mechanism is properly seated on the bracket. (2) If the adjust mechanism functions properly, route cable to the transaxle. Install battery and cable guide. (3) Snap cable into cable guide located at the left shock tower. (4) Insert cable into transaxle and through clutch release lever. Ensure the cable is routed through the smaller hole in the transaxle deck (Fig. 10). (5) Pull down on cable and insert cable retaining clip onto clutch cable end. (6) Check clutch pedal position switch operation.
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REMOVAL AND INSTALLATION (Continued)
CLUTCH
6 - 11
3. Remove the slave cylinder assembly. Refer to the slave cylinder removal and installation procedure in this section for detailed instructions on removal and installation of the slave cylinder.
REMOVAL 1. Disconnect the quick connect coupling to facilitate the removal of the master cylinder assembly and slave cylinder assembly separately (Fig. 14). Refer to the removal and installation procedure in this section for detailed instructions on disconnecting and connecting the quick connect coupling. 2. Remove the master cylinder assembly (Fig. 15). Refer to the master cylinder removal and installation procedure in this section for detailed instructions on removal of the master cylinder assembly.
6 - 12
CLUTCH
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REMOVAL 1. Disconnect the quick connect coupling by lightly pushing down on the black release collar on the male side of the quick connect coupling while separating it from the female side of the quick connect coupling (Fig. 14). INSTALLATION 1. Connect the male side of the quick connect coupling (part of the master cylinder assembly) by holding the clutch tube at the rear and inserting it into the female side of the quick connect coupling (part of the slave cylinder assembly) until an audible click is heard (Fig. 14). Do not push on the black release collar on the male side of the quick connect coupling while inserting it into the female side of the quick connect coupling. 2. Confirm the connection by pulling firmly on the clutch tube.
INSTALLATION (1) Position the master cylinder assembly to the clutch pedal bracket by tilting it 20 degrees upward and at the 2 oclock unlocked position. (2) Rotate the master cylinder counterclockwise to the 12 oclock locked position. (3) Install the rubber grommet into the dash panel at the master cylinder pass through (Fig. 16). (4) Connect the hydraulic line to the weld stud clips in the engine compartment (Fig. 14). (5) Connect the quick connect coupling. Refer to the Quick Connect Coupling removal and installation procedure in this section. (6) Install the self-retaining snap-on bushing into the master cylinder pushrod, if necessary. (7) Install the master cylinder pushrod with selfretaining snap-on bushing onto the clutch pedal pin by pressing it onto the clutch pedal pin until seats in the groove of the clutch pedal pin.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION 1. Position the slave cylinder assembly to the transaxle deck and secure with the nut and washer assemblies (2) and tighten to specifications (Fig. 14). 2. Make sure the slave cylinder pushrod is properly seated in the cup end of the clutch release lever. 3. Connect the quick connect coupling. Refer to the Quick Connect Coupling removal and installation procedure in this section.
CLUTCH
6 - 13
REMOVAL (1) Remove the transaxle, refer to Group 21, Transaxle. (2) Install universal clutch alignment tool into the clutch assembly (this will prevent the clutch from inadvertently being dropped). (3) To avoid distortion of the pressure plate, remove the clutch pressure plate bolts a few turns at a time. Use a crisscross pattern until all bolts are loosened. (4) Carefully remove the clutch pressure plate and disc (Fig. 18).
6 - 14
CLUTCH
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INSTALLATION (1) Position the clutch and pressure plate onto the flywheel. (2) Insert the universal clutch alignment tool into the clutch disc. (3) To avoid distortion of the pressure plate, bolts should be tightened a few turns at a time (Fig. 19). Use a crisscross pattern until all bolts are seated. Tighten pressure plate bolts to 27 Nm (20 ft. lbs.).
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REMOVAL AND INSTALLATION (Continued)
(3) Remove the fork from the bearing thrust plate (Fig. 22).
CLUTCH
6 - 15
OIL CONTAMINATION Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in color from amber to black. GREASE CONTAMINATION Grease contamination is usually a product of overlubrication. During clutch service, apply only a small amount of grease to the input shaft splines. Excess grease may be thrown off during operation, contaminating the disc. ROAD SPLASH/WATER CONTAMINATION Road splash contamination is usually caused by driving the vehicle through deep water puddles. Water can be forced into the clutch housing, causing clutch components to become contaminated. Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly may be required. Drive the vehicle until normal clutch operating temperature has been obtained. This will dry off disc assembly, pressure plate, and flywheel.
INSTALLATION (1) Before assembling the fork, lubricate the rounded thrust pads and the spring clip cavities with multipurpose grease. (2) Assemble the fork to the bearing by sliding the thrust pads under the spring clips. Be careful to avoid distorting the spring clips. These clips prevent the bearing thrust plate from rotating with the bearing. (3) Slide the bearing and fork assembly onto the input shaft bearing retainer. (4) Position the release shaft bushings in the housing and install the release shaft. A small amount of bearing grease between the release shaft bushing and the shaft is beneficial but not required. Install the retainer clip in the shaft groove near the large bushing. (5) Install the release lever and retaining clip on the outer end of the release shaft.
CLEANING PRECAUTIONS
Condensation from steam vapors tend to accumulate on the internal clutch mechanism when the vehicle is steam cleaned. Facing of disc will absorb moisture and will bond to flywheel and/or pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, it may require replacement of clutch assembly. After cleaning, drive the vehicle to its normal clutch operating temperature. This will dry off disc assembly, pressure plate, and flywheel.
6 - 16
CLUTCH
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ADJUSTER MECHANISM FUNCTION CHECK LHD (1) With slight pressure, pull the clutch release lever end of the cable to draw the cable taut. Push the clutch cable housing toward the dash panel (With less than 20 lbs. of effort, the cable housing should move 30-50mm.). This indicates proper adjuster mechanism function. If the cable does not adjust, determine if the mechanism is properly seated on the bracket. (2) If the adjust mechanism functions properly, route cable to the transaxle. (3) Insert cable into transaxle and through clutch release lever. Ensure the cable is routed through the smaller hole in the transaxle deck (Fig. 10). (4) Pull down on cable and insert cable retaining clip onto clutch cable end. (5) Check clutch pedal position switch operation.
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COOLING SYSTEM
7-1
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . 1 AUTOMATIC TRANSMISSION OIL COOLER 2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COOLANT RECOVERY SYSTEM (CRS) . . . . . . . 3 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2 ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 5 ENGINE THERMOSTAT . . . . . . . . . . . . . . . . . . . . 3 RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . . 4 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . 3 DESCRIPTION AND OPERATION COOLANT PERFORMANCE . . . . . . . . . . . . . . . . . 6 RADIATOR HOSES AND CLAMPS . . . . . . . . . . . 6 WATER PIPES3.0L ENGINE . . . . . . . . . . . . . . 6 WATER PUMP3.3/3.8L ENGINES . . . . . . . . . . 7 WATER PUMP2.4L ENGINE . . . . . . . . . . . . . . 6 WATER PUMP3.0L ENGINE . . . . . . . . . . . . . . 6 DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . . . . 7 COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . . 8 DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ELECTRIC FAN MOTOR TEST . . . . . . . . . . . . . . 14 LOW COOLANT LEVEL AERATION . . . . . . . . . . 15 PRESSURE TESTING RADIATOR CAP . . . . . . . 15 RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK . . . . . . . . . . . . . . 15 RADIATOR COOLANT FLOW TEST . . . . . . . . . . 14 RADIATOR FAN CONTROL . . . . . . . . . . . . . . . . 14 TEMPERATURE GAUGE INDICATION . . . . . . . . 16 TESTING COOLING SYSTEM FOR LEAKS . . . . 14 SERVICE PROCEDURES COOLANT LEVEL CHECKROUTINE . . . . . . . . 16 COOLANT LEVEL SERVICE . . . . . . . . . . . . . . . . 16 GENERAL INFORMATION ACCESSORY DRIVE BELTS
The accessory drive system utilizes two different style of drive belts. The conventional V-belt and the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump and water
COOLANTADDING ADDITIONAL . . . . . . . . . . COOLING SYSTEMDRAINING . . . . . . . . . . . . COOLING SYSTEMREFILLING . . . . . . . . . . . REMOVAL AND INSTALLATION ACCESSORY DRIVE BELTS2.4L . . . . . . . . . . ACCESSORY DRIVE BELTS3.0L . . . . . . . . . . ACCESSORY DRIVE BELT3.3/3.8L . . . . . . . . ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . FAN MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR DRAINCOCK . . . . . . . . . . . . . . . . . . RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT2.4L ENGINE . . . . . . . . . . . . . THERMOSTAT3.0L ENGINE . . . . . . . . . . . . . THERMOSTAT3.3/3.8L ENGINES . . . . . . . . . WATER PUMP INLET TUBE2.4L ENGINE . . . WATER PUMP3.3/3.8L ENGINES . . . . . . . . . WATER PUMP2.4L ENGINE . . . . . . . . . . . . WATER PUMP3.0L ENGINE . . . . . . . . . . . . . CLEANING AND INSPECTION ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . . . CHEMICAL CLEANING . . . . . . . . . . . . . . . . . . . COOLING SYSTEM CLEANING . . . . . . . . . . . . . RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . REVERSE FLUSHING THE ENGINE . . . . . . . . . REVERSE FLUSHING THE RADIATOR . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS BELT TENSION CHART . . . . . . . . . . . . . . . . . . . BELT TENSION GAUGE METHOD . . . . . . . . . . . PROPER BELT TENSION . . . . . . . . . . . . . . . . . SPECIFICATIONS COOLING SYSTEM CAPACITY . . . . . . . . . . . . . TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 16 16 23 24 24 23 22 21 21 19 20 20 17 19 17 18 25 25 25 25 25 25 24 26 26 25 26 26 26
pump. Satisfactory performance of these belts depends on belt condition and proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the drive belts.
7-2
COOLING SYSTEM
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COOLING SYSTEM
The cooling system has a radiator, coolant, electric fan motor, shroud, pressure cap, thermostat, coolant reserve system, transmission oil cooler, a water pump to circulate the coolant, hoses, and clamps to complete the circuit. When Engine is cold: thermostat is closed, cooling system has no flow through the radiator. The coolant bypass flows through the engine only. When Engine is warm: thermostat is open, cooling system has bypass flow and coolant flow through radiator.
Its primary purpose is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions. It also provides hot water (coolant) for heater performance and cooling for automatic transmission oil. It does this by transferring heat from engine metal to coolant, moving this heated coolant to the radiator, and then transferring this heat to the ambient air. Coolant flow circuits for 2.4L and 3.3/3.8L engines are shown in (Fig. 1), and 3.0L engine coolant routing is shown in (Fig. 2)
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GENERAL INFORMATION (Continued)
COOLING SYSTEM
7-3
WATER PUMPS
A quick test to tell whether the pump is working is to see if the heater warms properly. A defective pump can not circulate heated coolant through the long heater hose. The water pump on all models can be replaced without discharging the air conditioning system.
COOLANT
The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the radiator, where the tube/fin assemblies of these components can give it up to the air. The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or the equivalent is recommended for best engine cooling without corrosion, when mixed only to a freeze point of -37C (-35F) to -59C (-50F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended.
ENGINE THERMOSTAT
The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. They are designed to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature of 88 to 93C (192 to 199F). They also automatically reach wide open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104C (220F). Above this temperature the coolant temperature is controlled by the fan, the radiator, and the ambient temperature, not the thermostat.
RADIATOR
The radiators are cross-flow types (horizontal tubes) with design features that provide greater strength along with sufficient heat transfer capabili-
7-4
COOLING SYSTEM
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GENERAL INFORMATION (Continued)
COOLING SYSTEM
7-5
7-6
COOLING SYSTEM
NS
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -59C (-50F). CAUTION: Richer mixtures cannot be measured with field equipment. This can lead to problems associated with 100 percent glycol.
COOLANT PERFORMANCE
Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for each degree of temperature rise for each pound of water). This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100C (212F) and freezes at 0C (32F) 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point to -22C (-8F). 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of -37C (-35F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, sending unit and heater are all designed for 50/50 glycol.
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DESCRIPTION AND OPERATION (Continued)
COOLING SYSTEM
7-7
7-8
COOLING SYSTEM
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DIAGNOSIS AND TESTING (Continued)
COOLING SYSTEM
7-9
7 - 10
COOLING SYSTEM
NS
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DIAGNOSIS AND TESTING (Continued)
COOLING SYSTEM
7 - 11
7 - 12
COOLING SYSTEM
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DIAGNOSIS AND TESTING (Continued)
CONDITION - AND CHECKS
COOLING SYSTEM
7 - 13
DIAGNOSIS
Inadequate Air Conditioning Performance - Cooling System Suspected (1) Check for plugged air side of condenser and (1) Wash out with low-velocity water. radiator front and rear. (2) Assure fan runs whenever A/C head pressure (2) Repair as necessary. exceeds 1724 kPa (250 psi). (3) Check for missing air seals-recirculating air path. (4) Assure correct cooling system parts. Battery Dead - Suspect Fan Current Draw as Cause (1) With a good, fully charged battery. Hot Smell - Suspect Cooling System (1) Was temperature gauge high? (2) Heat shields all in place? (3) Fan control operating properly? (4) Heat exchanger air side plugged? (5) Engine missing or running rich? Poor Driveability - Suspect Failed Open Thermostat. (1) Check diagnostics - is code 17 set? (Engine too cold for too long) (1) a - Assure fan control is operating properly. (1) b - See charging system in Electrical, Group 8B. (1) (1) (2) (2) (3) (3) (4) (5) a - Yes, See Gauge Reads High b - No. See 2, 3, 4, and 5. a - Yes, See 3, 4, and 5. b - Repair or replace heat shields. a - Yes, See 4 and 5. b - No, See Radiator Fan Control this section. Clean as required. Repair as required.
Poor Heater Performance - Suspect Failed Open Thermostat (1) Does gauge read low? (1) See 3 (2) Check coolant level. (2) See 3 (3) Check diagnostics - is code 17 set? (Engine too (3) If yes, change thermostat. If no, check heater cold for too long) bypass valve, which should be closed except in Max A/C or off mode; if not, see Heater and Air Conditioning Group, 24. Steaming, Observe Water Vapor Through Grill or Head Gap at Standstill at Idle - In Wet Weather (1) This is normal. It is moisture, snow, or water on the (1) Normal condition - no service required. outside of the radiator that evaporates when the thermostat opens to put hot coolant into the radiator. This usually occurs in cold weather with no fan or air flow to blow it away.
7 - 14
COOLING SYSTEM
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DIAGNOSIS AND TESTING (Continued)
WARNING: WITH TOOL IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi). If the needle on the dial does not fluctuate, race the engine a few times. If an abnormal amount of coolant or steam emits from the tail pipe, it may indicate a coolant leak caused by a faulty head gasket, cracked engine block, or cracked cylinder head. There may be internal leaks that can be determined by removing the oil dipstick. If water globules appear intermixed with the oil it will indicate an internal leak in the engine. If there is an internal leak, the engine must be disassembled for repair.
COOLING SYSTEM
7 - 15
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED.
7 - 16
COOLING SYSTEM
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COOLANTADDING ADDITIONAL
The radiator cap should not be removed. When additional coolant is needed to maintain this level, it should be added to the coolant reserve tank. Use only 50/50 mix of ethylene glycol type antifreeze and water. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended.
COOLING SYSTEMREFILLING
First clean system to remove old coolant, see Cooling System Cleaning. Fill the system, using the correct antifreeze as described in the Coolant Section. Fill the system to 50 percent of its capacity with 100 percent glycol. Then complete filling system with water. The 2.4L engine requires venting by removal of the coolant sensor on top of the water outlet connector (Fig. 15). When coolant reaches this hole: Install coolant sensor and tighten to 7 Nm (60 in. lbs.) for 2.4L Engines.
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SERVICE PROCEDURES (Continued)
Continue filling system until full, this provides better heater performance. Be careful not to spill coolant on drive belts or the generator. Fill coolant reserve system to at least the MAX mark with 50/50 solution. It may be necessary to add coolant to the reserve tank after three or four warm up/cool down cycles to maintain coolant level between the MAX and MIN mark. This will allow trapped air to be removed from the system.
COOLING SYSTEM
7 - 17
(2) Assemble pump body to block and tighten screws to 12 Nm (105 in. lbs.) (Fig. 16). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. (3) Rotate pump by hand to check for freedom of movement. (4) Install rear timing belt cover. (5) Install camshaft sprockets and torque bolts to 101 Nm (75 ft. lbs.). (6) Install timing belt idler pulley and torque mounting bolt to 61 Nm (45 ft. lbs.). (7) Install timing belt. Refer to Group 9, Engine, 2.4L Timing Belt. (8) Install right engine mount bracket and engine mount. Refer to Group 9 for procedure. (9) Fill cooling system. See Cooling System Filling. (10) Install accessory drive belts, Refer to Accessory Drive Belts, in this section. (11) Lower vehicle and connect battery cable.
INSTALLATION (1) Inspect the O-ring for damage before installing the tube into the cylinder block (Fig. 19). (2) Lube O-ring with coolant and install into the cylinder block opening. (3) Install 2 fasteners and tighten to 12 Nm (105 in. lbs.). (4) Connect lower radiator hose and heater hose to inlet tube (Fig. 18).
7 - 18
COOLING SYSTEM
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Clean all gasket and O-ring surfaces on pump and water pipe inlet tube. (2) Install new O-ring on water inlet pipe (Fig. 22). Wet the O-ring (with water) to ease assembly.
CAUTION: Keep the O-ring free of oil or grease. (3) Install new gasket on water pump and install pump inlet opening over water pipe, press assembly to cause water pipe insertion into pump housing. (4) Install pump to block mounting bolts and tighten to 27 Nm (20 ft. lbs.). (5) See Timing Belt in Engine, Group 9 and install timing belt. Reassemble engine. (6) Fill cooling system. See Refilling Cooling System.
COOLING SYSTEM
7 - 19
THERMOSTAT2.4L ENGINE
REMOVAL (1) Drain cooling system down below the thermostat level. Refer to Draining Cooling System in this group. (2) Remove thermostat housing bolts and housing (Fig. 25). (3) Remove thermostat, discard gasket and clean both gasket sealing surfaces.
7 - 20
COOLING SYSTEM
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THERMOSTAT3.0L ENGINE
REMOVAL (1) Drain cooling system down below the thermostat level. Refer to Draining Cooling System in this group. (2) Remove thermostat housing bolts and housing (Fig. 26). (3) Remove thermostat, discard gasket and clean both gasket sealing surfaces.
THERMOSTAT3.3/3.8L ENGINES
REMOVAL (1) Drain cooling system down below the thermostat level. Refer to Cooling System Draining in this section. (2) Remove thermostat housing bolts and housing (Fig. 28). (3) Remove thermostat, discard gasket and clean both gasket sealing surfaces.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Place a new gasket (dipped in water) on the thermostat housing surface, center thermostat into opening in the intake manifold water box. (2) Place housing and gasket over the thermostat, making sure thermostat is in the recess provided (Fig. 28). (3) Bolt housing to intake manifold, tighten bolts to 28 Nm (250 in. lbs.). (4) Refill the cooling system to the proper level. Refer to Cooling System Refilling outlined in this section for procedure.
COOLING SYSTEM
7 - 21
RADIATOR
REMOVAL (1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. (2) Drain cooling system. Refer to Draining Cooling System of this section. (3) Remove air intake resonator. (4) Remove coolant reserve system tank to filler neck tube hose. (5) Disconnect fans from the connector located on the left side of the fan module. (6) Remove the Coolant Recovery System (CRS) tank retaining screw from the upper radiator closure panel crossmember. (7) Disconnect the upper radiator mounting screws from the crossmember. Disconnect the engine block heater wire if equipped. (8) Remove the upper radiator closure panel crossmember. Refer to Group 23 Body for procedure. (9) Remove air cleaner assembly. (10) Disconnect automatic transmission oil cooler lines at radiator and plug. (11) Disconnect inlet and outlet hoses from the radiator. Remove the lower hose clip from the fan module. (12) Remove A/C condenser fasteners and separate the condenser from the radiator (Fig. 29). Verify the condenser is supported in position. (13) Remove A/C filter/dryer mounting bracket, 2 bolts to the fan module, and 2 nuts to the filter/dryer. (14) Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not recommended. Damage may occur to part. Draincock should not be removed unless leakage observed. (1) Turn the draincock stem counterclockwise to unscrew the stem. When the stem is unscrewed to
7 - 22
COOLING SYSTEM
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FAN MODULE
REMOVAL There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as a assembly (Fig. 31). (1) Raise the vehicle on hoist. (2) Remove the radiator outlet hose from hose retaining clip and remove clip from shroud. (3) Remove lower auxiliary transmission cooler lines from retaining clips on the fan module shroud, if equipped. (4) Lower the vehicle. Remove the air intake resonator from the throttle body and air cleaner assembly. (5) Disconnect the fans electrical connector located on the left side of the fan module. (6) Remove the Coolant Recovery System (CRS) attaching screw from the upper crossmember. (7) Remove upper grill to crossmember valence panel. (8) Disconnect the upper radiator mounts from the crossmember. Remove the upper crossmember. Refer to Group 23 Body for procedure. (9) Remove the air cleaner assembly. (10) Remove fan module retaining fasteners (Fig. 31). (11) Remove upper auxiliary transmission cooler lines from retaining clips on the fan module shroud, if equipped.
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REMOVAL AND INSTALLATION (Continued)
(13) Raise the vehicle. Install the lower auxiliary transmission cooler lines to the retaining clips on the fan module shroud, if equipped. (14) Install outlet hose retainer clip to the shroud. Install the radiator outlet hose to the retaining clip. (15) Lower the vehicle.
COOLING SYSTEM
7 - 23
7 - 24
COOLING SYSTEM
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Proper Belt Tension and Belt Tension Chart in this Section for procedure. Tighten pulley lock nut to 54 Nm (40 ft. lbs.) after adjustment.
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CLEANING AND INSPECTION (Continued)
NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump.
COOLING SYSTEM
7 - 25
CHEMICAL CLEANING
One type of corrosion encountered with aluminum cylinder heads is aluminum hydroxide deposits. Corrosion products are carried to the radiator and deposited when cooled off. They appear as dark grey when wet and white when dry. This corrosion can be removed with a two part cleaner (oxalic acid and neutralizer) available in auto parts outlets. Follow manufacturers directions for use.
7 - 26
COOLING SYSTEM
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ADJUSTMENTS (Continued)
and the remove the splash shield to gain access to the drive belts.
3.0L
N/A
N/A
3.3/3.8L
TORQUE CHART
DESCRIPTION TORQUE Thermostat Housing Bolts2.4L & 3.3/3.8L . . . . . .28 Nm (250 in. lbs.) Bolts3.0L . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Water Pump Mounting Bolts2.4L & 3.3/3.8L . . . . . .12 Nm (250 in. lbs.) Bolts3.0L . . . . . . . . . . . . . . .27 Nm (240 in. lbs.) Water Pump Inlet Tube Bolts2.4L . . . . . . . . . . . . . . .12 Nm (250 in. lbs.) Bolts3.0L . . . . . . . . . . . . . . . .11 Nm (94 in. lbs.) Water Pump Pulley Bolts3.3/3.8L . . . . . . . . . . . .28 Nm (250 in. lbs.) Transaxle Oil Cooler Hose ClampsAll Engines . . . . . . . . .2 Nm (18 in. lbs.) Radiator Mounting Upper Bracket NutAll Engines . . . . . . . . . .12 Nm (105 in. lbs.)
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COOLING SYSTEM
7-1
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION COOLANT PRESSURE BOTTLE . . . . . . . . . . . . COOLING SYSTEM 2.0L GASOLINE . . . . . . COOLING SYSTEM 2.5L VM DIESEL . . . . . LOW COOLANT LEVEL SENSOR . . . . . . . . . . . RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION AUTOMATIC BELT TENSIONER . . . . . . . . . . . . BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT PERFORMANCE . . . . . . . . . . . . . . . PRESSURE/VENT CAP . . . . . . . . . . . . . . . . . . . THERMOSTAT OPERATION . . . . . . . . . . . . . . . THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE PROCEDURES ADDING ADDITIONAL COOLANT . . . . . . . . . . . DRAINING COOLING SYSTEM . . . . . . . . . . . . . REFILLING COOLING SYSTEM . . . . . . . . . . . . REMOVAL AND INSTALLATION ENGINE THERMOSTAT 2.0L GASOLINE . . . GENERAL INFORMATION COOLING SYSTEM 2.0L GASOLINE
1 1 1 1 2 6 5 5 4 4 6 3 7 7 7 9
GENERATOR/POWER STEERING BELT 2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR 2.5L VM DIESEL . . . . . . . . . . . THERMOSTAT 2.5L VM DIESEL . . . . . . . . . WATER PUMP BELT 2.5L VM DIESEL . . . WATER PUMP 2.0L GASOLINE . . . . . . . . . WATER PUMP 2.5L VM DIESEL . . . . . . . . CLEANING AND INSPECTION WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS BELT TENSION CHART . . . . . . . . . . . . . . . . . BELT TENSION GAUGE METHOD . . . . . . . . . SPECIFICATIONS COOLING SYSTEM CAPACITY . . . . . . . . . . . . TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 9 9 10 7 8 10 11 11 12 12 12
The 2.0L gasoline engine cooling system consists of an engine cooling module, thermostat, coolant, a water pump to circulate the coolant. The engine cooling module may consist of a radiator, electric fan motors, fan, shroud, coolant reserve system, hoses, clamps, air condition condenser. When the Engine is cold: The thermostat is closed; the cooling system has no flow through the radiator. The coolant flows through the engine, heater system and bypass. When the Engine is warm: Thermostat is open; the cooling system has flow through radiator, engine, heater system and bypass.
7-2
COOLING SYSTEM
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RADIATOR
The radiators are cross-flow types (horizontal tubes) with design features that provide greater strength along with sufficient heat transfer capabili-
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GENERAL INFORMATION (Continued)
COOLING SYSTEM
7-3
2.5L VM DIESEL The Diesel engine water pump has an aluminum body and housing with a stamped steel impeller. The pump uses an O-ring gasket between body and housing. The water pump is driven by the accessory drive belt, and the pump housing is bolted to the cylinder block (Fig. 9).
NOTE: The water pump on all models can be replaced without discharging the air conditioning system.
7-4
COOLING SYSTEM
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PRESSURE/VENT CAP
Fig. 8 Water Pump2.0L Gasoline Engine
WARNING: Engine coolant can reach temperatures of 200 fahrenheit or greater. If the cooling system is opened with coolant at a high temperature, hot coolant can be forced out of the system under high pressures, causing personal injury. Allow system to cool down prior to removing the pressure cap. The pressure/vent cap is secured to the coolant tank neck by a means of a cam lock system. This cap releases excess pressure at some point within a range of 90-117 kPa (13- 17 psi) for gasoline engines, and 110124 kPa (1618 psi) for diesel engines. The actual pressure relief point (in pounds) is labeled on top of the cap (Fig. 11). The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap (Fig. 11) contains a spring-loaded pressure relief valve. This valve opens when system pressure reaches approximately 103 kPa (15 psi). When the engine is cooling down, vacuum is formed within the cooling system. To prevent collapse of the radiator and coolant hoses from this vacuum, a vacuum valve is used within the cap. This valve prevents excessive pressure differences from occurring between the closed cooling system and the atmosphere. If the vacuum valve is stuck shut, the radiator and/or cooling system hoses will collapse on cooldown.
THERMOSTAT OPERATION
2.5 VM DIESEL The engine cooling thermostats are wax pellet driven, reverse poppet choke type. They are designed to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature (Fig. 10). The thermostat has a hole to bleed off air in the cooling system during engine warm up. The thermostat begins to open at 80 C 2 (176 F 4).
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DESCRIPTION AND OPERATION (Continued)
COOLING SYSTEM
7-5
100 Percent Ethylene-GlycolShould Not Be Used in Chrysler Vehicles Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F ). Propylene-glycol FormulationsShould Not Be Used in Chrysler Vehicles Propylene-glycol formulations do not meet Chrysler coolant specifications. Its overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycols freeze point. The boiling point (protection against summer boil-over) of propyleneglycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/Ethylene-glycol MixturesShould Not Be Used in Chrysler Vehicles Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.
COOLANT PERFORMANCE
ETHYLENE-GLYCOL MIXTURES The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37 deg. C (-35 deg. F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will freeze at a warmer temperature.
BELT TENSION
Correct accessory drive belt tension is required to be sure of optimum performance of belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate and greatly reduced belt life.
7-6
COOLING SYSTEM
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THERMOSTAT
DIAGNOSIS Diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded. Because of this, lower temperature gauge readings for diesel versus gasoline engines may, at times be normal. Typically, complaints of low engine coolant temperature are observed as low heater output when combined with cool or cold outside temperatures. To help promote faster engine warm-up, an electric engine block heater must be used with cool or cold outside temperatures. This will help keep the engine coolant warm when the vehicle is parked. Use the block heater if the outside temperature is below 4C (40F). Do not use the block heater if the outside temperature is above 4C (40F). TESTING
NOTE: The DRB scan tool shoud be used to monitor engine coolant temperature on the diesel engine. Refer to the 1998 GS Powertrain Diagnostic Manual for thermostat diagnosis procedure.
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COOLING SYSTEM
7-7
7-8
COOLING SYSTEM
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INSTALLATION (1) Install a new water pump to housing O-ring gasket. Install pump and tighten the attaching bolts to 22.6 Nm (205 in. lbs.)
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REMOVAL AND INSTALLATION (Continued)
COOLING SYSTEM
7-9
(2) Remove radiator hose at thermostat cover. (3) Remove thermostat cover bolts (Fig. 20). (4) Remove Thermostat.
7 - 10
COOLING SYSTEM
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INSTALLATION (1) Install water pump belt. (2) Turn adjusting bolt clockwise to tighten belt. (3) Tighten lock nut. (4) Tighten belt tensioner bracket bolts (5) Lower vehicle. (6) Install generator/power steering belt. Refer to procedure in this section.
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CLEANING AND INSPECTION (Continued)
COOLING SYSTEM
7 - 11
7 - 12
COOLING SYSTEM
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TORQUE CHART
COMPONENT Thermostat Cover Bolts Water Pump Mounting Bolts Water Pump Pulley Bolts Upper Radiator Mounting Bracket Bolts Turbocharger Oil Supply Line Turbocharger Oil Return Line Water Pump Housing Nuts Water Manifold Bolts Coolant Bottle Bolts 2.0L GASOLINE 105 in-lbs 12 Nm (105 in. lbs.) N/A 12 Nm (105 in. lbs.) N/A N/A N/A N/A 2.0 Nm (18 in. lbs.) 2.5L VM 10.8 Nm (96 in. lbs.) 22.6 Nm (204 in. lbs.) 27.5 Nm (240 in. lbs.) 12 Nm (105 in. lbs.) 24.5 Nm (215 in. lbs.) 10.8 Nm (96 in. lbs.) 9.5 Nm (84 in. lbs.) 11.2 Nm (96 in. lbs.) 10.8 Nm (96 in. lbs.)
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BATTERY
8A - 1
BATTERY
CONTENTS
page page
GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PRECAUTIONS AND WARNINGS . . . . . DESCRIPTION AND OPERATION BATTERY IGNITION OFF DRAW (IOD) . . . . . . . . CHARGING TIME REQUIRED . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING BATTERY BUILT-IN TEST INDICATOR . . . . . . . . BATTERY IGNITION OFF DRAW (IOD) . . . . . . . . BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . BATTERY OPEN CIRCUIT VOLTAGE TEST . . . . . GENERAL INFORMATION INTRODUCTION
1 1 1 2 2 3 4 6
SERVICE PROCEDURES BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . 6 CHARGING COMPLETELY DISCHARGED BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . 7 REMOVAL AND INSTALLATION BATTERY TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . 9 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . 10 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SAFETY PRECAUTIONS AND WARNINGS
WARNING: DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW THE DISABLED VEHICLES BATTERY TO EXCEED 16 VOLTS. PERSONAL INJURY OR DAMAGE TO ELECTRICAL SYSTEM CAN RESULT. TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN.
The battery stores, stabilizes, and delivers electrical current to operate various electrical systems in the vehicle. The determination of whether a battery is good or bad is made by its ability to accept a charge. It also must supply high-amperage current for a long enough period to be able to start the vehicle. The capability of the battery to store electrical current comes from a chemical reaction. This reaction takes place between the sulfuric acid solution (electrolyte) and the lead +/- plates in each cell of the battery. As the battery discharges, the plates react with the acid from the electrolyte. When the charging system charges the battery, the water is converted to sulfuric acid in the battery. The concentration of acid in the electrolyte is measured as specific gravity using a hydrometer. The original equipment (OE) battery is equipped with a hydrometer (test indicator) built into the battery cover. The specific gravity indicates the batterys state-of-charge. The OE battery is sealed and water cannot be added. The battery is vented to release gases that are created when the battery is being charged and discharged. The battery top, posts, and terminals should be cleaned when other under hood maintenance is performed. When the electrolyte level is below the top of the plates, Clear in the test Indicator, the battery must be replaced. The battery must be completely charged, and the battery top, posts, and cable clamps must be cleaned before diagnostic procedures are performed.
8A - 2
BATTERY
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SIZE OF BATTERY A completely discharged large heavy-duty battery may require more recharging time than a completely discharged small capacity battery, refer to the Battery Charging Timetable for charging times. BATTERY CHARGING TIMETABLE
Charging Amperage Open Circuit Voltage 12.25 to 12.39 12.00 to 12.24 11.95 to 11.99 10.00 to 11.94 less than 10.00 5 Amperes 10 Amperes 20 Amperes
Hours Charging at 21C (70F) 6 hours 8 hours 12 hours 14 hours 3 hours 4 hours 6 hours 7 hours 1.5 hours 2 hours 3 hours 3.5 hours
TEMPERATURE A longer time will be needed to charge a battery at -18C (0F) than at 27C (80F). When a fast charger is connected to a cold battery, current accepted by battery will be very low at first. In time, the battery will accept a higher rate as battery temperature warms. CHARGER CAPACITY A charger which can supply only five amperes will require a much longer period of charging than a charger that can supply 20 amperes or more. STATE OF CHARGE A completely discharged battery requires more charging time than a partially charged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current amperage will be low. As water is converted back to sulfuric acid inside the battery, the current amp rate will rise. Also, the specific gravity of the electrolyte will rise, bringing the green ball (Fig. 1) into view at approximately 75 percent state-of-charge.
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DIAGNOSIS AND TESTING (Continued)
BATTERY
8A - 3
Defective electrical circuit or component causing excess Ignition Off Draw (IOD). Refer to Battery Ignition Off Draw (IOD). Defective charging system. Defective battery.
CAUSES OF BATTERY DISCHARGING It is normal to have a small 5 to 25 milliamperes continuous electrical draw from the battery. This draw will take place with the ignition in the OFF position, and the courtesy, dome, storage compartments, and engine compartment lights OFF. The continuous draw is due to various electronic features or accessories that require electrical current with the ignition OFF to function properly. When a vehicle is not used over an extended period of approximately 20 days the IOD fuse should be pulled. The fuse is located in the power distribution center. Disconnection of this fuse will reduce the level of battery discharge. Refer to Battery Diagnosis and Testing table and to the proper procedures. ABNORMAL BATTERY DISCHARGING Corroded battery posts, cables or terminals. Loose or worn generator drive belt. Electrical loads that exceed the output of the charging system due to equipment or accessories installed after delivery. Slow driving speeds in heavy traffic conditions or prolonged idling with high-amperage electrical systems in use.
8A - 4
BATTERY
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(1) Battery is above 12.40 Volts (2) Battery is below 12.40 Volts. (1) Battery accepted Charge. (2) Battery will not accept charge
(1) Battery accepted charge. (2) Battery will not accept charge.
(c) If reading does not change, disconnect the TCM. (d) If reading is OK, replace TCM. (e) If reading stays, there is a short circuit to one of the modules. Refer to Group 8W, Wiring Diagrams.
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DIAGNOSIS AND TESTING (Continued)
BATTERY
8A - 5
9.3 volts 9.1 volts 8.9 volts 8.7 volts 8.5 volts
(6) If battery passes load test, it is in good condition and further tests are not necessary. If it fails load test, it should be replaced.
8A - 6
BATTERY
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It may be necessary to jiggle the battery or vehicle to bring the green dot in the test indicator into view.
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SERVICE PROCEDURES (Continued)
After the battery has been charged to 12.4 volts or greater, perform a load test to determine cranking capacity. Refer to Battery Load Test in this Group. If the battery passes the load test, return the battery to use. If battery will not endure a load test, it must be replaced. Properly clean and inspect battery hold downs, tray, terminals, cables, posts, and top before completing service.
BATTERY
8A - 7
charge current is measurable during charging time, the battery may be good, and charging should be completed in the normal manner.
VISUAL INSPECTION
CAUTION: Do not allow baking soda solution to enter vent holes, as damage to battery can result. (1) Clean top of battery with a solution of warm water and baking soda. (2) Apply soda solution with a bristle brush and allow to soak until acid deposits loosen (Fig. 11).
(1) Measure the voltage at battery posts with a voltmeter accurate to 1/10 volt (Fig. 10). If below 10 volts, charge current will be low, and it could take some time before it accepts a current in excess of a few milliamperes. Such low current may not be detectable on amp meters built into many chargers.
8A - 8
BATTERY
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REMOVAL (1) Verify that the ignition switch and all accessories are OFF. (2) Disconnect battery cable terminals from the battery posts, negative first (Fig. 14).
INSTALLATION Inspect and clean battery and attaching components before installation. (1) Install battery in vehicle making sure that battery is properly positioned on battery tray. (2) Install battery hold down.
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REMOVAL AND INSTALLATION (Continued)
BATTERY
8A - 9
BATTERY TRAY
REMOVAL (1) Remove battery, refer to the above procedures. (2) Remove nut and two bolts from battery tray (Fig. 18). (3) Remove battery tray from vehicle. (4) Remove speed control servo attaching bolt from battery tray (if equipped). Use care when disconnecting vacuum lines from reservoir (Fig. 19). INSTALLATION For installation, reverse the above procedures.
8A - 10
BATTERY
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TORQUE
DESCRIPTION TORQUE Battery Hold Down Bolt Clamp Bolt . . . . . . . . . . . . . . . . . . . .14 Nm (125 in. lbs.)
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BATTERY
8A - 1
BATTERY
CONTENTS
page page
GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PRECAUTIONS AND WARNINGS . . . . DESCRIPTION AND OPERATION BATTERY IGNITION OFF DRAW (IOD) . . . . . . . CHARGING TIME REQUIRED . . . . . . . . . . . . . . DIAGNOSIS AND TESTING BATTERY DISCHARGING . . . . . . . . . . . . . . . . . BATTERY IGNITION OFF DRAW . . . . . . . . . . . . BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . BATTERY OPEN CIRCUIT VOLTAGE TEST . . . . GENERAL INFORMATION INTRODUCTION
1 1 2 2 3 3 5 6
SERVICE PROCEDURES BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . CHARGING COMPLETELY DISCHARGED BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY TRAY . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 7 7 8 9 9 10
The battery stores, stabilizes, and delivers electrical current to operate various electrical systems in the vehicle (Fig. 1). The determination of whether a battery is good or bad is made by its ability to accept a charge. It also must supply high-amperage current for a long enough period to be able to start the vehicle. The capability of the battery to store electrical current comes from a chemical reaction. This reaction takes place between the sulfuric acid solution (electrolyte) and the lead +/- plates in each cell of the battery. As the battery discharges, the plates react with the acid from the electrolyte. When the charging system charges the battery, the water is converted to sulfuric acid in the battery. The concentration of acid in the electrolyte is measured as specific gravity using a hydrometer. The specific gravity indicates the batterys state-of-charge. The battery is vented to release gases that are created when the battery is being charged and discharged. The battery top, posts, and terminals should be cleaned when other under hood maintenance is performed. The battery top, posts, cable clamps must be cleaned and battery must be completely charged before diagnostic procedures are performed.
8A - 2
BATTERY
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CHARGER CAPACITY A charger which can supply only five amperes will require a much longer period of charging than a charger that can supply 20 amperes or more. STATE OF CHARGE A completely discharged battery requires more charging time than a partially charged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current amperage will be low. As water is converted back to sulfuric acid inside the battery, the current amp rate will rise. Also, the specific gravity of the electrolyte will rise. The electrolyte should be tested with a Hydrometer to check the specific gravity. USING HYDROMETER Before performing a hydrometer test, remove the battery caps and check the electrolyte level. Add distilled water as required.
NOTE: Periodically disassemble the hydrometer and wash components with soap and water. Inspect the float for possible leaks. If the paper inside has turned brown, the float is defective. Before testing, visually inspect the battery for any damage: Cracked container or cover Loose post Corrosion and any other thing that would cause the battery to be unserviceable. To interpret the hydrometer correctly, hold it with the top surface of the electrolyte in the hydrometer at eye level. Disregard the curvature of the liquid where the surface rises against the float because of surface cohesion (Fig. 3). Remove only enough electrolyte from the battery to keep the float off the bottom of the hydrometer barrel with pressure on the bulb released. Keep the hydrometer in a vertical position while drawing the electrolyte into the hydrometer and observing the specific gravity. Exercise care when inserting the tip of the hydrometer into a cell to avoid damage to the separators. Damaged separators can cause premature battery failure. Hydrometer floats are generally calibrated to indicate the specific gravity correctly only at one fixed temperature, 20C (68F). When testing the specific gravity at any other temperature, a correction factor is required, otherwise specific gravity readings will not indicate the true state of charge. The correction factor is approximately a specific gravity value of 0.004, referred to as 4 points of specific gravity for every 5.5C (10F). If electrolyte temperature is below 20C (68F) you subtract. If the temperature is above 20C (68F) you add to the
SIZE OF BATTERY A completely discharged large heavy-duty battery may require more recharging time than a completely discharged small capacity battery, refer to (Fig. 2) for charging times.
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DESCRIPTION AND OPERATION (Continued)
BATTERY
8A - 3
When the specific gravity of all cells is above 1.235 and variation between cells is less than 50 points (0.050), the battery may be tested under heavy load.
Example 1: Hydrometer reading: 1.260 Electrolyte temperature: -7C (20F) Subtract specific gravity: -0.019 Correction specific gravity: 1.241 Example 2: Hydrometer reading: 1.225 Electrolyte temperature: -38C (100F) Add specific gravity: +0.013 Correction specific gravity: 1.238 A fully charged relatively new battery has a specific gravity reading of 1.285 plus 0.015 or minus 0.010. If the specific gravity of all cells is above 1.235, but variation between cells is more than 50 points (0.050), it is an indication that the battery is unserviceable. If the specific gravity of one or more cells is less than 1.235, recharge the battery at a rate of approximately 5 amperes. Continue charging until three consecutive specific gravity tests, taken at one-hour intervals, are constant. If the cell specific gravity variation is more than 50 points (0.050) at the end of the charge period, replace the battery.
8A - 4
BATTERY
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(1) Battery accepted charge. (2) Battery will not accept charge.
meter. After all modules time-out the total vehicle IOD should be less than 25 milliamperes. If ignition off draw is more than 25 milliamperes go to Step 4. (4) Each time the test lamp or milliampere meter is disconnected and connected, all electronic timer functions will be activated for approximately one minute. The Body Control Module (BCM) ignition off draw can reach 90 milliamperes. (5) Remove the PDC fuses: Interior lamps Brake lamp IOD (6) If there is any reading, with fuses removed there is a short circuit in the wiring. Refer to Group 8W, wiring diagrams. If reading is less than 25 mA go to Step 8. (7) Install all fuses. After installing fuse, the current can reach 90 mA. After time-out the reading should not exceed 25 mA. If OK go to. If not, disconnect: Radio
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DIAGNOSIS AND TESTING (Continued)
BATTERY
8A - 5
(2) Connect a Volt/Ammeter/Load tester to the battery posts (Fig. 6). Rotate the load control knob of the Carbon pile rheostat to apply a 300 amp load. Apply this load for 15 seconds to remove the surface charge from the battery, and return the control knob to off (Fig. 7).
8A - 6
BATTERY
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(6) If battery passes load test, it is in good condition and further tests are not necessary. If it fails load test, it should be replaced.
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SERVICE PROCEDURES (Continued)
CAUTION: Disconnect the battery NEGATIVE cable first (Fig. 4) before charging battery to avoid damage to electrical systems. Do not exceed 16.0 volts while charging battery. Refer to the instructions supplied with charging equipment A battery is considered fully charged when it will meet all the following requirements. It has an open circuit voltage charge of at least 12.4 volts (Fig. 10). It passes the 15 second load test, refer to the Load Test Temperature chart. The specific gravity reading is 1.285 plus 0.015 or minus 0.010. Battery electrolyte will bubble inside of battery case while being charged properly. If the electrolyte boils violently, or is discharged from the vent holes while charging, immediately reduce charging rate or turn off charger. Evaluate battery condition. Battery damage may occur if charging is excessive. Some battery chargers are equipped with polarity sensing devices to protect the charger or battery from being damaged if improperly connected. If the battery state of charge is too low for the polarity sensor to detect, the sensor must be bypassed for charger to operate. Refer to operating instructions provided with battery charger being used. CAUTION: Do not overcharge Battery. Test the battery until the specific gravity reading is 1.285 plus 0.015 or minus 0.010. After the battery has been charged to 12.4 volts or greater, perform a load test to determine cranking capacity. Refer to Battery Load Test in this Group. If the battery passes the load test, return the battery to use. If battery will not endure a load test, it must be replaced. Properly clean and inspect battery hold downs, tray, terminals, cables, posts, and top before completing service.
BATTERY
8A - 7
VISUAL INSPECTION
CAUTION: Do not allow baking soda solution to enter vent holes, as damage to battery can result. (1) Clean top of battery with a solution of warm water and baking soda. (2) Apply soda solution with a bristle brush and allow to soak until acid deposits loosen (Fig. 13). (3) Rinse soda solution from battery with clear water and blot battery dry with paper toweling. Dispose of toweling in a safe manner. Refer to the WARNINGS on top of battery. (4) Inspect battery case and cover for cracks, leakage or damaged hold down ledge. If battery is damaged replace it.
8A - 8
BATTERY
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REMOVAL (1) Verify that the ignition switch and all accessories are OFF. (2) Disconnect battery cable terminals from the battery posts, negative first (Fig. 16). 3 (3) Remove battery hold down (Fig. 17). (4) Remove battery from vehicle (Fig. 18). INSTALLATION Inspect and clean battery and attaching components before installation. (1) Install battery in vehicle making sure that battery is properly positioned on battery tray. (2) Install battery hold down. (3) Connect battery cable terminals, positive cable first. Make sure the top of battery terminals are flush with top of posts.
WARNING: DO NOT OVER TIGHTEN BATTERY CABLE CLAMPS, DAMAGE TO CLAMPS CAN RESULT.
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REMOVAL AND INSTALLATION (Continued)
BATTERY
8A - 9
BATTERY TRAY
REMOVAL (1) Remove battery, refer to the above procedures. (2) Remove nut and two bolts from battery tray (Fig. 19). (3) Remove battery tray from vehicle. (4) Remove speed control servo attaching bolt from battery tray (if equipped). Use care when disconnecting vacuum lines from reservoir (Fig. 20). INSTALLATION For installation, reverse the above procedures.
8A - 10
BATTERY
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SPECIFICATIONS (Continued)
TORQUE
DESCRIPTION TORQUE Battery Hold Down Bolt Clamp Bolt . . . . . . . . . . . . . . . . . . . 14 Nm (125 in. lbs.)
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STARTER
8B - 1
STARTER
CONTENTS
page page
GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION SUPPLY CIRCUIT AND CONTROL CIRCUIT . . . . DIAGNOSIS AND TESTING CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . . FEED CIRCUIT RESISTANCE TEST . . . . . . . . . . . FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION INTRODUCTION
1 1 1 3 4
REMOVAL AND INSTALLATION STARTER2.4L ENGINE . . . . . . . . . . . . . . . . . . STARTER3.0L ENGINE . . . . . . . . . . . . . . . . . . STARTER3.3/3.8L ENGINE . . . . . . . . . . . . . . . SPECIFICATIONS STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 6 6 7 7
The starting system has (Fig. 1): Ignition switch Starter relay Powertrain Control Module (PCM) double start override Neutral starting and back up switch with automatic transmissions only Wiring harness Battery Starter motor with an integral solenoid Positive Temperature Coefficient (PTC) is the circuit protection for the ignition feed to the starter relay coil. The PTC is located in the Junction Block. These components form two separate circuits. A high amperage circuit that feeds the starter motor up to 300+ amps, and a control circuit that operates on less than 20 amps.
8B - 2
STARTER
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STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APPLIED (1) Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests. Refer to Battery Tests. (2) Perform Starter Solenoid test BEFORE performing the starter relay test. (3) Raise the vehicle. (4) Perform a visual inspection of the starter/ starter solenoid for corrosion, loose connections or faulty wiring. (5) Lower the vehicle. (6) Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. (7) Connect a remote starter switch or a jumper wire between the remote battery positive post and terminal 87 of the starter relay connector. (a) If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test. (b) If engine does not or solenoid chatters, check wiring and connectors from starter relay to starter solenoid for loose or corroded connections. Particularly at starter terminals. (c) Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter.
RELAY TEST The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described in this group to perform the following tests: (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. (2) Resistance between terminals 85 and 86 (electromagnet) should be 75 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. (3) Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay.
Starter Relay
RELAY CIRCUIT TEST (1) The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. (2) The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. (3) The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. (4) The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is held in the Start position. On
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED
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DIAGNOSIS AND TESTING (Continued)
vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure in this group. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch Test procedure in this group. (5) The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch Test procedure in this group. If not OK with a manual transmission, repair the circuit to ground as required.
STARTER
8B - 3
SAFETY SWITCHES For diagnostics, Clutch Pedal Position Switch, refer to Group 6, Clutch. Park/Neutral Position Switch, refer to Group 21, Transaxle IGNITION SWITCH After testing starter solenoid and relay, test ignition switch and wiring. Refer to Group 8D, Ignition Systems or Group 8W, Wiring Diagrams. Check all wiring for opens or shorts, and all connectors for being loose or corroded. BATTERY Refer to Group 8A, Battery for proper procedures. ALL RELATED WIRING AND CONNECTORS Refer to Group 8W, Wiring Diagrams,
8B - 4
STARTER
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DIAGNOSIS AND TESTING (Continued)
CAUTION: Before performing any starter tests, the ignition and fuel systems must be disabled. (1) Connect a volt-ampere tester to the battery terminals (Fig. 7). Refer to the operating instructions provided with the tester being used.
STARTER
8B - 5
equipment and connect ASD relay or the Fuel Solenoid. Start the vehicle several times to assure the problem has been corrected.
8B - 6
STARTER
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STARTER3.0L ENGINE
REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable (Fig. 8). (3) Hoist and support vehicle on safety stands. (4) Remove nut holding solenoid wire to terminal (Fig. 10).
STARTER3.3/3.8L ENGINE
REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable (Fig. 8). (3) Hoist and support vehicle on safety stands. (4) Remove nut holding B+ terminal to starter solenoid (Fig. 12).
INSTALLATION (1) Place starter in position on vehicle. (2) Install bolts to hold starter to transaxle bellhousing. (3) Place solenoid and B+ wires in position on starter terminals. (4) Install nut to hold B+ wire to terminal. (5) Install nut to hold solenoid wire to terminal. (6) Lower vehicle. (7) Connect battery negative cable. (8) Verify starter operation.
INSTALLATION (1) Place starter spacer in position on transaxle bellhousing, flange toward flywheel. (2) Place starter in position on bellhousing. (3) Install bolts to hold starter to transaxle bellhousing.
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REMOVAL AND INSTALLATION (Continued)
(8) Verify starter operation.
STARTER
8B - 7
SPECIFICATIONS STARTER
MANUFACTURER Engine Application Power rating Voltage No. of Fields No. of Poles Brushes Drive Free running Test Voltage Amperage Draw Minimum Speed SolenoidClosing Voltage Cranking Amperage Draw test 11 73 Amp 3401 RPM 7.5 Volts 150 - 200 Amps. NIPPONDENSO 2.4L /3.0L /3.3/3.8L 1.2 Kw 12 VOLTS 4 4 4 Conventional Gear Train
Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase starter amperage draw.
TORQUE
Fig. 14 Starter3.3/3.8L Engine
(4) (5) noid. (6) (7) Connect solenoid connector into starter. Install nut to hold B+ terminal to starter soleLower vehicle. Connect battery negative cable. DESCRIPTION TORQUE Starter Mounting Bolts. . . . . . . . .54 Nm (40 ft. lbs.) Starter Solenoid Battery Nut . . . .10 Nm (90 in. lbs.)
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STARTING SYSTEM
8B - 1
STARTING SYSTEM
CONTENTS
page
8B - 2
STARTING SYSTEM
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REMOVAL AND INSTALLATION (Continued)
STARTING SYSTEM
8B - 3
3.0L ENGINE
REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable (Fig. 1). (3) Hoist and support vehicle on safety stands. (4) Remove nut holding solenoid wire to terminal (Fig. 5). 6)
8B - 4
STARTING SYSTEM
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3.3/3.8L ENGINE
REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable (Fig. 1). (3) Hoist and support vehicle on safety stands. (4) Remove nut holding B+ terminal to starter solenoid (Fig. 7). (5) Disconnect solenoid connector from starter. (6) Remove bolts holding starter to transaxle bellhousing. (7) Remove starter from bellhousing (Fig. 8). (8) Separate starter spacer from transaxle bellhousing.
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REMOVAL AND INSTALLATION (Continued)
2.5L DIESEL ENGINE
REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable (Fig. 1). (3) Hoist and support vehicle on safety stands. (4) Disconnect solenoid wire connector from terminal. (5) Remove nut holding B+ wire to terminal. (6) Disconnect solenoid and B+ wires from starter terminal. (7) Remove three bolts holding starter to transaxle bellhousing (Fig. 9). (8) Remove starter. INSTALLATION For installation, reverse the above procedures and verify the operation of the starter.
STARTING SYSTEM
8B - 5
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CHARGING SYSTEM
8C - 1
CHARGING SYSTEM
CONTENTS
page page
GENERAL INFORMATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION BATTERY TEMPERATURE SENSOR . . . . . . . . . . CHARGING SYSTEM OPERATION . . . . . . . . . . . ELECTRONIC VOLTAGE REGULATOR . . . . . . . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING CHARGING SYSTEM RESISTANCE TESTS . . . . . CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION OVERVIEW
1 2 1 2 2 4 2
CURRENT OUTPUT TEST . . . . . . . . . . . . . . . . . . 4 ON-BOARD DIAGNOSTIC SYSTEM TEST . . . . . . 7 REMOVAL AND INSTALLATION GENERATOR2.4L ENGINE . . . . . . . . . . . . . . . . 9 GENERATOR3.0L ENGINE . . . . . . . . . . . . . . . . 9 GENERATOR3.3/3.8 L ENGINE . . . . . . . . . . . 10 SPECIFICATIONS GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION AND OPERATION CHARGING SYSTEM OPERATION
The charging system consists of: Generator Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM) Ignition switch (refer to Group 8D, Ignition System for information) Battery (refer to Group 8A, Battery for information) Temperature is measured by a sensor in the PCM circuitry Wiring harness and connections (refer to Group 8W, Wiring for information) The charging system is turned on and off with the ignition switch. When the ignition switch is turned to the ON position, battery voltage is applied to the generator rotor through one of the two field terminals to produce a magnetic field. The generator is driven by the engine through a serpentine belt and pulley arrangement. The amount of DC current produced by the generator is controlled by the EVR (field control) circuitry, contained within the PCM. This circuitry is connected in series with the second rotor field terminal and ground. All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including the EVR (field control) circuitry, are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. See OnBoard Diagnostic System Test in this group for more information.
The battery, starting, and charging systems operate with one another, and must be tested as a complete system. In order for the vehicle to start and charge properly, all of the components involved in these systems must perform within specifications. Group 8A covers the battery, Group 8B covers the starting system, and Group 8C covers the charging system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams. We have separated these systems to make it easier to locate the information you are seeking within this Service Manual. However, when attempting to diagnose any of these systems, it is important that you keep their interdependency in mind. The diagnostic procedures used in these groups include the most basic conventional diagnostic methods to the more sophisticated On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an induction ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt test lamp may be required. All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. See the On-Board Diagnostics Test in Group 8C - Charging System for more information.
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GENERATOR
The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: Worn, loose or defective bearings Loose or defective drive pulley Incorrect, worn, damaged or misadjusted drive belt Loose mounting bolts Misaligned drive pulley Defective stator or diode
INSPECTION (1) Inspect condition of battery cable terminals, battery posts, connections at engine block, starter solenoid and relay. They should be clean and tight. Repair as required. (2) Inspect all fuses in the fuseblock module and Power Distribution Center (PDC) for tightness in receptacles. They should be properly installed and tight. Repair or replace as required. (3) Inspect the electrolyte level in the battery. Replace battery if electrolyte level is low. (4) Inspect generator mounting bolts for tightness. Replace or tighten bolts if required. Refer to the Generator Removal/Installation section of this group for torque specifications. (5) Inspect generator drive belt condition and tension. Tighten or replace belt as required. Refer to Belt Tension Specifications in Group 7, Cooling System. (6) Inspect automatic belt tensioner (if equipped). Refer to Group 7, Cooling System for information. (7) Inspect connections at generator field, battery output, and ground terminals. Also check ground connection at engine. They should all be clean and tight. Repair as required.
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in this circuit to locate the excessive resistance. This test can also be performed between the generator case and the engine. If test voltage is higher than 0.3 volts, check for corrosion at generator mounting points or loose generator mounting.
PREPARATION (1) Before starting test, make sure battery is in good condition and is fully-charged. See Group 8A, Battery for more information. (2) Check condition of battery cables at battery. Clean if necessary. (3) Start the engine and allow it to reach normal operating temperature. (4) Shut engine off. (5) Connect an engine tachometer. (6) Fully engage the parking brake. TEST (1) Start engine. (2) Place heater blower in high position. (3) Turn on headlamps and place in high-beam position. (4) Turn rear window defogger on. (5) Bring engine speed up to 2400 rpm and hold. (6) Testing (+ positive) circuitry: (a) Touch the negative lead of voltmeter directly to battery positive POST (Fig. 2). (b) Touch the positive lead of voltmeter to the B+ output terminal stud on the generator (not the terminal mounting nut). Voltage should be no higher than 0.6 volts. If voltage is higher than 0.6 volts, touch test lead to terminal mounting stud nut and then to the wiring connector. If voltage is now below 0.6 volts, look for dirty, loose or poor connection at this point. Also check condition of the generator output wire-to-battery bullet connector. Refer to Group 8, Wiring for connector location. A voltage drop test may be performed at each (ground) connection in this circuit to locate the excessive resistance. (7) Testing (- ground) circuitry: (a) Touch the positive lead of voltmeter directly to battery negative POST. (b) Touch the negative lead of voltmeter to the generator case. Voltage should be no higher than 0.3 volts. If voltage is higher than 0.3 volts, touch test lead to generator case and then to the engine block. If voltage is now below 0.3 volts, look for dirty, loose or poor connection at this point. A voltage drop test may be performed at each connection
PREPARATION (1) Determine if any Diagnostic Trouble Codes (DTC) exist. To determine a DTC, refer to On-Board Diagnostics in this group. For repair, refer to the appropriate Powertrain Diagnostic Procedures manual. (2) Before starting test, make sure battery is in good condition and is fully-charged. See Group 8A, Battery for more information. (3) Check condition of battery cables at battery. Clean if necessary. (4) Perform the Voltage Drop Test. This will ensure clean and tight generator/battery electrical connections. (5) Be sure the generator drive belt is properly tensioned. Refer to Group 7, Cooling System for information. (6) A volt/amp tester equipped with both a battery load control (carbon pile rheostat) and an inductivetype pickup clamp (ammeter probe) will be used for this test. Refer to operating instructions supplied with tester. When using a tester equipped with an inductive-type clamp, removal of wiring at the generator will not be necessary. (7) Start the engine and allow it to reach operating temperature. (8) Shut engine off. (9) Turn off all electrical accessories and all vehicle lighting. (10) Connect the volt/amp tester leads to the battery. Be sure the carbon pile rheostat control is in the OPEN or OFF position before connecting leads. See Load Test in Group 8A, Battery for more information. Also refer to the operating instructions supplied with test equipment. (11) Connect the inductive clamp (ammeter probe). Refer to the operating instructions supplied with test equipment. (12) If volt/amp tester is not equipped with an engine tachometer, connect a separate tachometer to the engine.
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CHARGING SYSTEM TEST
CHARGING SYSTEM
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tor Ratings chart. This can be found in the Specifications section at the end of this group. A label stating a part reference number is attached to the generator case. On some engines this label may be located on the bottom of the case. Compare this reference number to the Generator Ratings chart. (7) Rotate the load control to the OFF position. (8) Continue holding engine speed at 2500. If EVR circuitry is OK, amperage should drop below 1520 amps. With all electrical accessories and vehicle lighting off, this could take several minutes of engine operation. If amperage did not drop, refer to the appropriate Powertrain Diagnostic Procedures manual for testing. (9) Remove volt/amp tester. If minimum amperage could not be met, refer to the appropriate Powertrain Diagnostic Procedures manual for testing.
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CHARGING SYSTEM
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GENERATOR3.0L ENGINE
REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable (Fig. 3). (3) Remove windshield wiper housing, refer to Group 8K, Windshield Wipers and Washers for proper procedures. (4) Remove accessory drive belt, refer to Group 7, Cooling System for proper procedures. (5) Remove bolt holding top of generator to mount bracket (Fig. 6). (6) Remove bolt holding bottom of generator to lower pivot bracket (Fig. 4). (7) Disengage push-in field wire connector from back of generator. (8) Remove nut holding B+ wire terminal to back of generator. (9) Remove B+ terminal from generator. INSTALLATION (1) Place B+ terminal in position on generator. (2) Install nut to hold B+ wire terminal to back of generator (3) Connect the push-in field wire connector into back of generator.
INSTALLATION (1) Place generator in position on vehicle. (2) Install bolt to hold bottom generator pivot to lower mount.
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GENERATOR3.3/3.8 L ENGINE
REMOVAL (1) Release hood latch and open hood. (2) Disconnect battery negative cable (Fig. 3). (3) Remove windshield wiper housing, refer to Group 8K, Windshield Wipers and Washers for proper procedures. (4) Remove accessory drive belt, refer to Group 7, Cooling System for proper procedures. (5) Remove bolt holding top of generator mount bracket to engine air intake plenum (Fig. 7). (6) Remove bolts holding outside of generator mount bracket to generator mount plate. (7) Remove bolt holding top of generator to mount bracket. (8) Remove generator mount bracket from vehicle. (9) Rotate generator toward rear dash panel. (10) Disconnect the push-in field wire connector from back of generator (Fig. 6). (11) Remove nut holding B+ wire terminal to back of generator. (12) Separate B+ terminal from generator. (13) Remove bolt holding bottom of generator to lower pivot bracket (Fig. 8). (14) Remove generator from vehicle (Fig. 9).
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REMOVAL AND INSTALLATION (Continued)
(2) Install bolt to hold bottom of generator to lower pivot bracket. (3) Place B+ terminal in position on generator. (4) Install nut to hold B+ wire terminal to back of generator. (5) Connect the push-in field wire connector into back of generator. (6) Rotate generator forward away from dash panel. (7) Place generator mount bracket in position on vehicle. (8) Install bolt to hold top of generator to mount bracket. (9) Install bolts to hold outside of generator mount bracket to generator mount plate. (10) Install bolt to hold top of generator mount bracket to engine air intake plenum. (11) Install accessory drive belt, refer to Group 7, Cooling System for proper procedures. (12) Install windshield wiper housing, refer to Group 8K, Windshield Wipers and Washers for proper procedures. (13) Connect battery negative cable. (14) Verify generator charge rate.
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SPECIFICATIONS GENERATOR
Type Nippondenso 90 A HS Nippondenso 120 A HS Part Number 4727220 4727221 Amperage output 86 Amp 98 Amp
TORQUE
DESCRIPTION TORQUE Battery Hold Down Bolt . . . . . . .14 Nm (125 in. lbs.) Generator Mounting Bolts . . . . . .54 Nm (40 ft. lbs.) Generator B+ Terminal . . . . . . . . .9 Nm (75 in. lbs.) Starter Mounting Bolts. . . . . . . . .54 Nm (40 ft. lbs.) Starter Solenoid Battery Nut . . . .10 Nm (90 in. lbs.)
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CONTENTS
page page
GENERAL INFORMATION
INDEX
page GENERAL INFORMATION AUTOMATIC SHUTDOWN (ASD) RELAY . . CAMSHAFT POSITION SENSOR . . . . . . . . CRANKSHAFT POSITION SENSOR . . . . . . ENGINE COOLANT TEMPERATURE (ECT) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION COIL . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . LOCK KEY CYLINDER . . . . . . . . . . . . . . . . MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . POWERTRAIN CONTROL MODULE . . . . . . SPARK PLUG CABLE . . . . . . . . . . . . . . . . . SPARK PLUGS2.4/3.0L . . . . . . . . . . . . . . SPARK PLUGS3.3/3.8L . . . . . . . . . . . . . . THROTTLE POSITION SENSOR (TPS) . . . page DIAGNOSIS AND TESTING CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR . . . . . . . . . 11 CHECK COIL TEST2.4L . . . . . . . . . . . . . . . . . . 9 CHECK COIL TEST3.3/3.8L . . . . . . . . . . . . . . . . 9 ENGINE COOLANT TEMPERATURE SENSOR . . 11 FAILURE TO START TEST . . . . . . . . . . . . . . . . . 10 IGNITION TIMING PROCEDURE . . . . . . . . . . . . 11 INTAKE AIR TEMPERATURE SENSOR . . . . . . . . 11 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . 11 SPARK PLUG CONDITION . . . . . . . . . . . . . . . . . 11 TESTING FOR SPARK AT COIL2.4/3.3/3.8L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TESTING FOR SPARK AT COIL3.0L . . . . . . . . . 8 THROTTLE POSITION SENSOR . . . . . . . . . . . . 13 SERVICE PROCEDURES IGNITION TIMING PROCEDURE . . . . . . . . . . . . 15 POWERTRAIN CONTROL MODULE . . . . . . . . . . 13 SPARK PLUG GAP ADJUSTMENT . . . . . . . . . . . 13
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IGNITION SYSTEM
NOTE: The 2.4, 3.0 and 3.3/3.8L engines use a fixed ignition timing system. Basic ignition timing is not adjustable. All spark advance is determined by the Powertrain Control Module (PCM). The distributorless ignition system used on 2.4 and 3.3/3.8L engines is refered to as the Direct Ignition System (DIS). The systems three main components are the coil pack, crankshaft position sensor, and camshaft position sensor. The crankshaft position sensor and camshaft position sensor are hall effect devices. The 3.0L engine uses a distributor, crankshaft sensor and ignition coil. The systems main components are the distributor, distributor pickup, camshaft signal, crankshaft signal and ignition coil.
SPARK PLUGS2.4/3.0L
All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester.
SPARK PLUGS3.3/3.8L
The 3.3/3.8L engines utilize platinum spark plugs. Refer to the maintenance schedule in Group 0 of this service manual.
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All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Group O - Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Refer to the Spark Plug Condition section of this group. The spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions per schedule A in this manual. The spark plugs have a recommended service life of 75,000 miles for serve driving conditions per schedule B in this manual. A thin platinum pad is welded to both electrode ends as show in (Fig. 3). Extreme care must be used to prevent spark plug cross threading, mis-gaping and ceramic insulator damage during plug removal and installation. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicles original spark plugs that have been determined good. Do not apply anti-seize compound to new spark plugs. NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the antiseize compound doesnt make contact with the spark plug electrodes or ceramic insulator. Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without reading the 3.3/3.8L Spark Plug Gap Measurement procedures in this section. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Overtightening can also damage the cylinder head. Tighten spark plugs to 28 Nm (20 ft. lbs.) torque. Due to the engine packaging environment for the 3.3/3.8L engines, extreme care should be used when
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SPARK PLUG CABLES3.3/3.8L The spark plug cables and spark plug boots are made from high temperature silicone materials. The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. They also identify proper heat shield installation on the boot for service. Refer to 3.3/3.8L Spark Plug Cable removal and installation. All spark plug cable leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B in this manual. The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse heat shields that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The bottom of the spark plug heat shield must make contact with the spark plug hex. The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures.
IGNITION COIL
WARNING: THE DIRECT IGNITION SYSTEM GENERATES APPROXIMATELY 40,000 VOLTS. PERSONAL INJURY COULD RESULT FROM CONTACT WITH THIS SYSTEM. The ignition coil assembly consists of 3 independent coils molded together (Fig. 4). The coil assembly is mounted on the intake manifold. Spark plug cables route to each cylinder from the coil. The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the other cylinder fires on the exhaust stroke. The Powertrain Control Module (PCM) determines which of the coils to charge and fire at the correct time. Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5, coil 3 fires cylinders 3 and 6.
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GENERAL INFORMATION (Continued)
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KNOCK SENSOR
The knock sensor threads into the side of the cylinder block in front of the starter motor. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystals vibration increase, the knock sensor output voltage also increases.
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DIAGNOSIS AND TESTING (Continued)
sure that the spark plugs are firing. Inspect the distributor rotor, cap, spark plug cables, and spark plugs. If they are in proper working order, the ignition system is not the reason why the engine will not start. Inspect the fuel system and engine for proper operation.
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DIAGNOSIS AND TESTING (Continued)
either the crankshaft position sensor/camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Use the DRB scan tool to test the camshaft position sensor and the sensor circuits. Refer to the appropriate Powertrain Diagnostics Procedure Manual. Refer to the wiring diagrams section for circuit information.
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COLD FOULING (CARBON FOULING) Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon (Fig. 23). A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. OIL FOULING A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones. OIL OR ASH ENCRUSTED If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers (Fig. 24). Sometimes fuel additives can cause ash encrustation on an entire set of spark
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DIAGNOSIS AND TESTING (Continued)
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SERVICE PROCEDURES (Continued)
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2.4L ENGINE
INDEX
page DESCRIPTION AND OPERATION CAMSHAFT POSITION SENSOR . . . . . . . . . . . . CRANKSHAFT POSITION SENSOR . . . . . . . . . . FIRING ORDER2.4L . . . . . . . . . . . . . . . . . . . . INTAKE AIR TEMPERATURE SENSOR2.4L . . . REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR . . . . . . . . . . . . CRANKSHAFT POSITION SENSOR . . . . . . . . . . ENGINE COOLANT TEMPERATURE SENSOR 2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION COIL2.4L . . . . . . . . . . . . . . . . . . . . . INTAKE AIR TEMPERATURE SENSOR2.4L . . . KNOCK SENSOR2.4L . . . . . . . . . . . . . . . MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR2.4/3.3/3.8L . . . . . . . . . . . . . . SPARK PLUG CABLE SERVICE2.4L . . . . SPARK PLUG SERVICE . . . . . . . . . . . . . . . THROTTLE POSITION SENSOR . . . . . . . . SPECIFICATIONS IGNITION COIL . . . . . . . . . . . . . . . . . . . . . SPARK PLUG CABLE RESISTANCE2.4L . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 18 18 20 22 22 22 22
17 16 16 17 19 19 20 18 21
FIRING ORDER2.4L
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DESCRIPTION AND OPERATION (Continued)
engine is operating, the smaller the pulse width on the oscilloscope. By counting the pulses and referencing the pulse from the 60 degree signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69 degrees before top dead center (BTDC). The second notch represents 49 degrees BTDC. The third notch represents 29 degrees. The last notch in each set represents 9 degrees before top dead center (TDC). The timing reference notches are machined to a uniform width representing 13.6 degrees of crankshaft rotation. From the voltage pulse width the PCM tells the difference between the timing reference notches and the 60 degree signature notch. The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. The crankshaft position sensor mounts to the engine block behind the generator, near the oil filter (Fig. 8).
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The camshaft position sensor attaches to the rear of the cylinder head (Fig. 2). A target magnet attaches to the rear of the camshaft and indexes to the correct position (Fig. 3). The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 4). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath.
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REMOVAL Always remove cables by grasping at the boot, rotating the boot 1/2 turn, and pulling straight back in a steady motion. (1) Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. (2) Remove the spark plug using a quality socket with a foam insert. (3) Inspect the spark plug condition. Refer to Spark Plug Condition in this section. INSTALLATION (1) To avoid cross threading, start the spark plug into the cylinder head by hand. (2) Tighten spark plugs to 28 Nm (20 ft. lbs.) torque. (3) Install spark plug cables over spark plugs. A click will be heard and felt when the cable properly attaches to the spark plug.
IGNITION COIL2.4L
REMOVAL
REMOVAL (1) Remove spark plug cables from coil (Fig. 7). Always twist the coil boots to break the seal with the coil and pull straight back on the boot. (2) Remove ignition coil electrical connector. (3) Remove ignition coil mounting bolts, throttle cable bracket or clip. (4) Remove ignition coil.
INSTALLATION (1) Reverse the above procedure for installation. Tighten mounting screws to 12 Nm (105 in. lbs.) torque. (2) Transfer ignition cables to new coil pack. The coil pack towers and cables are numbered with cylinder identification.
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REMOVAL (1) Raise and support vehicle. (2) Disconnect electrical connector from crankshaft position sensor. (3) Remove sensor mounting screw. (4) Pull crankshaft position sensor straight out. INSTALLATION
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor. (1) Install sensor and push sensor down until contact is made. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
REMOVAL (1) Disconnect the filtered air tube from the throttle body and air cleaner housing. Disconnect the air
INSTALLATION The target magnet has locating dowels that fit into off-set machined locating holes in end of the camshaft (Fig. 11).
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REMOVAL AND INSTALLATION (Continued)
REMOVAL (1) With the engine cold, drain coolant until level drops below cylinder head. Refer to Group 7, Cooling System. (2) Disconnect coolant sensor electrical connector. (3) Remove coolant sensor. INSTALLATION (1) Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. (2) Attach electrical connector to sensor. (3) Fill cooling system. Refer to Group 7, Cooling System.
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KNOCK SENSOR2.4L
The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 14).
REMOVAL (1) Disconnect electrical connector from knock sensor. (2) Use a crow foot socket to remove the knock sensors. INSTALLATION (1) Install knock sensor. Tighten knock sensor to 10 Nm (7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. (2) Attach electrical connector to knock sensor.
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Coil Polarity
SPARK PLUG
Engine 2.4L Spark Plug RC12YC5 Gap 0.048 TO 0.053 Thread Size 14mm (3/4 in.) reach
TORQUE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .TORQUE 2.4L Target Magnet Screw . . . . . . .3 Nm (30 in. lbs.) 2.4L Camshaft Position Sensoe Screw . .9 Nm (80 in. lbs.) Ignition Switch . . . . . . . . . . . . . . .2 Nm (17 in. lbs.) Spark Plugs . . . . . . . . . . . . . . . . .28 Nm (60 in. lbs.)
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IGNITION SYSTEM
8D - 23
3.0L ENGINE
INDEX
page DESCRIPTION AND OPERATION CAMSHAFT POSITION SENSOR . . . . . . . . . . . . FIRING ORDER3.0L . . . . . . . . . . . . . . . . . . . . MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR . . . . . . . . . . ENGINE COOLANT TEMPERATURE SENSOR 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION COIL3.OL . . . . . . . . . . . . . . . . . . . . MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR3.0L . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG SERVICE . . . . . . . . . . . . . . THROTTLE POSITION SENSOR . . . . . . . DISASSEMBLY AND ASSEMBLY DISTRIBUTOR3.0L . . . . . . . . . . . . . . . . CLEANING AND INSPECTION DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . DISTRIBUTOR ROTOR3.0L . . . . . . . . . . SPECIFICATIONS SPARK PLUG CABLE RESISTANCE3.0L SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . 24 . . . . . 25 . . . . . 26 . . . . . 26 . . . . . 27 . . . . . 27 . . . . . 27 . . . . . 27
23 23 23 25 25 24 24
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IGNITION SYSTEM
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IGNITION COIL3.OL
The ignition coil is located at the back of the intake manifold (Fig. 2).
REMOVAL Always remove cables by grasping at the boot, rotating the boot 1/2 turn, and pulling straight back in a steady motion. (1) Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. (2) Remove the spark plug using a quality socket with a foam insert. (3) Inspect the spark plug condition. Refer to Spark Plug Condition in this section.
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REMOVAL AND INSTALLATION (Continued)
IGNITION SYSTEM
8D - 25
REMOVAL (1) With the engine cold, drain coolant until level drops below cylinder head. Refer to Group 7, Cooling System. (2) Disconnect coolant sensor electrical connector. (3) Remove coolant sensor. INSTALLATION (1) Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. (2) Attach electrical connector to sensor. (3) Fill cooling system. Refer to Group 7, Cooling System.
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IGNITION SYSTEM
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INSTALLATION (1) Position distributor in engine. Make certain that the O-ring is properly seated on distributor. If O-ring is cracked or nicked replace with new one. (2) Carefully engage distributor drive with gear on camshaft. When the distributor is installed properly, the rotor will be in line with previously scribe line on air intake plenum. If engine was cranked while distributor was removed, it will be necessary to establish proper relationship between the distributor shaft and Number 1 piston position as follows: (a) Rotate the crankshaft until number one piston is at top of compression stroke. (b) Rotate rotor to number one rotor terminal (Fig. 8). (c) Lower the distributor into the opening, engaging distributor drive with drive on camshaft. With distributor fully seated on engine, rotor should be under the number 1 terminal.
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CLEANING AND INSPECTION (Continued)
IGNITION SYSTEM
8D - 27
solution of warm water and a mild detergent. Scrub the cap with a soft brush. Thoroughly rinse the cap and dry it with a clean soft cloth.
DISTRIBUTOR ROTOR3.0L
Replace the rotor if it is cracked, the tip is excessively burned or heavily scaled (Fig. 10).
TORQUE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .TORQUE Distributor Hold Down. . . . . . . .14 Nm (124 in. lbs.) Ignition Coil Bracket . . . . . . . . . .10 Nm (96 in. lbs.) Ignition Switch . . . . . . . . . . . . . . .2 Nm (17 in. lbs.) Spark Plugs . . . . . . . . . . . . . . . . .28 Nm (60 in. lbs.)
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IGNITION SYSTEM
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3.3/3.8L ENGINE
INDEX
page DESCRIPTION AND OPERATION FIRING ORDER3.3/3.8L . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION CAMSHAFT POSITION SENSOR . . . . . . . . . . CRANKSHAFT POSITION SENSOR . . . . . . . . ENGINE COOLANT TEMPERATURE SENSOR IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . KNOCK SENSOR3.3/3.8L . . . . . . . . . . . . . . MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG CABLE SERVICE3.3/3.8L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG SERVICE3.3/3.8L ENGINES . THROTTLE POSITION SENSOR . . . . . . . . . . SPECIFICATIONS IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUG CABLE RESISTANCE3.3/3.8L SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . page
. . 28 . . . . . . . . . . 31 30 32 30 32
. . 28 . . 29 . . 32 . . . . . . . . 33 34 33 34
. . 32
Firing Order3.3/3.8L
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REMOVAL AND INSTALLATION (Continued)
CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor.
IGNITION SYSTEM
8D - 29
terminal engagement is felt when the terminals are properly attached. (2) Rotate Generator back into place. (3) Install upper Generator bracket with the four bolts. (4) Install the accessory drive belt, refer to Group 7, Cooling.
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IGNITION SYSTEM
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SPARK PLUG #1
REMOVAL (1) Remove the accessory drive belt, refer to Group 7, Cooling. (2) Remove the 4 bolts from the upper half of the generator bracket. (3) Push the Generator rearward. (4) Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. (5) Remove spark plug INSTALLATION (1) Install spark plug and tighten to 28 Nm (20 ft. lbs.). (2) When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be heard or felt when the terminals are properly attached. (3) Pull Generator back into place. (4) Install upper Generator bracket with the 4 bolts. (5) Install the accessory drive belt, refer to Group 7, Cooling.
IGNITION COIL
REMOVAL (1) Remove spark plug cables from coil (Fig. 2). Always twist the spark plug boots to break the seal with the plug and pull straight back on the boot. (2) Remove ignition coil electrical connector. (3) Remove ignition coil mounting screws. (4) Remove ignition coil. INSTALLATION (1) Reverse the above procedure for installation. Tighten mounting screws to 12 Nm (105 in. lbs.) torque. (2) Transfer spark plug cables to new coil pack. The coil pack towers and cables are numbered with the cylinder identification.
INSTALLATION
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor (Fig. 4). (1) Install sensor in transaxle and push sensor down until contact is made with the drive plate.
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REMOVAL AND INSTALLATION (Continued)
IGNITION SYSTEM
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INSTALLATION If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before
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IGNITION SYSTEM
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REMOVAL (1) Drain cooling system until coolant level is below sensor. Refer to Group 7, Cooling System. (2) Remove electrical connector from coil (Fig. 11). (3) Remove coil mounting screws. (4) Rotate coil away from engine coolant temperature sensor. (5) Disconnect electrical connector from engine coolant temperature sensor. (6) Remove sensor from engine.
KNOCK SENSOR3.3/3.8L
The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
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REMOVAL AND INSTALLATION (Continued)
REMOVAL (1) Disconnect electrical connector from knock sensor. (2) Use a crow foot socket to remove the knock sensor. INSTALLATION (1) Install knock sensor. Tighten knock sensor to 10 Nm (7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control. (2) Attach electrical connector to knock sensor.
IGNITION SYSTEM
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Primary Resistance at 21C-27C (70F-80F) 0.45 TO 0.65 Ohms 0.45 TO 0.65 Ohms
Secondary Resistance at 21C27C (70F-80F) 7,000 to 15,800 Ohms 7,000 to 15,800 Ohms
Coil Polarity
Coil Polarity
8D - 34
IGNITION SYSTEM
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SPECIFICATIONS (Continued)
SPARK PLUG
Engine 3.3L 3.8L * New Spark Plug Gap Spark Plug RN14PMP5 RN14PMP5 Gap * 0.048 TO 0.053 0.048 TO 0.053 Thread Size 14mm (3/4 in.) reach 14mm (3/4 in. ) reach
TORQUE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .TORQUE 3.3L Camshaft Position Sensor Screw . . . . . . . . . . . . .12 Nm (105 in. lbs.) 3.3L Engine Coolant Sensor. . . . . .7 Nm (60 in. lbs.) 3.3L Crankshaft Position Sensor Screw . . . . . . . . . . . . .12 Nm (105 in. lbs.) 3.3/3.8L Ignition Coil . . . . . . . . .12 Nm (105 in. lbs.) Ignition Switch . . . . . . . . . . . . . . .2 Nm (17 in. lbs.) Spark Plugs . . . . . . . . . . . . . . . . .28 Nm (20 ft. lbs.)
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IGNITION SYSTEM
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IGNITION SYSTEM
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REMOVAL AND INSTALLATION (Continued)
IGNITION SYSTEM
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IGNITION SYSTEM
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IGNITION INTERLOCK
Refer to Group 21, Transaxle for Shifter/Ignition Interlock Service.
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GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 DESCRIPTION AND OPERATION INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 2 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2 SELF DIAGNOSTIC TEST . . . . . . . . . . . . . . . . . . 2 TRACTION CONTROL SWITCH . . . . . . . . . . . . . 17 REMOVAL AND INSTALLATION BODY CONTROL MODULE (BCM) . . . . . . . . . . 18 CONVENIENCE BIN - CUP HOLDER . . . . . . . . . 17 CONVENIENCE BIN LAMP . . . . . . . . . . . . . . . . 17 CONVENIENCE BIN TRACK . . . . . . . . . . . . . . . 18 GLOVE BOX LAMP AND SWITCH . . . . . . . . . . 19 GLOVE BOX LOCK STRIKER . . . . . . . . . . . . . . 20 GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 HEADLAMP SWITCH LAMP(S) . . . . . . . . . . . . 21 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 20 HVAC CONTROL LAMP . . . . . . . . . . . . . . . . . . 21 INSTRUMENT CLUSTER BACK PANEL . . . . . . 21 INSTRUMENT CLUSTER BEZEL . . . . . . . . . . . . 21 INSTRUMENT CLUSTER ELECTRONIC ODOMETER AND TRANSMISSION RANGE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTRUMENT CLUSTER LAMPS . . . . . . . . . . . 22 INSTRUMENT CLUSTER LENS - MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTRUMENT CLUSTER LENS . . . . . . . . . . . . . 22
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER SUBDIAL . . . . . . . . . . INSTRUMENT CLUSTER SUBDIAL MECHANICAL TRANSMISSION RANGE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER WITH ELECTRONIC TRANSMISSION RANGE INDICATOR . . . . . . INSTRUMENT CLUSTER WITH MECHANICAL TRANSMISSION RANGE INDICATOR . . . . . . INSTRUMENT PANEL LEFT END COVER . . . . . INSTRUMENT PANEL LOUVERS . . . . . . . . . . . INSTRUMENT PANEL RIGHT END COVER . . . . INSTRUMENT PANEL TOP COVER . . . . . . . . . . INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . KNEE BLOCKER REINFORCEMENT . . . . . . . . . LOWER CONSOLE . . . . . . . . . . . . . . . . . . . . . . LOWER INSTRUMENT PANEL . . . . . . . . . . . . . LOWER STEERING COLUMN COVER . . . . . . . . MECHANICAL TRANSMISSION RANGE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . MESSAGE CENTER LAMP . . . . . . . . . . . . . . . . MESSAGE CENTER . . . . . . . . . . . . . . . . . . . . . . OUTLET (12 VOLT) BASE . . . . . . . . . . . . . . . . . OVER STEERING COLUMN BEZEL . . . . . . . . . . POWER MIRROR SWITCH LAMP . . . . . . . . . . POWER MIRROR SWITCH . . . . . . . . . . . . . . . . RADIO BEZEL AND HVAC CONTROL . . . . . . . . REAR HEATER-A/C SWITCH LAMP . . . . . . . . . REAR HEATER-A/C SWITCH . . . . . . . . . . . . . . . TRACTION CONTROL SWITCH . . . . . . . . . . . . . DESCRIPTION AND OPERATION INSTRUMENT CLUSTER
23 23
23 23 24 27 27 29 29 25 30 30 30 31 31 32 32 32 32 32 34 34 34 35 35 35
The mechanical instrument cluster with a tachometer is equipped with a electronic vacuum fluorescent transmission range indicator (PRND3L), odometer, and trip odometer display. The mechanical instrument cluster without a tachometer is equipped with a cable operated transmission range indicator (PRND21).
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HEADLAMP SWITCH
Using a Digital Multimeter, equipped with a diode test to perform the Headlamp Switch Test below (Fig. 1). Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within specifications replace as necessary. The Chrysler Town and Country is available with optional Automatic Headlamps. For diagnosis, refer to the proper Body Diagnostic Procedures Manual.
DIM TEST When CHEC-0 is displayed in the odometer window, the clusters vacuum fluorescent (VF) displays
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DIAGNOSIS AND TESTING (Continued)
INSTRUMENT CLUSTER DTC TABLE
DTC 110 111 905 921 940 999 DESCRIPTION Memory Fault in cluster Calibration fault in cluster No CCD bus messages from TCM Odometer fault from BCM No CCD bus messages from PCM End of Codes
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CALIBRATION TEST When CHEC-1 is displayed in the odometer window, each of the clusters gauge pointers will move sequentially through each calibration point. The Calibration Table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III). Refer to the proper Body Diagnostic Procedure Manual for calibration procedures. ODOMETER SEGMENT TEST When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate sequentially. If a segment in the odometer does not illuminate normally, a problem exists in the display. ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST When CHEC-3 is displayed in the odometer window, each segment of the transmission range indicator will illuminate sequentially. If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display board. CONDITIONS Refer to the following tables: Instrument Cluster Speedometer Tachometer Fuel Gauge Temperature Gauge Odometer Electronic Transmission Range Indicator (PRND3L) Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and corrections.
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2. No speed CCD Bus Message or Zero mph CCD Speed Bus Message.
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DIAGNOSIS AND TESTING (Continued)
CONDITION ERRATIC POINTER MOVEMENT POSSIBLE CAUSES 1. Erratic Message from another Module.
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CORRECTION 1. (a) Check the BCM using a scan tool If OK, go to Step (b). If not OK, refer to the BCM section of the service manual to repair the BCM. (b) Check the PCM using a scan tool. If OK, go to Step (c). If not OK, refer to the PCM section of the service manual to repair the PCM. (c) Check the speed signal input into the PCM. The speed signal originates from one of the following sources: A distance sensor for vehicles with 3 speed automatic transmission. Check continuity from distance sensor to PCM. If OK, replace distance sensor. If not OK, repair wiring. The Electronic Transmission Control Module (TCM) vehicles with the 4 speed electronic transmissions. Check continuity from TCM to engine controller. If OK, use a scan tool to check TCM. Refer to the electronic section of the service manual to repair the TCM. If not OK, repair wiring. 2. (a) Perform cluster self diagnostic test and check for fault codes. If the pointer moves during test but still appears erratic and fault codes 110 or 111 dont appear in the odometer display, then go to Step (b). If fault code 110 is displayed in the odometer, go to Step (e). If fault code 111 appears in the odometer display go to Step (d). If fault codes 905, 920, or 940 are displayed in the odometer display refer to the fault code chart to identify which module is causing the fault and repair module. (b) Replace cluster subdial assembly. To Step (c). (c) Connect cluster into instrument panel wiring harness. Place it back into the proper position in the instrument panel. Put in the top two mounting screws to hold the cluster in place. DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS CALIBRATED AND TESTED. Go to Step (d). (d) Use a scan tool to calibrate cluster and perform Self Diagnostic Test. If OK, continue installation. If not OK, go to Step (e). Replace main cluster pc board and use a scan tool to calibrate cluster. If not OK, look at another possible cause for the speedometer failure.
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DIAGNOSIS AND TESTING (Continued)
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TACHOMETER DIAGNOSIS
CONDITION NO POINTER MOVEMENT POSSIBLE CAUSES 1. Internal Cluster Failure. CORRECTION 1. (a) Perform Cluster Self Diagnostic Test and check for fault codes. If tachometer pointer moves to calibration points during test and fault codes 110 or 111 dont appear in the odometer display then failure is not in the cluster. Look for another possible cause of failure. If the pointer doesnt move during test, go to Step (b). If fault code 110 is displayed in the odometer, go to Step (b). If fault code 111 is displayed in the odometer then go to Step (f). If fault codes 920 or 940 are displayed in the odometer display refer to the fault code chart to identify which module is causing the fault an repair module. (b) Replace main cluster pc board. Go to Step (c). (c) Connect cluster into instrument panel wiring harness. Place it back into the proper position in the instrument panel. Put in the top two mounting screws to hold the cluster in place. DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS CALIBRATED AND TESTED. Go to Step (d). (d) use a scan tool to calibrate cluster and perform Self Diagnostic Test. If OK, continue installation. If not OK, go to Step (e). (e) Replace subdial assembly and use a scan tool to calibrate cluster. If not OK, look at another possible cause for the tachometer failure. (f) Use a scan tool to calibrate tachometer and perform Self Diagnostic Test. If OK, stop. If not OK, go to Step (b). 2. Check the PCM using a scan tool. Refer to the PCM section of the manual to properly diagnose and repair.
2. No rpm CCD Bus Message or Zero rpm CCD Bus Message from Engine Controller.
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TACHOMETER INACCURATE.
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DIAGNOSIS AND TESTING (Continued)
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2. No CCD Fuel Message or Empty CCD Bus Message from Body Controller.
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DIAGNOSIS AND TESTING (Continued)
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2. No CCD Temperature Message or Cold CCD Bus Message from the Body Control Module.
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DIAGNOSIS AND TESTING (Continued)
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ODOMETER DIAGNOSIS
CONDITION NO DISPLAY POSSIBLE CAUSES 1. No CCD Odometer Bus Message from Body Control Module. 2. Internal Cluster Failure. CORRECTION 1. Use a scan tool to check the BCM. Refer to the BCM section of the manual to properly diagnose and repair.
2. (a) Perform Cluster Self Diagnostic Test and check for fault codes. If odometer passes the dim test and segment check and fault codes 110 or 111 dont appear in the odometer display then failure is not in the cluster. Look for another possible cause of failure. If odometer doesnt work go to Step (b). If fault code 110 is displayed in the odometer, go to Step (b). If fault code 920 or 921 is displayed use a scan tool to check BCM. (b) Remove cluster from instrument panel and verify that odometer assembly is properly connected to main pc board. If OK, go to Step (c). If not OK, reconnect odometer assembly to main pc board. (c) Replace odometer assembly. Go to Step (d). (d) Connect cluster into instrument panel wiring harness. Place it back into the proper position in the instrument panel. DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS TESTED. Go to Step (e). (e) Perform Self Diagnostic Test. If OK, continue installation. If not OK, go to Step (f). (f) Replace main cluster pc board and use a scan tool to calibrate cluster. If not OK, look at another possible cause for the odometer failure.
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2. Bad CCD Bus Message from Body Controller Module. ODOMETER WONT GO INTO TRIP MODE. TRIP ODOMETER WONT RESET. 1. Trip Switch Doesnt Work. 1. Reset Switch Doesnt Work.
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DIAGNOSIS AND TESTING (Continued)
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2. Bad CCD Bus Message from the Electronic Transmission Control Module (TCM). ALL SEGMENTS ARE ON 1. No CCD bus message from the electronic Transmission Control Module (TCM).
1. (a) Perform Cluster Self Diagnostic test. If PRND3L passes test go to Step (b). If PRND3L fails test go to Step (c). (b) Check electronic TCM using a scan tool. Refer to the electronic TCM section of the manual to properly diagnose and repair. (c) Replace PRND3L assembly. Connect cluster into instrument panel wiring harness. Place it back into the proper position in the instrument panel. DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS TESTED. Go to Step (d). (d) Perform Self Diagnostic Test. If OK, continue installation. If not OK, go to Step (e). (e) Replace main cluster pc board and use a scan tool to calibrate cluster. If not OK, look at another possible cause for the PRND3L failure.
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DIAGNOSIS AND TESTING (Continued)
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Not attached.
1. Cable dislodged from its path on the indicator base. 2. Incorrect attachment of cable to shift lever pin.
(1) Remove over steering column bezel. Refer to Over Steering Column Bezel. Removal procedures. (2) Using an ohmmeter check for continuity reading between pins. Refer to Switch Continuity Table.
REMOVAL (1) Pull out and remove the convenience bin - cup holder. Refer to Convenience Bin - Cup Holder removal in this section.
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REMOVAL AND INSTALLATION (Continued)
(3) Disconnect two wire connectors from bottom of Body Control Module (BCM) (4) Remove bolts holding Junction Block to dash panel mounting bracket (Fig. 8).
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INSTALLATION (1) Install the shift indicator and screws to cluster lens. (2) Position the lens on cluster and carefully guide the shift indicator cable and guide through cluster opening. (3) Install the cluster lens and screws to the rear shell around perimeter of lens. (4) Install the instrument cluster.
GLOVE BOX
REMOVAL (FIG. 4) (1) Open glove box (Fig. 9). (2) Disengage clip holding checkstraps to glove box door. (3) Pivot glove box downward and disengage hinge hooks from instrument panel. (4) Remove glove box. INSTALLATION (1) Place glove box in position. (2) Engage hinge hooks into instrument panel and pivot glove box upward. (3) Engage clip to hold checkstraps to glove box door. (4) Close glove box door.
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HEADLAMP SWITCH
REMOVAL (1) Remove instrument cluster bezel (Fig. 13).
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Connect wire connectors into back of the bezel. (2) Place cluster bezel in position on instrument panel. Use care not to place hands on louvers. (3) Connect clips to hold cluster bezel to instrument panel. Use care not to add pressure on the A/C louvers to seat the cluster bezel clips. (4) Install screws to hold cluster bezel to instrument panel on each side of steering column. (5) Install screw at left end of cluster bezel and headlamp switch. (6) Install left end cover. (7) Install over steering column bezel. (8) Install lower steering column cover.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL (1) Remove instrument cluster. (2) Remove screws holding cluster lens to the rear shell from around perimeter of lens. (3) Remove lens from cluster, guide shift indicator cable through cluster shell. (4) Remove gauge subdial from cluster. INSTALLATION (1) Position gauge subdial on cluster. (2) Position lens on cluster, guide shift indicator cable through cluster shell. (3) Install cluster lens and screws to the rear shell around perimeter of lens. (4) Install instrument cluster.
INSTALLATION For installation, reverse the above procedures. After installing the print circuit board it will have to be calibrated using a scan tool (DRB III). Refer to the proper Body Diagnostic Procedure Manual for calibration procedures.
NOTE: Speedometer and/or Tachometer will not operate properly until all gauges have been calibrated
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REMOVAL AND INSTALLATION (Continued)
(8) Using the indicator adjuster thumbwheel on the indicator clip below the steering column. Rotate the indicator thumbwheel to position the indicator calibration arrow to the center of the N slot on the instrument cluster mask. (9) After the indicator has been properly adjusted, move the shift lever through each gear position to verify the appropriate gear position has been selected and the slot is fully covered by the indicator. The left edge of the indicator will just peek at the left edge of the P slot in Park. (10) If the indicator is not covering each of the selected gear positions when selected, place the shift lever back into neutral N and readjust the indicator. Repeat the process until each gear is covered when selected. (11) Install the metal knee blocker panel. (12) Install the lower steering column cover.
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INSTRUMENT PANEL
The instrument panel is removed as a unit. The steering column and wiring harnesses are assembled into the panel before installation. Service procedures for interior trim not related to the instrument panel can be found in Group 23, Body.
REMOVAL (1) Disconnect the battery, negative cable first. (2) Remove the lower console. (3) Remove the screw holding the lower heat duct to the instrument panel support (Fig. 26). (4) Disconnect the heat duct from the vehicle. (5) Remove the bolts holding the lower supports to the instrument panel frame (Fig. 27).
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REMOVAL AND INSTALLATION (Continued)
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(5) Remove instrument panel end cover and foam pad covering the A/C inlet projection of the end cover if equipped.
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PASSENGER SIDE LOUVERS The inner, outer louver and inner, outer housing are serviceable.
REMOVAL (1) Using medium flat blade tool, position it in between the right side of louver and the housing (Fig. 35). (2) Twist the tool to release the pivot pin from the louver and pull outward till released from pin. (3) Place tool on the other side of louver and release the other pivot pin and pull housing free from the instrument panel. Use the same procedure for either inner or outer louver. INSTALLATION The inner and outer louvers have different size pivot pins on the housing. The outer housing has a larger pin on the right side then the inner housing
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REMOVAL AND INSTALLATION (Continued)
(2) Lightly pry housing inward and by hand pull the housing free from panel (Fig. 38).
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JUNCTION BLOCK
REMOVAL (1) Disconnect battery negative cable. (2) Remove lower steering column cover and knee blocker reinforcement. (3) Disconnect four, forty-way connectors from Junction Block (Fig. 41).
INSTALLATION (1) Place reinforcement in position. (2) Install screws to hold knee blocker reinforcement to instrument panel. (3) Install lower steering column cover.
LOWER CONSOLE
REMOVAL (1) Remove screws holding lower console to floor bracket and instrument panel (Fig. 43).
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Place lower console in position. (2) Slide console forward around instrument panel supports. (3) Install screws to hold lower console to floor bracket and instrument panel.
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(17) Remove the screws holding lower instrument panel to the support frame in floor console area. (18) Separate the lower instrument from the upper instrument panel. (19) Disconnect the wire connectors from back of the 12 volt outlet base. (20) Remove the lower instrument from vehicle.
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INSTALLATION (1) Place message center in position on top cover. (2) Install screws to hold message center to instrument panel top cover. (3) Connect wire connector into back of message center. (4) Install instrument panel top cover. (5) Install A-pillar trim.
MESSAGE CENTER
REMOVAL (1) Remove A-pillar trim. (2) Remove instrument panel top cover. Refer to instrument panel top cover removal procedures. (3) Disconnect the wire connector from back of message center.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Place the over steering column bezel in position and engage clips to the cluster bezel. If equipped
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REMOVAL AND INSTALLATION (Continued)
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GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION HEADLAMP AND POWER MIRROR SWITCH LAMP(S) . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . SELF DIAGNOSTIC TEST . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION ASH RECEIVER CONVENIENCE BIN LAMP MODULE . . . . . . . . . . . . . . . . . . BODY CONTROL MODULE (BCM) . . . . . . . . . CIGAR LIGHTER BASE . . . . . . . . . . . . . . . . . . CONVENIENCE BIN . . . . . . . . . . . . . . . . . . . . CONVENIENCE BIN - CUP HOLDER . . . . . . . GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . GLOVE BOX LAMP AND SWITCH . . . . . . . . . GLOVE BOX LOCK STRIKER . . . . . . . . . . . . . HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . HEADLAMP SWITCH LAMP(S) . . . . . . . . . . . HVAC CONTROL LAMP . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . GENERAL INFORMATION INTRODUCTION
1 2 2 2 3
15 16 16 15 15 17 17 17 18 18 18 20
INSTRUMENT CLUSTER BACK PANEL . . . . . INSTRUMENT CLUSTER BEZEL . . . . . . . . . . INSTRUMENT CLUSTER LENS . . . . . . . . . . . INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER SUBDIAL . . . . . . . . INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . INSTRUMENT PANEL LEFT END COVER . . . . INSTRUMENT PANEL LOUVERS . . . . . . . . . . INSTRUMENT PANEL RIGHT END COVER . . INSTRUMENT PANEL TOP COVER . . . . . . . . JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . KNEE BLOCKER REINFORCEMENT . . . . . . . . LOWER CONSOLE . . . . . . . . . . . . . . . . . . . . . LOWER INSTRUMENT PANEL . . . . . . . . . . . . LOWER STEERING COLUMN COVER . . . . . . MESSAGE CENTER . . . . . . . . . . . . . . . . . . . . OVER STEERING COLUMN BEZEL . . . . . . . . POWER MIRROR SWITCH . . . . . . . . . . . . . . POWER MIRROR SWITCH LAMP . . . . . . . . . RADIO BEZEL AND HVAC CONTROL . . . . . . . REAR HEATER-A/C SWITCH . . . . . . . . . . . . . REAR HEATER-A/C SWITCH LAMP . . . . . . . . DESCRIPTION AND OPERATION HEADLAMP AND POWER MIRROR SWITCH LAMP(S)
18 18 19 19 20 20 22 22 25 24 25 25 26 26 27 27 28 28 28 29 29 29
The instrumentation gauges on GS vehicles are contained in a subdial assemblies within the instrument cluster. The individual gauges are not serviced separately. If one of the cluster gauges becomes faulty the entire subdial would require replacement and all gauges will have to be calibrated. Refer to the proper Body Diagnostic Procedure Manual for calibration procedures.
The Headlamp Switch and Power Mirror Switch lamps are shown in (Fig. 1). For replacement of the lamp(s) refer to Headlamp Switch Lamp(s) Removal and Installation procedures below. Refer to Group 8T, Power Mirrors for mirror test procedures.
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HEADLAMP SWITCH
Fig. 1 Headlamp and Mirror Switch Lamps
INSTRUMENT CLUSTER
The mechanical instrument cluster with a tachometer is equipped with a electronic vacuum fluorescent odometer, and trip odometer display. The instrument cluster is equipped with the following warning lamps (Fig. 2). Battery Voltage Lift Gate Ajar
Using a Digital Multimeter, equipped with a diode test to perform the Headlamp Switch Test below (Fig. 3). Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within specifications replace as necessary.
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DIAGNOSIS AND TESTING (Continued)
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DIM TEST When CHEC-0 is displayed in the odometer window, the clusters vacuum fluorescent (VF) displays will dim down. If the VF display brightness does not change, a problem exists in the cluster. CLUSTER CALIBRATION TABLE
Speedometer Calibration Point 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Km/h (0 mph) 2 . . . . . . . . . . . . . . . . . . . . . . . . . 40 Km/h (20 mph) 3 . . . . . . . . . . . . . . . . . . . . . . . . . 80 Km/h (55 mph ) 4 . . . . . . . . . . . . . . . . . . . . . . . . 120 Km/h (75 mph) Tachometer Calibration Point 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 rpm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 rpm 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 rpm Fuel Gauge Calibration Point 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Empty (E) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8 Filled 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 Filled 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full (F) Temp Gauge Calibration Point 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold (C) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Normal 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Normal 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot (H)
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DIAGNOSIS AND TESTING (Continued)
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DIAGNOSIS AND TESTING (Continued)
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DIAGNOSIS AND TESTING (Continued)
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DIAGNOSIS AND TESTING (Continued)
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DIAGNOSIS AND TESTING (Continued)
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CONVENIENCE BIN
REMOVAL (1) Remove the ash receiver/cup holder from the instrument panel. (2) Remove the screw access cover from the bottom of the radio bezel (Fig. 5). (3) Remove the center bezel. (4) Remove the ash receiver/cup holder attaching screws and pull the ash receiver/cup holder track rearward to disengage the rear guide studs from instrument panel (Fig. 7). (5) Remove the ash receiver/cup holder.
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INSTALLATION (1) Connect wire to light ring and install ring. (2) Connect wires to base. (3) Push base into the bezel till it locks. (4) Install lighter element and check operation of element.
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REMOVAL AND INSTALLATION (Continued)
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GLOVE BOX
REMOVAL (FIG. 4) (1) Open glove box (Fig. 10).
INSTALLATION (1) Place glove box in position. (2) Engage hinge hooks into instrument panel and pivot glove box upward. (3) Engage clip to hold checkstraps to glove box door. (4) Close glove box door.
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HEADLAMP SWITCH
REMOVAL (1) Remove instrument cluster bezel (Fig. 14).
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Connect wire connectors into back of the bezel. (2) Place cluster bezel in position on instrument panel. Use care not to place hands on louvers. (3) Connect clips to hold cluster bezel to instrument panel. Use care not to add pressure on the A/C louvers to seat the cluster bezel clips. (4) Install screws to hold cluster bezel to instrument panel on each side of steering column. (5) Install screw at left end of cluster bezel and headlamp switch. (6) Install left end cover. (7) Install over steering column bezel. (8) Install lower steering column cover.
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INSTALLATION For installation, reverse the above procedures. After installing the print circuit board it will have to be calibrated using a scan tool (DRB III). Refer to the proper Body Diagnostic Procedure Manual for calibration procedures.
NOTE: Speedometer and/or Tachometer will not operate properly until all gauges have been calibrated
INSTRUMENT PANEL
The instrument panel is removed as a unit. The steering column and wiring harnesses are assembled into the panel before installation. Service procedures for interior trim not related to the instrument panel can be found in Group 23, Body.
REMOVAL (1) Disconnect the battery, negative cable first. (2) Remove the lower console. (3) Remove the screw holding the lower heat duct to the instrument panel support (Fig. 23).
INSTRUMENT CLUSTER
REMOVAL (1) Remove instrument cluster bezel (Fig. 22). (2) Remove screws holding instrument cluster to instrument panel. (3) Rotate top of cluster outward. (4) Remove instrument cluster from instrument panel.
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REMOVAL AND INSTALLATION (Continued)
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(16) Disconnect the instrument panel wire harness connector from the bottom of Body Control Module. (17) Disconnect the two forty pin connectors from the right of the steering column (Fig. 26).
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REMOVAL AND INSTALLATION (Continued)
(5) Applying pressure on the housing, release the upper right lock tab and the lower right. (6) Push out the louver housing from the cluster bezel.
8E - 23
(3) Using a flat bladed tool, release the louver housing locks tabs. (4) Release the upper left lock tab first, then the other upper lock tab. (5) Applying pressure on the housing, release the lower lock tabs. (6) Push out the louver housing from the cluster bezel. INSTALLATION (1) Verify the function of the vanes. (2) Set louver housing into the cluster bezel and align the slot of the housing with the T location pins. (3) Using care do not push on the vanes, apply pressure on outer edge of the housing and push louver housing into place. (4) After in place check function of the vanes.
PASSENGER SIDE LOUVERS The inner, outer louver and inner, outer housing are serviceable.
REMOVAL (1) Using medium flat blade tool, position it in between the right side of louver and the housing (Fig. 32). (2) Twist the tool to release the pivot pin from the louver and pull outward till released from pin. (3) Place tool on the other side of louver and release the other pivot pin and pull housing free from the instrument panel. Use the same procedure for either inner or outer louver.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Place instrument panel top cover in position on vehicle. (2) Push top cover forward to engage hooks to hold front of top cover to instrument panel. (3) Connect wire harness to message center. (4) Engage clips to hold rear edge of top cover to instrument panel. (5) Pull top cover rearward. (6) Install A-pillar trim.
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JUNCTION BLOCK
REMOVAL (1) Disconnect battery negative cable. (2) Remove lower steering column cover and knee blocker reinforcement. (3) Disconnect four, forty-way connectors from Junction Block (Fig. 38).
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INSTALLATION (1) Place reinforcement in position. (2) Install screws to hold knee blocker reinforcement to instrument panel. (3) Install lower steering column cover.
INSTALLATION (1) Place lower console in position. (2) Slide console forward around instrument panel supports. (3) Install screws to hold lower console to floor bracket and instrument panel.
LOWER CONSOLE
REMOVAL (1) Remove screws holding lower console to floor bracket and instrument panel (Fig. 40).
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REMOVAL AND INSTALLATION (Continued)
(11) Remove screw holding lower instrument panel to right side of instrument panel. (12) Remove screw holding lower instrument panel to upper instrument panel at left side panel above accelerator pedal. (13) Remove instrument cluster bezel as necessary to gain access to lower instrument panel screws. (14) Remove screw lower holding instrument panel to upper panel below instrument cluster. (15) Remove screws holding rear of storage pocket to panel support frame. (16) Remove screws holding lower instrument panel to upper instrument panel from below radio. (17) Remove screws holding lower instrument panel to support frame in floor console area. (18) Separate lower instrument from upper instrument panel. (19) Disengage wire connectors from back of accessory plug. (20) Separate lower instrument from vehicle.
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MESSAGE CENTER
Fig. 42 Park Brake Release Handle
(2) Remove screws holding bottom of lower steering column cover to instrument panel (Fig. 43). (3) Remove screw holding right side of lower steering column cover to instrument panel. (4) Disengage park brake release cable case from groove on end of release handle (Fig. 44). (5) Disengage cable end pivot from slot on release handle (Fig. 44).
REMOVAL (1) Remove A-pillar trim. (2) Remove instrument panel top cover. Refer to instrument panel top cover removal procedures. (3) Disconnect the wire connector from back of message center. (4) Remove screws holding message center to instrument panel top cover. (5) Remove message center from instrument panel top cover.
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INSTALLATION (1) Place the over steering column bezel in position and engage clips to the cluster bezel. If equipped with traction control switch connect the wire pigtail before engaging clips. (2) Install the screws to hold the over steering column bezel to the cluster bezel. (3) Install the lower column cover.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION For installation, reverse the above procedures.
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INSTALLATION (1) Hold the radio bezel up and connect the wire connector into the back of the HVAC control. (2) Connect the wire connector into back of the rear blower switch, if equipped. (3) Place the radio bezel in position on the instrument panel. (4) Install screws to hold the top of radio bezel to instrument panel. (5) Install screws to the hold bottom of the radio bezel to the instrument panel. (6) Install the access cover.
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AUDIO SYSTEMS
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AUDIO SYSTEMS
CONTENTS
page page
GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHOKEINFINITY SPEAKERS . . . . . . . . . . . . . . INTERFERENCE ELIMINATION . . . . . . . . . . . . . . NAME BRAND SPEAKER RELAY . . . . . . . . . . . . RADIO IGNITION INTERFERENCE . . . . . . . . . . . RADIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE RADIO SWITCHES . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION INTRODUCTION
1 1 2 1 3 2 1 3 3
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 4 RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOTE RADIO SWITCHES . . . . . . . . . . . . . . . . 6 REMOVAL AND INSTALLATION ANTENNA EXTENSION CABLE . . . . . . . . . . . . . . 7 ANTENNA MAST AND CABLE LEAD . . . . . . . . . 7 DPILLAR SPEAKER . . . . . . . . . . . . . . . . . . . . 10 FRONT DOOR SPEAKER . . . . . . . . . . . . . . . . . . . 9 INSTRUMENT PANEL SPEAKER . . . . . . . . . . . . . 8 QUARTER PANEL SPEAKER . . . . . . . . . . . . . . . 10 RADIO/TAPE/CD PLAYER . . . . . . . . . . . . . . . . . . 8 REMOTE RADIO SWITCHES . . . . . . . . . . . . . . . . 9
required or possible when replacing the receiver or the antenna.
Operating instructions for the factory installed audio systems can be found in the Owners Manual provided with the vehicle. NS vehicles are equipped with an Ignition Off Draw (IOD) fuse in the power distribution center located in the engine compartment. After the IOD fuse or battery has been disconnected, the radio station sets and clock will require resetting.
INTERFERENCE ELIMINATION
Some components used on the vehicles are equipped with a capacitor to suppress radio frequency interference/static. Capacitors are mounted in various locations internal to the generator, instrument cluster and windshield wiper motor. To eliminate radio interference, ground straps are used in different areas of the vehicle. These ground circuits should be securely tightened to assure good metal to metal contact. The ground straps conduct very small high frequency electrical signals to ground and require clean surface contact area. The radio ground is supplied from the instrument panel harness and is attached to the rear of the radio. Some engines have other ground straps to eliminate further radio interference: Radio chassis to instrument panel structure Engine to dash panel Engine to chassis A/C h valve to dash panel Radio resistance type spark plug cables in the high tension circuit of the ignition system complete the interference suppression. Faulty or deteriorated spark plug wires should be replaced.
RADIOS
Available factory-installed radio receivers for this model include an AM/FM/cassette (RAS sales code), an AM/FM/cassette/5-band graphic equalizer with CD changer control feature (RBN sales code), an AM/FM/
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CHOKEINFINITY SPEAKERS
If the audio system is lacking bass response, check for continuity across the choke connector. If no continuity Replace choke. The choke is located on the
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DESCRIPTION AND OPERATION (Continued)
bracket behind the junction block/body control module (Fig. 5).
AUDIO SYSTEMS
8F - 3
messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owners manual in the vehicle glove box.
TEST 1 Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: (1) Unplug the antenna coaxial cable connector from the radio chassis and isolate. (2) Connect one ohmmeter test lead to the tip of the antenna mast. Connect the other test lead to the antenna base. Check for continuity. (3) There should be no continuity. If continuity is found, replace the faulty or damaged antenna base and cable assembly.
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AUDIO SYSTEMS
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AUDIO SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
RADIO
If the vehicle is equipped with remote radio switches located on the backs of the steering wheel spokes, and the problem being diagnosed is related to one of the symptoms listed below, be certain to check the remote radio switches and circuits as described in this group, prior to attempting radio diagnosis or repair. Stations changing with no remote radio switch input Radio memory presets not working properly Volume changes with no remote radio switch input Remote radio switch buttons taking on other functions CD player skipping tracks Remote radio switch inoperative. For circuit descriptions and diagrams, refer to Group 8W - Wiring Diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a floating ground system. Do not allow any speaker lead to short to ground, as damage to the radio may result.
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DIAGNOSIS AND TESTING (Continued)
AUDIO SYSTEM DIAGNOSIS
CONDITION NO AUDIO. POSSIBLE CAUSE 1. FUSE FAULTY. 2. RADIO CONNECTOR FAULTY. 3. WIRING FAULTY. 4. GROUND FAULTY. 5. RADIO FAULTY. 6. SPEAKERS FAULTY.
AUDIO SYSTEMS
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CORRECTION 1. CHECK RADIO FUSES IN FUSEBLOCK MODULE. REPLACE FUSES, IF REQUIRED. 2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR. REPAIR, IF REQUIRED. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR. REPAIR WIRING, IF REQUIRED. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND A KNOWN GOOD GROUND. THERE SHOULD BE CONTINUITY. REPAIR GROUND, IF REQUIRED. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED. 6. SEE SPEAKER DIAGNOSIS, IN THIS GROUP. 1. CHECK RADIO FUSES IN FUSEBLOCK MODULE. REPLACE FUSES, IF REQUIRED. 2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR. REPAIR, IF REQUIRED. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR. REPAIR WIRING, IF REQUIRED. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND A KNOWN GOOD GROUND. THERE SHOULD BE CONTINUITY. REPAIR GROUND, IF REQUIRED. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED. 1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE, IF REQUIRED. 2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR. REPAIR, IF REQUIRED. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR. REPAIR WIRING, IF REQUIRED. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND A KNOWN GOOD GROUND. THERE SHOULD BE CONTINUITY. REPAIR GROUND, IF REQUIRED. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED. 1. SEE ANTENNA DIAGNOSIS, IN THIS GROUP. REPAIR OR REPLACE ANTENNA, IF REQUIRED. 2. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND A KNOWN GOOD GROUND. THERE SHOULD BE CONTINUITY. REPAIR GROUND, IF REQUIRED.. 3. EXCHANGE OR REPLACE RADIO, IF REQUIRED. 1. INSERT KNOWN GOOD TAPE AND TEST OPERATION. 2. REMOVE FOREIGN OBJECTS AND TEST OPERATION. 3. CLEAN HEAD WITH MOPAR CASSETTE HEAD CLEANER. 4. EXCHANGE OR REPLACE RADIO, IF REQUIRED. 1. INSERT KNOWN GOOD CD AND TEST OPERATION. 2. CLEAN CD AND TEST OPERATION. 3. ALLOW TEMPERATURE OF VEHICLE INTERIOR TO STABILIZE AND TEST OPERATION. 4. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO DISPLAY.
1. FUSE FAULTY. 2. RADIO CONNECTOR FAULTY. 3. WIRING FAULTY. 4. GROUND FAULTY. 5. RADIO FAULTY.
NO MEMORY.
1. FUSE FAULTY. 2. RADIO CONNECTOR FAULTY. 3. WIRING FAULTY. 4. GROUND FAULTY. 5. RADIO FAULTY.
1. FAULTY TAPE. 2. FOREIGN OBJECTS BEHIND TAPE DOOR. 3. DIRTY CASSETTE TAPE HEAD. 4. FAULTY TAPE DECK. 1. FAULTY CD. 2. FOREIGN MATERIAL ON CD. 3. CONDENSATION ON CD OR OPTICS. 4. FAULTY CD PLAYER.
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AUDIO SYSTEMS
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(4) If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. (5) Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit as required. (6) Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 7. If not OK, repair the short circuit as required. (7) Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the BCM and the CCD data bus. If not OK, repair the open circuit as required.
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AUDIO SYSTEMS
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AUDIO SYSTEMS
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RADIO/TAPE/CD PLAYER
REMOVAL (1) Remove HVAC switch bezel, refer to Group 8E, Instrument Panel and Systems for proper procedure. (2) Remove screws holding radio to instrument panel (Fig. 12).
Fig. 12 Radio
(3) Pull radio rearward to gain access to radio (Fig. 13). (4) Remove bolt holding ground strap to radio. (5) Disconnect antenna cable from back of (6) Disconnect the wire connectors from radio. (7) Remove radio from vehicle. back of back of radio. back of
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REMOVAL AND INSTALLATION (Continued)
AUDIO SYSTEMS
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REMOVAL (1) Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. (2) From the underside of the steering wheel, remove the (3) bolts that secure the driver side airbag module to the steering wheel. (3) Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. (4) Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. (5) Remove the driver side airbag module from the vehicle. (6) Remove the steering wheel from the steering column. Refer to Group 19Steering, for service procedure. (7) Unplug the wire harness connector from the remote radio switch (s). (8) Remove three screws securing steering wheel rear cover. Refer to Group 19, Steering for serivce procedure. (9) Remove the remote radio switch from the steering wheel by depressing tabs on each side of switch..
NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat.
INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be careful to index them correctly before pressing them into place. Tighten the airbag module mounting screws to 10.2 Nm (90 in. lbs.).
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DPILLAR SPEAKER
REMOVAL (1) Remove D-pillar trim panel as necessary to gain access to door speaker. Refer to Group 23, Body for proper procedures. (2) Disconnect wire connector from speaker. (3) Remove by sliding speaker out of bracket by pushing on magnet. The capacitor is wrapped with foam tape (Fig. 18).
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HORNS
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HORNS
CONTENTS
page page
DESCRIPTION AND OPERATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . HORN SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION INTRODUCTION
1 1 3 3
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HORNS SOUND CONTINUOUSLY . . . . . . . . . . . . HORNS WILL NOT SOUND . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING HORN
1 3 2 4 4
WARNING: ON VEHICLES EQUIPPED WITH AIRBAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR SAFETY PRECAUTIONS. DISCONNECT THE NEGATIVE CABLE FROM THE BATTERY BEFORE SERVICING COMPONENTS INVOLVING THE AIRBAG SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG AND PERSONAL INJURY CAN RESULT. The horn circuit consists of a horn switch, clockspring, horn relay, horns and Body Control Module (Fig. 1). The horn switch is a membrane switch located in the airbag cover. The horns are located forward of the left front wheel behind the bumper fascia. The horn relay plugs into the junction block. For circuit information and component locations refer to Group 8W, Wiring Diagrams.
(1) Disconnect wire connector at horn. (2) Using a voltmeter, connect one lead to ground terminal and the other lead to the positive wire terminal (Fig. 3). (3) Depress the horn switch, battery voltage should be present. (4) If no voltage, refer to Horn Will Not Sound. If voltage is OK, go to step Step 5. (5) Using ohmmeter, test ground wire for continuity to ground. (6) If no ground repair as necessary. (7) If wires test OK and horn does not sound, replace horn.
HORN RELAY
(1) Remove horn relay. (2) Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance (Fig. 2). If resistance not OK, replace relay. (3) Test for continuity between ground and terminal 85 of horn relay. (a) When the horn switch is not depressed, no continuity should be present. (b) Continuity to ground when horn switch is depressed. (c) If continuity is not correct repair horn switch or wiring as necessary, refer to Group 8W, Wiring Diagrams Group 8M Restraint System for Drivers Airbag Module removal procedures. (4) Using voltmeter, test voltage at: (a) Terminals 30 and 86 of the horn relay to body ground. (b) If NO voltage check fuse 7 of the BCM. (c) If incorrect voltage repair as necessary. Refer to Group 8W, Wiring Diagrams. (5) Insert a jumper wire between terminal 30 and 87 of the power distribution center. (a) If horn sounds replace relay.
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FUSE BLOWN (1) Verify condition of battery terminals and voltage, refer to Group 8A, Battery. If battery connections and battery charge is OK proceed to Step 2. (2) Using a voltmeter, test for battery voltage at both sides of horn fuse 7. If voltage is OK, on both sides of fuse, proceed to Fuse OK. If voltage is OK, on one side of fuse, the fuse is blown, proceed to Step 3. (3) Using a suitable ammeter in place of the fuse, test amperage draw of the horn circuit. If amperage draw is greater than 20 amps without the horn switch depressed, a grounded circuit exists between the fuse and the horn relay. Proceed to Step 4. If amperage draw is greater than 20 amps with the horn switch depressed, a grounded circuit exists between the horn relay and the horn. Proceed to step Step 5. (4) Remove the horn relay from the Junction Block. If the amperage draw drops to 0 amps, the horn switch or circuit is shorted. Refer to group 8W, Wiring Diagrams for circuit information. If the amperage draw does not drop to 0 amps, repair short at the Junction Block. (5) Disengage a wire connector from one of the horns. If amperage drops and the connected horn sounds, replace the faulty horn. If amperage does not drop with both horns disconnected and the horn switch depressed, proceed to Step 6. (6) Using a continuity tester, with the horns disconnected test continuity of the X2 cavity of the horn relay to ground. Refer to Group 8W, Wiring Diagrams for circuit information. If continuity is detected, the circuit is grounded between the Junction Block and the horns. Locate and repair pinched harness.
FUSE OK (1) Remove the horn relay from the Junction Block. (2) Using a continuity tester, Depress horn switch and test continuity from the X3 cavity of the horn relay to ground. Refer to Group 8W, Wiring Diagrams for circuit information. (a) If continuity is detected, proceed to Step 3. (b) If NO continuity, proceed to Step 4. (3) Using a suitable jumper wire, jump across the fuse F62 cavity and the X2 cavity of the horn relay in the Junction Block. (a) If the horn sounds, replace the horn relay. (b) If the horn does not sound, proceed to Step 4. (4) Remove airbag/horn pad from steering wheel. Refer to Group 8M, Restraint Systems for proper procedures. (5) Test continuity across horn switch connectors with horn switch depressed. (a) If continuity is detected, repair open circuit between the relay and the horn switch. (b) If NO continuity, replace airbag cover. (6) Install horn relay into Junction Block. (7) Disengage wire connectors from horns. (8) Using a voltmeter, with the horn switch depressed test voltage across horn connector terminals of the wire harness (Fig. 3). (a) If voltage is detected, replace horns. (b) If NO voltage, proceed to step Step 9.
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DIAGNOSIS AND TESTING (Continued)
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HORN SYSTEM
Refer to Horn System Test below. If the horn does not sound, check horn fuse located in the Power Distribution Center. If the fuse is blown, replace with the correct fuse. If the horn fail to sound and the new fuse blows when depressing the horn switch, a short circuit in the horn or the horn wiring between the fuse terminal and the horn is responsible, or a defective horn switch allowed the horn to burn out is responsible. If the fuse is OK, test horn relay refer to Horn Relay Test. If the relay is OK, test horn. Refer to Horn System Test. CAUTION: Continuous sounding of horn may cause horn relay to fail. Should the horn sound continuously: Unplug the horn relay from Power Distribution Center. Refer to Horn Relay Test. Refer to Group 8W, Wiring Diagrams for circuit and wiring information.
(1) Horn relay control circuit X3 is shorted to ground inside steering column or wheel. (2) Pinched horn switch wire under Driver Airbag Module (3) Defective horn switch (1) Check fuse 6 in PDC (2) No Voltage at horn relay terminals 30 & 86, and fuse is OK. (3) Open circuit from terminal 85 of the horn relay to horn switch, X3 circuit. (4) Defective or damaged horn. (5) Defective horn switch
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HORNS
REMOVAL (1) Hoist and support the front of the vehicle on safety stands. (2) From behind the front fascia and forward of the left front wheel, disconnect the wire connectors from horn. (3) Remove the mount bracket attaching nut from the bottom of radiator closure panel. Do not remove the horn from mounting bracket (Fig. 4). (4) Separate the horn from vehicle. INSTALLATION For installation reverse the above procedures.
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GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . POWERTRAIN CONTROL MODULE . . . . . . . . . . SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . SPEED CONTROL SERVO . . . . . . . . . . . . . . . . . . SPEED CONTROL SWITCHES . . . . . . . . . . . . . . STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . VEHICLE SPEED AND DISTANCE . . . . . . . . . . . . DIAGNOSIS AND TESTING CHECKING FOR DIAGNOSTIC CODES . . . . . . . . ELECTRICAL TESTS AT POWERTRAIN CONTROL MODULE . . . . . . . . . . . . . . . . . . . . .
2 2 2 1 1 2 3 3 3 6
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET . . . . . . . . . . . . . . . . . . . 3 ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVO VACUUM TEST . . . . . . . . . . . . . . . . . . . . 6 SPEED CONTROL ELECTRICAL TEST . . . . . . . . 4 SPEED CONTROL SWITCH TEST . . . . . . . . . . . . 6 STOP LAMP SWITCH TEST . . . . . . . . . . . . . . . . 6 VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . . 8 VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . 8 REMOVAL AND INSTALLATION POWERTRAIN CONTROL MODULE . . . . . . . . . . 9 SPEED CONTROL CABLE . . . . . . . . . . . . . . . . . . 9 SPEED CONTROL SERVO . . . . . . . . . . . . . . . . . . 8 SPEED CONTROL SWITCHES . . . . . . . . . . . . . . 9 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 9 VACUUM RESEROIR . . . . . . . . . . . . . . . . . . . . . 10 VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 10 DESCRIPTION AND OPERATION SPEED CONTROL SERVO
The servo unit consists of a solenoid valve body, and a vacuum chamber. The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly.
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SERVO CABLE
The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm.
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DESCRIPTION AND OPERATION (Continued)
STEP IS NOT DONE A DIAGONSTIC TROUBLE CODE (DTC) MAY BE SET.
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VACUUM RESERVOIR
The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty.
terminals and a light coating of Mopar Multipurpose Grease, or equivalent, applied. Leaking vacuum reservoir. Loose or leaking vacuum hoses or connections. Defective one-way vacuum check valve. Secure attachment at both ends of the speed control servo cable. Smooth operation of throttle linkage and throttle body air valve. Conduct electrical test at PCM. Failed speed control servo. Do the servo vacuum test. CAUTION: When test probing for voltage or continuity at electrical connectors, care must be taken not to damage connector, terminals or seals. If these components are damaged, intermittent or complete system failure may occur.
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OF
56 57 52
MUX S/C Switch High MUX S/C Switch Low S/C Power Relay Or 12V Driver Circuit
Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded. Refer to Group 25, for further information and useage of the DRB scan tool and a more complete list of Diagnostic Trouble Code. The other test method uses a volt/ohm meter. The volt/ohm meter method is described in the following tests. If any information is needed concerning wiring, refer to Group 8W, Wiring Diagrams (Fig. 2). CAUTION: When test probing for voltage or continuity at electrical connectors, care must be taken not to damage connector, terminals, or seals. If these components are damaged, intermittent or complete system failure may occur. When electrical connections are removed, corrosion should be removed from electrical terminals and a light coating of Mopar Multi-Purpose Grease, or equivalent, applied. Inspect connectors for damage terminals. A poor connection can cause a complete or intermittent malfunction and is also the only connection in the circuit, that can not be tested. For this reason, a loose connection may be misdiagnosed as a component malfunction.
SPEED CONTROL SLOWS DOWN BY ITSELF Test vehicle speed sensor, refer to group 8E. If sensor fails replace sensor, if it passes perform the following test: (1) Perform the speed control switch test on the DECEL switch, if it fails replace switch. (2) If the switch passes, conduct the vacuum supply test. (3) If it passes, conduct the servo vacuum test. If it fails replace servo. (4) If continuity, replace the PCM.
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DIAGNOSIS AND TESTING (Continued)
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DIAGNOSIS AND TESTING (Continued)
(a) Using an ohmmeter, check for continuity between cavity 41 of the PCM connector and cavity 1 of each speed control switch connector (Fig. 6). (b) If no continuity, repair as necessary. (c) Using an ohmmeter, check for continuity between cavity 41 of the PCM connector and ground. (d) If continuity, repair as necessary. (e) If no continuity, perform the Switch Test. (f) Plug GRAY 40 way connector into PCM. (g) Plug switch connectors back into switches.
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(j) Using an ohmmeter, check continuity from cavity 1 of servo connector to cavity 56 (2.4, 3.3, 3.8L) or cavity 78 (3.0L) on PCM connector. If no continuity, repair open circuit. (k) Using an ohmmeter, check continuity from cavity 1 of servo connector to ground. If continuity, repair as necessary. (l) If continuity is OK, check continuity from cavity 2 of servo connector to cavity 80 of PCM connector. If no continuity, repair open circuit. (m) Using an ohmmeter, check continuity from cavity 2 of servo connector to ground. If continuity, repair as necessary. (n) Using an ohmmeter, check continuity from cavity 1 of servo connector to cavity 2 of servo connector. If continuity, repair as necessary. (o) Reconnect the 4 way connector to servo. (5) Using an ohmmeter, check continuity from cavity 62 of the PCM connector to ground. If continuity is OK with brake pedal in unpressed position, proceed to Step 6. (a) If no continuity, perform the Stop Lamp switch test. Replace or adjust switch as required. (b) If switch passes test, check continuity from cavity 62 of the PCM connector to cavity 1 of the stop lamp switch connector. Repair open circuit as required. (c) If continuity is OK between cavity 62 and cavity 1, repair open circuit between cavity 2 of the stop lamp switch connector and ground. (6) Using an ohmmeter, check continuity from cavity 76 on PCM connector to ground with the transmission in drive. If continuity, test TRS/ ParkNeutral switch and switch wiring. (7) Turn speed control and ignition switch OFF. (8) Unplug the BLACK 40-way connector from the Powertrain Control Module (PCM). (9) Using an ohmmeter, check continuity from cavity 3 of servo connector to cavity 5 on the PCM connector. (a) If no continuity, skip to Step 10. (b) If continuity is OK, check continuity from pin 5 of PCM connector to ground. If continuity, repair short to ground. If no contunity, replace PCM. Jump to Step 11. (10) Remove stop lamp switch and conduct Stop Lamp Switch Test. If test fails, adjust or replace as necessary. (a) If switch passes, measure continuity from cavity 4 of stop lamp switch connector to cavity 3 of servo connector. Repair open circuit if necessary. (b) If continuity is OK, measure continuity from cavity 3 of stop lamp switch to cavity 5 of PCM connector. Repair open circuit as necessary. (11) Install PCM connectors onto PCM and speed control servo connector to servo.
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REMOVAL AND INSTALLATION (Continued)
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VACUUM RESEROIR
REMOVAL (1) Disconnect negative cable from battery. (2) Remove battery, Refer to Group 8B, for Battery Removal/Installation (3) Remove battery tray. (4) Disconnect vacuum hoses from vacuum reservoir INSTALLATION (1) Connect vacuum hoses to vacuum reservoir. (2) Install battery tray (3) Install battery, Refer to Group 8B, for Battery Removal/Installation. (4) Connect negative cable to battery.
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GENERAL INFORMATION COMBINATION FLASHER . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION COMBINATION FLASHER / DAYTIME RUNNING LAMPS (DRL) MODULE . . . . . . . . . COMBINATION FLASHER FUNCTION . . . . . . . . .
1 1
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DIAGNOSIS AND TESTING COMBINATION FLASHER WITH / WITHOUT DAYTIME RUNNING LAMPS MODULE CIRCUIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . 3 TURN SIGNAL MULTI-FUNCTION SWITCH . . . . 2 REMOVAL AND INSTALLATION COMBINATION FLASHER WITH / WITHOUT DRL MODULE . . . . . . . . . . . . . . . . . . . . . . . . 11 MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . 11
The Junction Block is adjacent to and left of the steering column of the vehicle.
COMBINATION FLASHER
The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at position 4 (Fig. 1), where all wiring associated with its operation is terminated.
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DIAGNOSIS AND TESTING (Continued)
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Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/DRL. The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: Back-Up Lamps Electrochromic Inside Rear view Mirror A/C Control Head Mini-Trip Computer ABS Module Front Blower Relay Coil Rear Blower Relay Coil AWD Solenoids Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. For diagnostic test procedures, refer to Combination Flasher Diagnosis tables.
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DIAGNOSIS AND TESTING (Continued)
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SYSTEM WILL FLASH HAZARD WARNING LAMPS BUT WILL NOT FLASH RIGHT OR LEFT TURN SIGNAL LAMPS
1. REPLACE FAULTY FUSE IN JUNCTION BLOCK. 2. REPLACE COMBINATION FLASHER. 3. REPLACE FAULTY MULTIFUNCTION SWITCH. 4. REPLACE JUNCTION BLOCK. 1. REPAIR OR REPLACE FAULTY WIRING CONNECTION BETWEEN JUNCTION BLOCK AND MULTIFUNCTION SWITCH. 2. REPLACE COMBINATION FLASHER. 3. REPLACE FAULTY MULTIFUNCTION SWITCH. 4. REPLACE JUNCTION BLOCK. 1. REPLACE LEFT FRONT OR LEFT REAR TURN SIGNAL LAMP. 2. REPAIR OR REPLACE WIRING CONNECTION FROM JUNCTION BLOCK TO LEFT FRONT OR LEFT REAR TURN SIGNAL LAMP. 3. REPAIR OR REPLACE FAULTY GROUND WIRING CONNECTION TO LEFT FRONT OR LEFT REAR TURN SIGNAL LAMP. 4. REPLACE FAULTY MULTIFUNCTION SWITCH. 5. REPLACE JUNCTION BLOCK.
SYSTEM WILL FLASH HAZARD WARNING LAMPS AND RIGHT TURN SIGNAL LAMPS, BUT WILL NOT FLASH LEFT TURN SIGNAL LAMPS
RIGHT TURN SIGNAL OPERATES PROPERLY BUT LEFT TURN SIGNAL FLASHES FAST
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DIAGNOSIS AND TESTING (Continued)
CONDITION LEFT TURN SIGNAL OPERATES PROPERLY BUT RIGHT TURN SIGNAL FLASHES FAST POSSIBLE CAUSES
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CORRECTION 1. REPLACE RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 2. REPAIR OR REPLACE WIRING CONNECTION FROM JUNCTION BLOCK TO RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 3. REPAIR OR REPLACE FAULTY GROUND WIRING CONNECTION TO RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 4. REPLACE FAULTY MULTIFUNCTION SWITCH. 5. REPLACE JUNCTION BLOCK. 1. REPAIR OR REPLACE WIRING CONNECTION FROM COWL GROUND SPLICE.
1. FAULTY RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 2. FAULTY WIRING CONNECTION FROM JUNCTION BLOCK TO RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 3. FAULTY GROUND WIRING CONNECTION FROM RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 4. FAULTY MULTI-FUNCTION SWITCH CONTACTS. 5. FAULTY TERMINALS IN JUNCTION BLOCK. 1. FAULTY GROUND WIRING CONNECTION FROM COWL GROUND SPLICE.
BOTH TURN SIGNAL INDICATORS IN MESSAGE CENTER DO NOT FLASH IN CONJUNCTION WITH OUTSIDE TURN SIGNAL LAMPS LEFT OR RIGHT TURN SIGNAL INDICATOR IN MESSAGE CENTER DOES NOT FLASH IN CONJUNCTION WITH OUTSIDE TURN SIGNAL LAMPS, BUT OTHER INDICATOR PERFORMS PROPERLY
1. FAULTY INDICATOR LAMP IN MESSAGE CENTER. 2. FAULTY WIRING CONNECTION BETWEEN MESSAGE CENTER AND JUNCTION BLOCK.
1. REPLACE FAULTY INDICATOR LAMP IN MESSAGE CENTER. 2. REPAIR OR REPLACE FAULTY WIRING CONNECTION BETWEEN MESSAGE CENTER AND JUNCTION BLOCK.
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SYSTEM WILL FLASH HAZARD WARNING LAMPS BUT WILL NOT FLASH RIGHT OR LEFT TURN SIGNAL LAMPS
RIGHT TURN SIGNAL OPERATES PROPERLY BUT LEFT TURN SIGNAL FLASHES FAST (Hazard mode can be used for a system check)
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DIAGNOSIS AND TESTING (Continued)
CONDITION LEFT TURN SIGNAL OPERATES PROPERLY BUT RIGHT TURN SIGNAL FLASHES FAST (Hazard mode can be used for a system check) POSSIBLE CAUSES
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CORRECTION 1. REPLACE RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 2. REPAIR OR REPLACE WIRING CONNECTION FROM JUNCTION BLOCK TO RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 3. REPAIR OR REPLACE FAULTY GROUND WIRING CONNECTION TO RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 4. REPLACE FAULTY MULTIFUNCTION SWITCH. 5. REPLACE JUNCTION BLOCK. 1. REPAIR OR REPLACE WIRING CONNECTION FROM COWL GROUND SPLICE.
1. FAULTY RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 2. FAULTY WIRING CONNECTION FROM JUNCTION BLOCK TO RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 3. FAULTY GROUND WIRING CONNECTION FROM RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP. 4. FAULTY MULTI-FUNCTION SWITCH CONTACTS. 5. FAULTY TERMINALS IN JUNCTION BLOCK. 1. FAULTY GROUND WIRING CONNECTION FROM COWL GROUND SPLICE.
BOTH TURN SIGNAL INDICATORS IN MESSAGE CENTER DO NOT FLASH IN CONJUNCTION WITH OUTSIDE TURN SIGNAL LAMPS LEFT OR RIGHT TURN SIGNAL INDICATOR IN MESSAGE CENTER DOES NOT FLASH IN CONJUNCTION WITH OUTSIDE TURN SIGNAL LAMPS, BUT OTHER INDICATOR PERFORMS PROPERLY
1. FAULTY INDICATOR LAMP IN MESSAGE CENTER. 2. FAULTY WIRING CONNECTION BETWEEN MESSAGE CENTER AND JUNCTION BLOCK.
1. REPLACE FAULTY INDICATOR LAMP IN MESSAGE CENTER. 2. REPAIR OR REPLACE FAULTY WIRING CONNECTION BETWEEN MESSAGE CENTER AND JUNCTION BLOCK.
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REMOVAL (1) Release hood latch and open hood. (2) Disconnect and isolate battery negative cable. (3) Remove upper and lower steering column shrouds, refer to Group 19, Steering for proper procedures. (4) Disconnect wire connector from back of turn signal multi-function switch (Fig. 6). (5) Remove screws holding turn signal switch to steering column adapter collar. (6) Remove turn signal switch. INSTALLATION For installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch.
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Control Module (BCM). The intermittent mode, with the vehicle traveling greater than 10.4 mph, has a range of 0.5 to 18 seconds. With the vehicle traveling less than 10.4 mph, and the time delay is not adjusted, time delay doubles to a range of 1 to 36 seconds. The wiper arms will park at the base of the windshield just above the cowl cover after the wiper switch is turned OFF. The windshield wiper motor and linkage is located in an integral wiper unit at the rear of the engine compartment. The wiper unit must be removed to gain access to the wiper motor.
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1. FAULTY SWITCH. 2. LOCK OF DYNAMIC BRAKE ON WET GLASS. 1. WIPER ARMS ARE PARKED INCORRECTLY.
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DIAGNOSIS AND TESTING (Continued)
CONDITION BLADES CHATTER
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POSSIBLE CAUSES 1. FOREIGN SUBSTANCE SUCH AS POLISH ON GLASS OR BLADES. 2. ARMS TWISTED, BLADE AT WRONG ANGLE ON GLASS. 3. BLADE STRUCTURE BENT. 4. BLADE ELEMENT HAS PERMANENT SET. 1. LINKAGE BUSHINGS WORN. 2. ARMATURE ENDPLAY IN MOTOR.
CORRECTION 1. CLEAN GLASS AND BLADE ELEMENT WITH NON-ABRASIVE CLEANER. 2. REPLACE ARM. 3. REPLACE BLADE. 4. REPLACE BLADE ELEMENT.
1. REPLACE WORN LINK. REFER TO WIPER LINKAGE REMOVAL AND INSTALLATION. 2. REPLACE WIPER MOTOR. REFER TO WIPER MOTOR REMOVAL AND INSTALLATION. 1. REPLACE FUSE, AND RUN SYSTEM. 2. CHECK FOR SHORT IN WIRING OR SWITCH. 3. REPLACE FUSE, REMOVE MOTOR CONNECTOR, TURN SWITCH ON, FUSE DOES NOT BLOW, REPLACE MOTOR. 4. CHECK SWITCH AND WIRING HARNESS. REFER TO GROUP 8W, WIRING DIAGRAMS. 5. REPAIR GROUND WIRE CONNECTION AS NECESSARY.
1. 2. 3. 4. 5.
BLOWN FUSE. NEW FUSE BLOWS. NEW FUSE BLOWS. NO VOLTAGE AT MOTOR. POOR GROUND.
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MULTI-FUNCTION SWITCH
To test the windshield wiper and washer portion of the multi-function switch: (1) Remove the multi-function switch, refer to removal procedures. (2) Using an ohmmeter check continuity reading between switch pins, refer to (Fig. 1) for proper pin numbers.
either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch.
REMOVAL (1) Release hood latch and open hood. (2) Disconnect and isolate battery negative cable. (3) Remove upper and lower steering column shrouds, refer to Group 19, Steering for proper procedures. (4) Disconnect wire connector from back of turn signal multi-function switch (Fig. 2). (5) Remove screws holding turn signal switch to steering column adapter collar. (6) Remove turn signal switch. INSTALLATION For installation, reverse the above procedures. Verify switch operation by placing the control stalk in
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REMOVAL AND INSTALLATION (Continued)
(6) Disconnect front washer hose at front wiper unit in the engine compartment (Fig. 4). The front hose will be removed with the bottle.
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(5) Remove bolts holding wiper motor to mount plate and remove motor (Fig. 9) and (Fig. 10).
INSTALLATION (1) Insert the element vertebra (Fig. 8) into claw at the open end of the wiper blade and through each claw location along the blade.
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REMOVAL AND INSTALLATION (Continued)
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WIPER ARM
CAUTION: The Driver side wiper arm must be parked above the passenger side. Failure to do so will result in damage to the arms, blades, or system.
REMOVAL (1) Disengage the clip holding outside end of the wiper arm pivot cover to the wiper arm. (2) Lift the arm cap upward. (3) Remove the nut holding wiper arm to the wiper pivot. (4) Using a suitable two jaw puller, separate the wiper arm from the wiper pivot (Fig. 11).
WIPER UNIT
REMOVAL (1) Remove the wiper arms. (2) Remove the cowl cover. Refer to Group 23 Body for proper procedure. (3) Release the hood latch and open hood. (4) Disconnect the positive lock on the wiper unit wire connector (Fig. 13). (5) Disconnect the wiper unit wire connector from the engine compartment wire harness. (6) Disconnect the windshield washer hose from coupling inside unit.
WIPER LINKAGE
REMOVAL (1) Remove the windshield wiper unit from vehicle.
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DIAGNOSTIC PROCEDURES
The rear window wiper system operates in several modes: Continuous wipe Intermittent wipe Wash Wipe after wash The windshield wiper circuits are continuously monitored and controlled by the Body Control Module (BCM). If a problem occurs in the electronic components, wiring, switch (except integral motor park switch) and wiper motor a Diagnostic Trouble Code (DTC) will be stored in the BCM memory. The DTC(s) can be retrieved using a scan tool (DRB). Refer to proper Body Diagnostic Procedures manual for DTC descriptions and retrieval information.
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HEADLAMP WASHERS
................... 1
HEADLAMP WASHERS
INDEX
page GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION HEADLAMP WASHER NOZZLE . . . . . . . . . . . . . 1 page HEADLAMP WASHER PUMP . . . . . . . . . . . . . . . 2 WINDSHIELD/HEADLAMP WASHER RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(5) Partially remove the front fascia to aid in the removal of the reservoir. (6) Remove the reservoir mounting bolts. (Fig. 1) (7) Slide the reservoir rearward and remove from the vehicle.
8K - 2
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LAMPS
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LAMPS
CONTENTS
page page
LAMP DIAGNOSIS
INDEX
page GENERAL INFORMATION ELECTRONIC DAYTIME RUNNING LIGHT (DRL) . 1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 page SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 2 test continuity of the circuit ground. Refer to Group 8W, Wiring Diagrams, for component location and circuit information.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT. CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. Do not use bulbs with higher candle power than indicated in the Bulb Application table at the end of this group. Damage to lamp and/or Daytime Running Lamp Module can result. Do not use fuses, circuit breakers or relays having greater amperage value than indicated on the fuse panel or in the Owners Manual. When it is necessary to remove components to service another, it should not be necessary to apply excessive force or bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured edges are not holding the component in place.
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LAMPS
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SYSTEM FUNCTION The combination-flasher/DRL may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL mode, the ignition circuit must be completed to the module. While the combination-flasher portion is idle, there is no current drawn through the module. The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition OFF, there is no current drawn through the module. While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the DRL function. The DRL function may be inhibited by applying a signal ground input from either the park brake circuit or the headlamp relay activation circuit.
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DIAGNOSIS AND TESTING (Continued)
HEADLAMP DIAGNOSIS
CONDITION HEADLAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF POSSIBLE CAUSES 1. Loose or corroded battery cables. 2. Loose or worn generator drive belt. 3. Charging system output too low. 4. Battery has insufficient charge. 5. Battery is sulfated or shorted. 6. Poor lighting circuit Z1-ground. 7. Low beam headlamp / foglamp fuse blown. HEADLAMP BULBS BURN OUT FREQUENTLY 1. Charging system output too high. 2. Loose or corroded terminals or splices in circuit. HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1. Charging system output too low. 2. Poor lighting circuit Z1-ground. 3. High resistance in headlamp circuit. 4. Low beam headlamp / fog lamp fuse blown. HEADLAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 2. High resistance in headlamp circuit. 3. Loose or corroded terminals or splices in circuit. HEADLAMPS DO NOT ILLUMINATE 1. No voltage to headlamps. 2. No Z1-ground at headlamps. 3. Faulty headlamp switch. 4. Faulty headlamp dimmer (multifunction) switch. 5. Broken connector terminal or wire splice in headlamp circuit. 6. Defective or burned out bulb. 7. Body controller malfunction.
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8L - 3
CORRECTION 1. Clean and secure battery cable clamps and posts. 2. Adjust or replace generator drive belt. 3. Test and repair charging system. Refer to Group 8A. 4. Test battery state-of -charge. Refer to Group 8A. 5. Load test battery. Refer to Group 8A. 6. Test for voltage drop across Z1-ground locations. Refer to Group 8W. 7. Locate cause of blown fuse and repair. 1. Test and repair charging system. Refer to Group 8A. 2. Inspect and repair all connectors and splices. Refer to Group 8W. 1. Test and repair charging system. Refer to Group 8A. 2. Test for voltage drop across Z1-ground locations. Refer to Group 8W. 3. Test amperage draw of headlamp circuit. 4. Locate cause of blown fuse and repair. 1. Test for voltage drop across Z1-ground locations, refer to Group 8W. 2. Test amperage draw of headlamp circuit. 3. Inspect and repair all connectors and splices. Refer to Group 8W. 1. Repair open headlamp circuit. Refer to Group 8W. 2. Repair circuit ground. Refer to Group 8W. 3. Replace headlamp switch. 4. Replace multi-function switch. 5. Repair connector terminal or wire splice. 6. Replace bulb. 7. Refer to appropriate body controller diagnostics.
8L - 4
LAMPS
NS
1. Charging system output too high. 2. Loose or corroded terminals or splices in circuit.
3. High resistance in fog lamp circuit. FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground.
2. High resistance in fog lamp circuit. 3. Faulty fog lamp switch. 4. Loose or corroded terminals or splices in circuit. FOG LAMPS DO NOT ILLUMINATE 1. Blown fuse for fog lamp. 2. No Z1-ground at fog lamps. 3. Faulty fog lamp switch. 4. Broken connector terminal or wire splice in fog lamp circuit. 5. Defective or burned out bulb.
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LAMPS
8L - 5
HEADLAMP ALIGNMENT
INDEX
page GENERAL INFORMATION HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . 5 SERVICE PROCEDURES HEADLAMP ALIGNMENT PREPARATION . . . . . . . 5 page ADJUSTMENTS HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN . . . . . . . . . . . . . . . . . . . . 5
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LAMPS
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ADJUSTMENTS (Continued)
HEADLAMP ADJUSTMENT A properly aimed low beam headlamp will project the center of the low beam hot spot on the alignment screen 229 mm (9 in.) 50 mm (2 in.) below the headlamp center line. The center of the hot spot should be 100 mm (4 in.) 50 mm (2 in.) right of the headlamp center line (Fig. 2). The high beams on a vehicle with aero headlamps cannot be aligned. The high beam pattern should be correct when the low beams are aligned properly. To adjust headlamp alignment, rotate adjusting screws to achieve the specified low beam hot spot location (Fig. 3). HEADLAMP ADJUSTMENT TOWN AND COUNTRY A properly aimed low beam headlamp will project the center of the low beam hot spot on the alignment screen 152 mm (6 in.) 50 mm (2 in.) below the headlamp center line. The center of the hot spot should be 254 mm (10 in.) 50 mm (2 in.) right of the headlamp center line (Fig. 4). The high beams on a vehicle with aero headlamps cannot be aligned. The
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ADJUSTMENTS (Continued)
LAMPS
8L - 7
BUBBLE LEVEL CALIBRATION (VERTICAL AIM) After the headlamp alignment has been verified or set and the bubble level is not centered, calibrate the bubble level.
NOTE: Any calibration of the headlamp bubble level must be done on a level surface and the headlamp cool. Do not operate the headlamps for a minimum of 20 minutes prior to beginning adjustments. (1) Remove screws holding magnifying window to top of headlamp module (Fig. 5). (2) Position magnifying window to the side between headlamp module and radiator closure panel. (3) Through slotted hole in magnifying window, insert small screw driver into bubble level calibration screw.
MAGNIFYING WINDOW CALIBRATION (HORIZONTAL AIM) After the headlamp alignment has been verified or set and the magnifying window is not centered, calibrate the magnifying window. (1) Loosen screws holding magnifying window to top of headlamp module (Fig. 5). (2) Using the calibration knob above headlamp lens, rotate magnifying window until window is centered over the O on the gauge below the window.
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ADJUSTMENTS (Continued)
(3) Tighten screws to hold magnifying window to headlamp module. Do not over tighten.
FOG LAMP ALIGNMENT Prepare an alignment screen. Refer to the Alignment Screen Preparation paragraph in this section. A properly aligned fog lamp will project a pattern on the alignment screen 100 mm (4 in.) below the fog lamp center line and straight ahead (Fig. 6). To improve visual interpretation of the fog lamp pattern on the alignment screen, disable the headlamps by disengaging the wire connectors from the headlamp bulbs. The Town and Country fog lamp adjustment screw is located through the lens (Fig. 7).
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13 11 10 12 11
(3) Rotate headlamp bulb retaining ring clockwise. (4) Connect wire connector into headlamp bulb base. (5) Verify headlamp alignment.
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LAMPS
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CAUTION: Do not touch the glass of halogen bulbs with fingers or other oily surfaces, reduced bulb life will result.
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REMOVAL AND INSTALLATION (Continued)
(1) Connect wire connector into fog lamp wire harness. (2) Insert bulb into lamp so index notches on bulb engage with bosses in lamp (Fig. 5). (3) Hinge wire retainer clip over bulb base. (4) Engage wire clip to hold bulb into lamp. (5) Install rear cover on fog lamp. (6) Install fog lamp on vehicle.
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(2) Remove housing by pulling rearward and away from fascia (Fig. 7). (3) Rotate lamp socket counterclockwise one quarter turn. (4) Pull bulb socket from the rear of lamp (Fig. 8). (5) Pull bulb from socket.
Fig. 8 Front Side Marker Lamp Sockets Fig. 6 Fog Lamp Bulb T&C
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs with fingers or other oily surfaces, reduced bulb life will result. (1) base. (2) (3) (4) (5) Connect wire connector into fog lamp bulb Insert bulb into fog lamp housing. Rotate lamp bulb clockwise to engage bulb. Verify bulb operation. Verify fog lamp alignment.
INSTALLATION (1) Insert bulb into socket. (2) Insert bulb socket into rear of housing. (3) Rotate park and turn signal socket clockwise one quarter turn. (4) Verify bulb operation. (5) Install screw attaching side marker lamp.
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FRONT PARKING AND TURN SIGNAL LAMP BULB TOWN and COUNTRY
REMOVAL (1) Remove screw attaching side marker lamp to fascia. (2) Remove housing by pulling outward and away from the fascia (Fig. 10). (3) Remove screw attaching parking and turn signal lamp housing. (4) Rotate lamp socket(s) counterclockwise one quarter turn (Fig. 11). (5) Pull bulb socket(s). (6) Pull bulb from socket(s).
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REMOVAL AND INSTALLATION (Continued)
LAMPS
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LAMPS
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. . . . . . . 14 . . . . . . . 14 . . . . . . . 14
. 15 . 15 . 14 . 16 . 16
. . . . . . . 17 . . . . . . . 15 . . . . . . . 14
HEADLAMP SWITCH
Service procedures for the headlamp switch can be found in Group 8E, Instrument Panel and Gauges. More information can be found in Group 8W, Wiring Diagrams.
FOG LAMP
REMOVAL (1) Remove screws holding fog lamp to front bumper fascia (Fig. 2). (2) Remove fog lamp from fascia. (3) Disconnect wire connector from body wire harness. (4) Remove fog lamp from vehicle.
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REMOVAL AND INSTALLATION (Continued)
LAMPS
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LAMPS
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REMOVAL AND INSTALLATION (Continued)
NOTE: Wire connector may be disconnected at socket which eliminates removal of liftgate trim.
LAMPS
8L - 17
(2) Disengage clips holding CHMSL access cover to liftgate. (3) Remove cover from liftgate. (4) Rotate bulb sockets counterclockwise one quarter turn. (5) Pull sockets from lamp. (6) Remove screws holding CHMSL to liftgate. (7) Remove CHMSL from vehicle (Fig. 9).
Fig. 9 CHMSL
INSTALLATION (1) Place CHMSL in position on vehicle. (2) Install screws to hold CHMSL to liftgate. (3) Insert bulb into socket. (4) Insert sockets into lamp. (5) Rotate bulb sockets clockwise one quarter turn. (6) Place CHMSL access cover in position on liftgate. (7) Engage clips to hold access cover to liftgate. (8) Verify CHMSL operation.
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LAMPS
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INTERIOR LAMPS
INDEX
page REMOVAL AND INSTALLATION CONVENIENCE BIN LAMP . . . . . . . . . . . . . . DOME LAMP BULB . . . . . . . . . . . . . . . . . . . DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . FRONT DOOR COURTESY LAMP BULB . . . FRONT DOOR COURTESY LAMP . . . . . . . . GLOVE BOX LAMP AND SWITCH . . . . . . . . GLOVE BOX LAMP BULB . . . . . . . . . . . . . . . HEADER READING/COURTESY LAMP BULB HEADER READING/COURTESY LAMP . . . . . . IGNITION HALO LAMP BULB . . . . . . . . . . . . . . INSTRUMENT PANEL LAMPS AND SWITCHES LIFTGATE COURTESY LAMP BULB . . . . . . . . . LIFTGATE COURTESY LAMP . . . . . . . . . . . . . . OVERHEAD CONSOLE READING/COURTESY LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . . RAIL LAMP MODULE BULB . . . . . . . . . . . . . . . page . . . . . 18 19 20 24 23
. . . . . . . .
. . . . . . . .
. . . . . . . .
20 21 21 22 21 19 19 19
. 18 . 23
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REMOVAL AND INSTALLATION (Continued)
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8L - 19
(5) Rotate light shield upward and snap inboard edge into lamp housing. (6) Position lens switch tab to lamp switch. (7) Press lens pivots to tabs on lamp housing until both pivots are seated.
Fig. 3 Reading/Courtesy Lamp Lens Fig. 5 Glove Box Lamp and Switch
INSTALLATION (1) Position glove box lamp in vehicle. (2) Connect wire connector from glove box lamp. (3) Position glove box lamp in instrument panel. (4) Press lamp into instrument panel until fully seated.
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LAMPS
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REMOVAL AND INSTALLATION (Continued)
LAMPS
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DOME LAMP
REMOVAL (1) Insert a small, flat bladed pry tool between dome lamp lens and dome lamp body on left side of dome lamp. (2) Disengage left side of dome lamp lens from lamp body (Fig. 11). (3) Pivot dome lamp lens downward until lens hook is clear of headlining. (4) Slide dome lamp toward right side of vehicle until hook on dome lamp is clear of headlining (Fig. 12). (5) Remove dome lamp from headlining. (6) Disconnect wire connector from dome lamp. (7) Remove dome lamp from vehicle.
INSTALLATION (1) Position dome lamp in vehicle. (2) Connect wire connector to dome lamp. (3) Position dome lamp to headlining. (4) Position hook on dome lamp above headlining and slide lamp toward left side of vehicle until hook on dome lamp is fully engaged to headlining. (5) Push upward on dome lamp until dome lamp is tight to headlining. (6) Pivot dome lamp lens upward. Verify that lamp lens hook is above the headlining. (7) Install left side of dome lamp lens to lamp body.
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Fig. 15 Door Courtesy Lamp Lens Fig. 14 Door Courtesy Lamp Housing
INSTALLATION (1) Position lamp housing to vehicle. (2) Engage wire connector to lamp. (3) Slide tab on forward edge of housing behind trim panel. (4) Snap rear edge of housing into trim panel.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Position bulb to lamp contacts. (2) Engage bulb to lamp contacts. (3) Insert long edge of lens into lamp housing. (4) Press on center of lens to engage remainder of clips
LAMPS
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LAMPS
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LAMPS
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BULB APPLICATION
INDEX
page GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 25 page SPECIFICATIONS EXTERIOR LAMP BULBS . . . . . . . . . . . . . . . . . . 25 INTERIOR LAMP BULBS . . . . . . . . . . . . . . . . . . 25
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LAMPS
8L - 1
LAMPS
CONTENTS
page page
LAMP DIAGNOSIS
INDEX
page GENERAL INFORMATION HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . 2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1 page SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 2 Begin electrical system failure diagnosis by testing related fuses in the fuse block and power distribution center. Verify that bulbs are in good condition and test continuity of the circuit ground. Refer to Group 8W, Wiring Diagrams, for component location and circuit information.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT. CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. Do not use bulbs with higher candle power than indicated in the Bulb Application table at the end of this group. Damage to lamp and/or Daytime Running Lamp Module can result. Do not use fuses, circuit breakers or relays having greater amperage value than indicated on the fuse panel or in the Owners Manual. When it is necessary to remove components to service another, it should not be necessary to apply excessive force or bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured edges are not holding the component in place.
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LAMPS
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HEADLAMP DIAGNOSIS
CONDITION HEADLAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF POSSIBLE CAUSES 1. Loose or corroded battery cables. 2. Loose or worn alternator drive belt. 3. Charging system output too low. 4. Battery has insufficient charge. 5. Battery is sulfated or shorted. 6. Poor lighting circuit Z1-ground. HEADLAMP BULBS BURN OUT FREQUENTLY 1. Charging system output too high. 2. Loose or corroded terminals or splices in circuit. HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1. Charging system output too low. 2. Poor lighting circuit Z1-ground. 3. High resistance in headlamp circuit. HEADLAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 2. High resistance in headlamp circuit. 3. Loose or corroded terminals or splices in circuit. HEADLAMPS DO NOT ILLUMINATE 1. No voltage to headlamps. 2. No Z1-ground at headlamps. 3. Faulty headlamp switch. 4. Faulty headlamp dimmer (multi-function) switch. 5. Broken connector terminal or wire splice in headlamp circuit. 6. Defective or burned out bulb. 7. Body controller malfunction. CORRECTION 1. Clean and secure battery cable clamps and posts. 2. Adjust or replace alternator drive belt. 3. Test and repair charging system. Refer to Group 8A. 4. Test battery state-of -charge. Refer to Group 8A. 5. Load test battery. Refer to Group 8A. 6. Test for voltage drop across Z1-ground locations. Refer to Group 8W. 1. Test and repair charging system. Refer to Group 8A. 2. Inspect and repair all connectors and splices. Refer to Group 8W. 1. Test and repair charging system. Refer to Group 8A. 2. Test for voltage drop across Z1-ground locations. Refer to Group 8W. 3. Test amperage draw of headlamp circuit. 1. Test for voltage drop across Z1-ground locations, refer to Group 8W. 2. Test amperage draw of headlamp circuit. 3. Inspect and repair all connectors and splices. Refer to Group 8W. 1. Repair open headlamp circuit. Refer to Group 8W. 2. Repair circuit ground. Refer to Group 8W. 3. Replace headlamp switch. 4. Replace multi-function switch. 5. Repair connector terminal or wire splice. 6. Replace bulb. 7. Refer to appropriate body controller diagnostics.
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DIAGNOSIS AND TESTING (Continued)
FOG LAMP DIAGNOSIS
CONDITION FOG LAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF. POSSIBLE CAUSES 1. Loose or corroded battery cables. 2. Loose or worn alternator drive belt. 3. Charging system output too low. 4. Battery has insufficient charge. 5. Battery is sulfated or shorted. 6. Poor lighting circuit Z1-ground.
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CORRECTION 1. Clean and secure battery cable clamps and posts. 2. Adjust or replace alternator drive belt. 3. Test and repair charging system. Refer to Group 8A, 4. Test battery state-of -charge. Refer to Group 8A. 5. Load test battery. Refer to Group 8A. 6. Test for voltage drop across Z1-ground locations. Refer to Group 8W. 1. Test and repair charging system. Refer to Group 8A. 2. Inspect and repair all connectors and splices. Refer to Group 8W. 1. Test and repair charging system. Refer to Group 8A. 2. Test for voltage drop across Z1-ground locations. Refer to Group 8W. 3. Test amperage draw of fog lamp circuit. 1. Test for voltage drop across Z1-ground locations. Refer to Group 8W. 2. Test amperage draw of fog lamp circuit. 3. Replace fog lamp switch. 4. Inspect and repair all connectors and splices. Refer to Group 8W. 1. Replace fuse. Refer to Group 8W. 2. Repair circuit ground. Refer to Group 8W. 3. Replace fog lamp switch. 4. Repair connector terminal or wire splice. 5. Replace bulb.
1. Charging system output too high. 2. Loose or corroded terminals or splices in circuit.
3. High resistance in fog lamp circuit. FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground.
2. High resistance in fog lamp circuit. 3. Faulty fog lamp switch. 4. Loose or corroded terminals or splices in circuit. FOG LAMPS DO NOT ILLUMINATE 1. Blown fuse for fog lamp. 2. No Z1-ground at fog lamps. 3. Faulty fog lamp switch. 4. Broken connector terminal or wire splice in fog lamp circuit. 5. Defective or burned out bulb.
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LAMPS
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LAMPS
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HEADLAMP ALIGNMENT
INDEX
page SERVICE PROCEDURES HEADLAMP ALIGNMENT PREPARATION . . . . . . 5 page ADJUSTMENTS HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN . . . . . . . . . . . . . . . . . . 5
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ADJUSTMENTS (Continued)
(5) Rock vehicle side-to-side three times and allow suspension to stabilize. (6) Jounce front suspension three times by pushing downward on front bumper and releasing. (7) Measure the distance from the center of headlamp lens to the floor. Transfer measurement to the alignment screen (with tape). Use this line for up/down adjustment reference. (8) Place a tape line 130 mm below and parallel to the center of headlamp line. (9) Measure distance from the centerline of the vehicle to the center of each headlamp being aligned. Transfer measurements to screen (with tape) to each side of vehicle centerline. Use these lines for left/ right adjustment reference.
HEADLAMP ADJUSTMENT A properly aimed low beam headlamp will project a high intensity light pattern on the screen with the horizontal cut-off line aligned with the tape line 130 mm (5.12 in.) below the headlamp centerline (Fig. 1). The intersection of the horizontal and 15 degree cutoff lines in the projected pattern should align to the intersection of the headlamp centerline vertical tape line and the tape line 130 mm (5.12 in.) below the headlamp horizontal centerline. The high beams on a vehicle with aero headlamps cannot be aligned. The high beam pattern should be correct when the low beams are aligned properly.
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ADJUSTMENTS (Continued)
To adjust headlamp alignment, rotate alignment screws to achieve the specified low beam hot spot pattern (Fig. 2).
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FOG LAMP ALIGNMENT Prepare an alignment screen. Refer to the Alignment Screen Preparation paragraph in this section. A properly aligned fog lamp will project a pattern on the alignment screen 200 mm (8 in.) below the fog lamp centerline and straight ahead (Fig. 3). To improve visual interpretation of the fog lamp pattern on the alignment screen, disable the headlamps by disengaging the wire connectors from the headlamp bulbs.
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LAMPS
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REMOVAL AND INSTALLATION (Continued)
(2) Rotate front turn signal lamp socket one quarter turn counterclockwise. (3) Pull socket from back of lamp. (4) Pull bulb from socket (Fig. 4).
LAMPS
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LAMPS
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INSTALLATION (1) Push and twist bulb into socket. (2) Push side repeater lamp socket into side repeater lamp. (3) Position side repeater lamp to hole in fender. (4) Push side repeater lamp to one side and seat retaining tab into fender. (5) Verify lamp operation.
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REMOVAL AND INSTALLATION (Continued)
REMOVAL (1) Release liftgate latch and open liftgate. (2) Remove screws holding tail lamp to rear door opening trough (Fig. 10). (3) Separate inner end of lamp from quarter panel. (4) Disengage hook holding outer end of lamp to quarter panel opening. (5) Separate lamp from quarter panel. (6) Remove screws holding bulb holder to lamp housing (Fig. 11). (7) Separate bulb holder from lamp housing. (8) Retrieve the rubber washers that seal the bulb holder to the lamp housing at the bulb holder screw locations. (9) Pull bulb from bulb holder socket (Fig. 12).
LAMPS
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LAMPS
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LAMPS
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LAMP SERVICE
INDEX
page GENERAL INFORMATION HEADLAMP DIMMER SWITCH . . . . . . . . . . . . . 13 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 13 REMOVAL AND INSTALLATION CENTER HIGH MOUNTED STOP LAMP (CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FOG LAMP . . . . . . . . . . . . . . . . HEADLAMP LEVELING MOTOR HEADLAMP MODULE . . . . . . . LICENSE PLATE LAMP . . . . . . SIDE REPEATER LAMP . . . . . . TAIL LAMP . . . . . . . . . . . . . . . . (8) Separate headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . . 14 14 13 15 14 15
module
from
vehicle.
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LAMPS
NS/GS
FOG LAMP
REMOVAL (1) Remove screws holding fog lamp to front bumper fascia (Fig. 4). (2) Separate fog lamp from fascia. (3) Disengage wire connector from body wire harness. (4) Separate fog lamp from vehicle.
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REMOVAL AND INSTALLATION (Continued)
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TAIL LAMP
The tail lamp houses the tail/stop lamp, rear turn signal lamp, back-up lamp, and rear fog lamp bulbs.
REMOVAL (1) Release liftgate latch and open liftgate. (2) Remove screws holding tail lamp to rear door opening trough. (3) Separate inner end of lamp from quarter panel. (4) Disengage hook holding outer end of lamp to quarter panel opening. (5) Separate lamp from quarter panel (Fig. 7). (6) Disengage positive lock on wire connector (Fig. 8). (7) Depress lock tab on the side of the body harness connector. (8) Disengage wire connector from bulb holder. (9) Separate tail lamp from vehicle. INSTALLATION (1) Place tail lamp in position on vehicle. (2) Engage wire connector into bulb holder.
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LAMPS
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LAMPS
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BULB APPLICATION
INDEX
page GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 17 CLEANING AND INSPECTION HEADLAMP CLEANING . . . . . . . . . . . . . . . . . . 17 page SPECIFICATIONS EXTERIOR LAMP BULBS . . . . . . . . . . . . . . . . . 17 INTERIOR LAMP BULBS . . . . . . . . . . . . . . . . . 17
LAMP BULB Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3 Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4 License Plate . . . . . . . . . . . . . . . . . . . . . . . . . . C5W Front Turn Signal . . . . . . . . . . . . . . . . . . . . PY21W Citylight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T4W Front Side Repeater . . . . . . . . . . . . . . . . . . . . . T4W Tail, Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . P21/5W Rear Turn Signal . . . . . . . . . . . . . . . . . . . . . . P21W Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . P21W
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RESTRAINT SYSTEM
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RESTRAINT SYSTEM
CONTENTS
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GENERAL INFORMATION WARNINGS AND PRECAUTIONS . . . . . . . . . . . . DESCRIPTION AND OPERATION AIRBAG CONTROL MODULE (ACM) . . . . . . . . . CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVER AND PASSENGER AIRBAG MODULES . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING AIRBAG SYSTEM TEST . . . . . . . . . . . . . . . . . . . SERVICE PROCEDURES CLEANUP PROCEDURE . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION WARNINGS AND PRECAUTIONS
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HANDLING AIRBAG MODULE . . . . . . . . . . . . . . REMOVAL AND INSTALLATION AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVER AIRBAG MODULE . . . . . . . . . . . . . . . . . PASSENGER AIRBAG . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS CLOCKSPRING CENTERING PROCEDURE . . . . .
3 3 5 5 6 7
WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE DOWN ON A SOLID SURFACE, THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN PERSONAL INJURY. WHEN CARRYING OR HANDLING AN UNDEPLOYED AIRBAG MODULE, THE TRIM SIDE OF THE AIRBAG SHOULD BE POINTING AWAY FROM THE BODY TO MINIMIZE POSSIBILITY OF INJURY IF ACCIDENTAL DEPLOYMENT OCCURS. REPLACE AIRBAG SYSTEM COMPONENTS WITH MOPAR REPLACEMENT PARTS. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. WEAR SAFETY GLASSES, RUBBER GLOVES, AND LONG SLEEVED CLOTHING WHEN CLEANING POWDER RESIDUE FROM VEHICLE AFTER AIRBAG DEPLOYMENT. SODIUM HYDROXIDE POWDER
RESIDUE EMITTED FROM A DEPLOYED AIRBAG CAN CAUSE SKIN IRRITATION. FLUSH AFFECTED AREA WITH COOL WATER IF IRRITATION IS EXPERIENCED. IF NASAL OR THROAT IRRITATION IS EXPERIENCED, EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF IRRITATION CONTINUES, SEE A PHYSICIAN. DO NOT USE A REPLACEMENT AIRBAG THAT IS NOT IN THE ORIGINAL PACKAGING, IMPROPER DEPLOYMENT AND PERSONAL INJURY CAN RESULT. THE FACTORY INSTALLED FASTENERS, SCREWS AND BOLTS USED TO FASTEN AIRBAG COMPONENTS HAVE A SPECIAL COATING AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. DO NOT USE SUBSTITUTE FASTENERS, USE ONLY ORIGINAL EQUIPMENT FASTENERS LISTED IN THE PARTS CATALOG WHEN FASTENER REPLACEMENT IS REQUIRED. NOTE: Airbags should be stored in a cool dry location away from excessive heat and static electrical activity with the fabric airbag facing UP, or a premature deployment can result. If the Driver/Passenger Airbag Module is defective and not deployed, refer to Chrysler Corporation current return list for proper handling procedures.
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RESTRAINT SYSTEM
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CLOCKSPRING
The clockspring is snapped into a plastic mounting platform on the steering column behind the steering wheel. The clockspring is used to maintain a continuous electrical circuit between the wiring harness and the drivers airbag module. This assembly consists of a flat ribbon like electrically conductive tape which winds and unwinds with the steering wheel rotation.
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RESTRAINT SYSTEM
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REMOVAL (1) Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the Airbag Control Module (ACM) to discharge.
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RESTRAINT SYSTEM
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For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with the proper screws and tighten to 805 to 11.9 Nm (75 to 105 in. lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
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REMOVAL AND INSTALLATION (Continued)
RESTRAINT SYSTEM
8M - 5
CLOCKSPRING
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS.
REMOVAL (1) Position steering wheel and front wheels straight ahead. (2) Release hood latch and open hood. (3) Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the ACM to discharge. (4) Remove driver airbag from steering wheel (Fig. 7). (5) Disconnect wire connectors from back of airbag module. (6) Remove steering wheel (Fig. 8). (7) Remove steering column shrouds (Fig. 9).
INSTALLATION For installation, reverse the above procedures. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
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RESTRAINT SYSTEM
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PASSENGER AIRBAG
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS.
DEPLOYED MODULE
REMOVAL (1) Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the Airbag Control Module to discharge. (2) Clean powder residue from interior of vehicle, refer to Cleanup Procedure in this section. (3) Remove instrument panel, refer to Group 8E, Instrument Panel and Systems for proper procedures. (4) Remove all reusable components from the upper instrument panel. INSTALLATION Transfer all reusable components to the new the upper instrument panel. (1) Install new Passenger Airbag Module into instrument panel. (2) Install airbag module attaching screws to the instrument panel.
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REMOVAL AND INSTALLATION (Continued)
(3) Install Instrument panel. Refer to Group 8E, Instrument Panel and Systems for installation procedures. (4) Through access holes in instrument panel above glove box opening, install screws holding airbag to back of panel. (5) Install the bolts attaching forward airbag mount to the instrument panel (Fig. 11).
RESTRAINT SYSTEM
8M - 7
(9) Remove airbag from instrument panel through top of instrument panel. INSTALLATION For installation, reverse the above procedures. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
UNDEPLOYED
REMOVAL (1) Disconnect battery negative cable. Allow at least two minutes for the reserve capacitor in the ACM to discharge. (2) Remove instrument panel top cover. (3) Remove right front instrument panel speaker. (4) Remove glove box. (5) Disconnect yellow wire connector from passenger airbag. (6) Remove bolts attaching forward airbag mount to the instrument panel (7) Through access holes in instrument panel above glove box opening, remove screws holding airbag to back of panel. (8) Remove screws attaching airbag to upper instrument panel.
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8N - 1
DESCRIPTION AND OPERATION HVAC MOUNTED SWITCH . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING GRID LINE TEST . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION AND OPERATION INTRODUCTION
The electrically heated Rear Window Defogger (Fig. 1), Heated Power Side View Mirrors, and Heated Windshield Wiper De-icer (Fig. 2) is available on NS vehicles. The Rear Window Defogger system consists of two vertical bus bars linked by a series of grid lines on the inside surface of the rear window. The electrical circuit consists of the rear defogger switch in the HVAC and a relay with timer switch to turn OFF the system after ten minutes. The main feed circuit is protected by fuse one (40 amp) in the Junction Block. The rear defogger switch and relay also activates the heated power side view mirrors and heated windshield wiper de-icer. The HVAC rear defogger switch is protected by fuse ten (10 amp) in the Junction Block. The heated mirror circuit is protected by fuse 12 (10 amp) in the junction block. The heated windshield wiper de-icer circuit is protected by fuse 21 (25 amp) in the Junction Block. The Heated Windshield Wiper Deicer is also activated when the DEFROST mode is selected on the HVAC. In the DEFROST mode the rear defogger relay/timer is bypassed, the heated windshield wiper de-icer will stay ON until the another mode is selected. For circuit information and component location refer to Group 8W, Wiring Diagrams. CAUTION: Since grid lines can be damaged or scraped off with sharp instruments, care should be taken in cleaning the glass or removing foreign materials, decals or stickers. Normal glass cleaning solvents or hot water used with rags or toweling is recommended.
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DIAGNOSIS AND TESTING (Continued)
(3) With negative lead of voltmeter, contact a good body ground point. The voltage reading should not change. A different reading indicates a poor ground connection. (4) Connect negative lead of voltmeter to terminal A on passenger side bus bar and touch each grid line at Mid-Point with positive lead. A reading of approximately 6 volts indicates a line is good. A reading of 0 volts indicates a break in line between Mid-Point C and terminal B. A reading of 10-14 volts indicates a break between Mid-Point C and ground terminal A. Move toward break and voltage will change as soon as break is crossed.
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(3) Remove package separator clamp and mix plastic conductive epoxy thoroughly. (4) For grid line, mark off area to be repaired with masking tape (Fig. 5). (5) Apply conductive epoxy through slit in masking tape. Overlap both ends of the break. (6) For a terminal replacement, apply a thin layer of epoxy to area where terminal was fastened. (7) Apply a thin layer of epoxy on terminal and place terminal on desired location. To prevent terminal from falling off use a wooden wedge to secure it. (8) Carefully remove masking tape from grid line. CAUTION: Do not allow the laminated windshield glass surface to exceed 82 C (180 F) or the glass may fracture. The rear window glass surface should not exceed 204 C (400 F). (9) Allow epoxy to cure 24 hours at room temperature. (10) After epoxy is properly cured remove wedge from terminal and check the operation of the rear window defogger.
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Rolling automatic lock (ENABLE), doors automatically lock at approximately at 25.7 Km/h (16 mph). No rolling automatic lock (DISABLE), doors do not automatically lock when the vehicle is moving. The BCM is equipped with a disable feature to stop the speed sensitive automatic door locks from functioning. The DISABLE feature can be switched ON or OFF as desired. When the system is DISABLED the door locks will operate normally, but will not lock automatically when the vehicle is rolling. When the door locks are ENABLED the door locks will automatically lock when the vehicle is moving at about 25.7 Km/h (16 mph).
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SERVICE PROCEDURES (Continued)
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8Q - 1
GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION ARMING PROCEDURE . . . . . . . . . . . . . . . . . . . . TIME-OUT PERIOD . . . . . . . . . . . . . . . . . . . . . . . TRIGGERING THE VTSS . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION BODY CONTROL MODULE . . . . . . . . . . . . . . . . . GENERAL INFORMATION INTRODUCTION
1 1 2 2 2 2
DOOR LOCK CYLINDER SWITCH . . . . . . . . . . . . FRONT DOOR AJAR (VTSS TRIGGER) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOOD AJAR (VTSS TRIGGER) SWITCH . . . . . . LIFTGATE AJAR (VTSS TRIGGER) SWITCH . . . . LIFTGATE LOCK CYLINDER SWITCH . . . . . . . . . SLIDING DOOR AJAR (VTSS TRIGGER) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Vehicles equipped with the Vehicle Theft Security System (VTSS) system, the doors, liftgate, hood and ignition circuit are monitored by the Body Control Module (BCM) when the system is armed. The VTSS will prevent the engine from starting until the BCM receives a disarm signal. If the VTSS is triggered, the horn will pulse, headlamps/marker lamps will flash, and the VTSS warning lamp will flash. If BCM determines the threat to be false and the VTSS is not triggered again, the system will shut down and rearm itself after three minutes. The VTSS monitoring portion of the system is split into two sections. The engine compartment section and the passenger compartment section. If a malfunction occurs in the engine compartment section, the passenger compartment section would still arm and function normally. If an electrical malfunction occurs in either section of the system a Diagnostic Trouble Code (DTC) would be stored the BCM memory to aid system repair. DTCs can be retrieved using scan tool (DRB) attached to the diagnostic connector above the accelerator pedal.
engine run cycles. When this has occurred the total VTSS will function. If during alarm being set the BCM receives a request from the RKE module to enter PANIC mode the BCM will cancel the alarm, return VTSS armed state and then perform the RKE PANIC feature.
ENABLING To initialize the VTSS feature the operator must, with the engine compartment hood open, cycle the key in the liftgate key cylinder to the unlock position giving the BCM a disarm signal. At this time the visual alarm outputs the headlamps and marker lamps will function. However the audio alarm output the horn and engine disable portion of the VTSS will not function until there has been twenty consecutive
8Q - 2
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TIME-OUT PERIOD
The VTSS requires 16 consecutive seconds to timeout and arm the alarm. If a door is key unlocked, key fob unlocked. or the ignition is switched ON, the VTSS will cancel out. To reset the VTSS, perform methods A or B.
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REMOVAL AND INSTALLATION (Continued)
8Q - 3
8Q - 4
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NS/GS
8Q - 1
GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . SMART KEY IMMOBILIZER SYSTEM . . . . . . . DESCRIPTION AND OPERATION SMART KEY IMMOBILIZER MODULE . . . . . . . SMART KEY IMMOBILIZER SYSTEM INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . SMART KEY IMMOBILIZER TRANSPONDER . GENERAL INFORMATION INTRODUCTION
1 1 1 3 2
DIAGNOSIS AND TESTING SMART KEY IMMOBILIZER SYSTEM . . . . . . . 3 SERVICE PROCEDURES SMART KEY IMMOBILIZER SYSTEM TRANSPONDER PROGRAMMING . . . . . . . . . 4 REMOVAL AND INSTALLATION SMART KEY IMMOBILIZER MODULE . . . . . . . 4
malfunction is detected. The SKIS can be diagnosed, and any stored DTC can be retrieved using a DRB scan tool as described in the proper Diagnostic Procedures manual.
The Smart Key Immobilizer System (SKIS) is available factory-installed optional equipment for this model. Following are some general descriptions of the features and components of the SKIS. Refer to the vehicle owners manual for more information on the use and operation of the SKIS. Refer to 8W-30 - Fuel/ Ignition System in Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
8Q - 2
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DESCRIPTION AND OPERATION (Continued)
determine whether a valid key is in the ignition lock cylinder. The Smart Key transponder cannot be repaired and, if faulty or damaged, it must be replaced.
8Q - 3
8Q - 4
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PROGRAMMING THE SKIM MODULE WITH THE DRBIII (1) Turn the ignition on. Transmission must be in park or neutral. Alarm set lamp will flash. (2) Use the DRBIII and select SKIM under the MISCELLANEOUS menu. (3) Select PROGRAM PIN and enter the customer 4digit PIN number. (4) Select UPDATE VIN. The SKIM module will learn the VIN from the PCM in gasoline engine vehicles, and from the BCM in diesel engine vehicles. (5) Select COUNTRY CODE and enter the correct country. (6) Select PROGRAM NEW EMS. The SKIM module will send the secret key data to the PCM. (7) Program ignition keys to the SKIM module. PROGRAMMING IGNITION KEYS WITH THE DRBIII (1) Turn ignition on. Transmission must be in park or neutral. Alarm set lamp will flash. (2) Use the DRBIII and select SKIM under the MISCELLANEOUS menu. (3) Select LEARN NEW KEY. Alarm Set lamp will begin flashing.
NOTE: The PIN must be re-entered each time an additional key is learned.
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REMOVAL AND INSTALLATION (Continued)
8Q - 5
(8) Remove the screw securing the SKIM module to the steering column. (9) Release the clip holding the SKIM antenna to the ignition lock housing on the steering column. (10) Remove the SKIM from the vehicle. (11) Reverse the removal procedures to install. Tighten the non-tilt steering column mounting nuts to 22 Nm (200 in. lbs.) and the steering column shroud mounting screws to 2 Nm (18 in. lbs.). (12) If the SKIM is replaced with a new unit, a DRB scan tool and the proper Diagnostic Procedures manual MUST be used to initialize the new SKIM and to program at least two Smart Key transponders.
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POWER WINDOWS
8S - 1
POWER WINDOWS
CONTENTS
page page
GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING POWER VENT WINDOW MOTOR TEST . . . . . . . POWER WINDOW AND VENT SWITCH TEST . . POWER WINDOW MOTOR TEST . . . . . . . . . . . . GENERAL INFORMATION INTRODUCTION
1 1 2 2
WIRING VOLTAGE TEST . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION POWER VENT WINDOW MOTOR . . . . . . . . . . . . POWER WINDOW MOTOR . . . . . . . . . . . . . . . . . POWER WINDOW SWITCH . . . . . . . . . . . . . . . .
3 3 3 3
cause the motor to rotate in the opposite direction. Refer to Group 8W, Wiring Diagrams for circuit information and component locations.
Front door window lift motors use permanent type magnets. The B+ and ground applied at the motor terminal pins will cause the motor to rotate in one direction. Reversing current through the motor terminals will cause the motor to rotate in the opposite direction. The power window motors ground through the master switch in the driver door (Fig. 1) by a black wire attached to the left cowl panel. Refer to Group 8W, Wiring Diagrams from circuit information and component locations.
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POWER WINDOWS
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* MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 (3) Test passenger door switch for continuity as described in (Fig. 3). (4) If the results are not OK, replace the switch. The driver door power window switch has a AutoDown feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the
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DIAGNOSIS AND TESTING (Continued)
If motor grunts and does not move, verify that regulator is not binding.
POWER WINDOWS
8S - 3
REMOVAL (1) Tape the window in its existing position to remove its weight from the regulator system. (2) Cut and remove the tie wrap at the window motor. Its no longer required. (3) Disconnect window motor wire connector from door harness. (4) Remove screws and nuts holding window motor to the inner panel. (5) Remove the motor from the door inner panel, let it hang from the cables. (6) With the cables still attached to the failed motor, Install the replacement motor to the door inner panel. Tighten down the screws and nuts to 3.4 to 4.5 Nm ( 30 to 40 in. lbs.) of torque. (7) Separate the failed motor from regulator by: Removing the drum cover plate. Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously (Fig. 5).
CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the cables unwind.
INSTALLATION (1) Install the cable guide and drum into the replacement motor.
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POWER WINDOWS
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POWER SEATS
8R - 1
POWER SEATS
CONTENTS
page page
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER SEATS
INDEX
page GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 1 page POWER SEAT SWITCH . . . . . . . . . . . . . . . . . . . . 1 SEAT MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
If seat motors test OK, refer to the Seat Switch in the Diagnostic and Testing in this section. Refer to Group 8W Wiring Diagrams for wire circuit information.
SEAT MOTORS
(1) Remove power seat switch from seat. Refer to Group 23 Body for procedures. (2) Disconnect wire connector. (3) Using a voltmeter check for battery voltage at Pin 5. Using an ohmmeter, check Pin 1 for ground. (4) To test the seat motors, refer to (Fig. 1) and verify proper seat responses. Using two jumper wires, connect one to a battery supply and the other to a ground. Connect the other ends to the seat wire harness connector as described in (Fig. 1). If any motor fails to operate, check wire connectors to the motor. If not OK, repair as necessary. If OK, replace seat motor/track assembly.
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POWER SEATS
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POWER SEATS
8R - 3
The Memory Seat/Mirror Module monitors a data link between the RKE receiver and the Body Control Module (BCM) and will respond to stored information or modify stored information when requested by a valid data stream. The Memory Seat/Mirror Module is connected to the system through a seat wiring harness that interfaces will all of the components within the seat structure, and with electrical distribution wiring harness connections to the non-seat mounted components. The module operates the seat and recliner motors through relays: four dedicated to track forward/rearward, track front up/down, track rear up/down, and recliner forward/rearward. A fifth relay controls the direction of operation of those motors.
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POWER SEATS
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DEFINITION OF: MOMENTARILY AND RELEASE The memory seat/mirror module has switch input timing requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must be met for proper operation of the system.
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DIAGNOSIS AND TESTING (Continued)
POWER SEATS
8R - 5
DIAGNOSTIC MODE
MODE 1 Diagnostic Mode 1 clears soft limits and sets memory selector switches (1 and 2) to predetermined values.
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POWER SEATS
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MODE 2 Diagnostic mode 2 provides a way to determine if the seat/mirror motors and position sensors are connected properly. ACTIVATION- Press and hold the S and 2 buttons for 5 seconds to enter diagnostic mode 2. This mode is exited after 5 seconds of switch inactivity or upon grounding the RKE input by moving the transmission out of the PARK position. Mode 2 will: Place the seat and mirror motors at their midpoint When a single axis of seat or mirror motion is requested by pressing a switch, the corresponding motor is energized. This tests switch input and motor output When the switch is released, the motor will automatically return to its original position. If the corresponding sensor is out of range, then the motor will not return to its original position. This tests the integrity of the sensors and motor outputs. Refer to (Fig. 3), (Fig. 4), (Fig. 5) and (Fig. 6) for module connector call outs.
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DIAGNOSIS AND TESTING (Continued)
POWER SEATS
8R - 7
CIRCUIT DESCRIPTION
Power to both driver and passenger seats, as well as power door locks, rear blower, and front fog lamps (if so equipped), is provided by the A3 circuit through a 40 amp MAXI-fuse in the Power Distribution Center (PDC) under the hood. If all of these devices are nonfunctional, replace the MAXI-fuse. If the new MAXI-fuse blows immediately, correct the wiring short to Ground that could be on any of those aforementioned loads before proceeding further. Once the power is back ON, if the power seats still do not work, check the 30 amp circuit breaker that is located in the drivers seat wiring harness approximately 10 inches from the 4-way connector. The power feed circuit to the 30 amp circuit breaker is 14 ga. A3 RD/WT. Following the 30 amp circuit breaker is a 14 ga. wire designated as F35 RD that provides power into the Memory Seat/Mirror Module and is double crimped with a 14 ga. F35A RD that provides power to the passenger seat through the 4-way connector.
If the power door locks, rear blower, and front fog lamps (if so equipped) are functional and the seats are both nonfunctional, repair/replace the open wiring and/or circuit breaker in the drivers seat harness to correct the condition. Ensure that the 12 ga. ground wire Z1 BK from the electrical distribution wiring ground splice into the 4-way connector is providing ground. The Z1 BK is double crimped at the seat harness side of the 4-way connector taking a 14 ga. Z1 BK into the 10-way connector (cavity 7) 14 ga. This double crimp carries a 20 ga. Z1A BK to cavity 3 of the power seat switch 10-way. If the passenger power seat is functional, and the drivers seat is nonfunctional examine the circuit F35 RD from the double crimped circuit breaker connector into the 10-way connector cavity 8 of the control module for continuity. Repair or replace as necessary. If the drivers seat is still nonfunctional, use a multi-function meter to check the P9 RD 20 ga. circuit from the control module 21-way connector (cavity 11) to the power seat switch 10-way con-
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POWER SEATS
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DIAGNOSIS AND TESTING (Continued)
coming from the module, replace the Memory Seat/ Mirror Module. If P9 low current battery is present at (cavity 5) referenced to ground Z1 (cavity 1) of the seat switch, verify the presence of the P9 voltage at the switch outputs. If there is no output voltage from the switch, replace the switch. If P9 voltage is present at the output of the switch, but there is no reaction from the memory seat/mirror module, verify that the P9 voltage is present at the appropriate 21-way connector pins into the module. If the P9 voltage is not present at the 21-way connector, repair or replace the seat wiring harness. If the verification check of the seat wiring harness is correct, replace the control module. (2) If the control module does not respond with a relay click to a specific seat switch when actuated, verify the continuity of the particular circuit between the seat switch and the Memory Seat/Mirror Module. If the P9 voltage is present at the correct input of the 21-way connector of the module when the switch is actuated, but there is no response by the module, replace the Memory Seat/Mirror Module. (3) If the Memory Seat/Mirror Module responds with a relay click when a seat switch is actuated for a given direction, but there is no reaction from a seat or recliner motor relating to that switch input, disconnect the 10-way connector from the control module. Jumper the battery and ground from cavities 8 and 7 of the seat harness 10-way connector to the proper cavities for the seat or recliner motor in question and direction of travel desired. If the motor operates, replace the control module. If the motor does not operate, verify continuity of the wiring into the motor 2-way connector. Repair or replace the wiring as necessary. If the wiring has continuity, and the motor will not operate when fed directly, replace the track assembly, since the motor/transmission combinations are not designed to be serviced on an individual basis.
POWER SEATS
8R - 9
age reading between 3.5 and 5 volts when a seat or recliner switch is activated. An internal timer in the Memory Seat/Mirror Module (MSM Module) regulates the length of time this voltage stays active i.e., 3 seconds from the time that the switch was activated, unless the switch is held or while the transmission is out of PARK. If the voltage is less than 3.5, there is a fault in the system that is drawing it down. To troubleshoot this circuit, disconnect the 25-way connector from the MSM Module (this removes all of the vehicle mirror circuitry). If the voltage is still less than 3.5, disconnect each of the position sense connectors from each of the motors. If the voltage remains less than 3.5, replace the MSM Module. If the voltage increases when a motor is disconnected from the system, determine if the fault is in the wiring or the motor assembly. Repair or replace the wire harness assembly as needed. If the fault is in the motor position sensing potentiometer, replace the track assembly. The potentiometers built onto the motor end-bell provide voltages to the MSM Module through the 21-way connector, which change as follows, corresponding to the given seat actuations. Refer to Seat Actuations Table.
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POWER SEATS
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Memory Seat/Mirror Module in the recall mode to the values that are stored in the modules memory. (8) Whenever the module receives a specific data stream from the RKE receiver that involves the programming of a new transmitter into the RKE receiver, the module will clear its nonvolatile memory seat and recliner values for both memory 1 and 2 and will default to a location consisting of seat track rearward, seat vertical risers down, and recliner forward in both memory 1 and 2. After this has occurred, the customer must reprogram their desired seat and mirror positions. (9) A recall is possible any time that the vehicle transmission is in PARK. This condition is monitored by the Body Control Module (BCM). (10) A ground placed on the serial data link by the BCM whenever that the transmission is not in PARK, will inhibit a recall request from the door mounted memory switch 1 or 2 or the RKE receiver that was initiated by either of the validly programmed transmitters. NOTE: The module will abort a recall if the transmission is moved out of the PARK position or if any seat, recliner or memory switch is pressed.
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POWER MIRRORS
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POWER MIRRORS
CONTENTS
page page
GENERAL INFORMATION HEATED MIRROR . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . MEMORY MIRRORS . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING HEATED MIRROR TEST . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION INTRODUCTION
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MIRROR MOTOR TEST . . . . . . . . . . . . . . . . . . . MIRROR SWITCH TEST . . . . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION POWER MIRROR SWITCH . . . . . . . . . . . . . . . . . POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . .
1 1 3 3
(4) If results shown in chart are not obtained, check for broken or shorted circuit, or replace mirror assembly as necessary.
Electrically-operated remote control mirrors are controlled by a switch assembly located on the headlamp switch bezel in the instrument panel. The vehicle uses a rocker switch for right or left side mirror selection and a single platform button for mirror UP, DOWN, RIGHT, or LEFT movement. The motors which operate the mirrors are part of the mirror assembly and cannot be serviced separately.
HEATED MIRROR
Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the rear window defogger is ON.
MEMORY MIRRORS
For memory mirrors refer to Group 8R, Power Seats section Memory Seat/Mirror system.
TEST PROCEDURE (1) The mirror should be warm to the touch. (2) If not, check the 10 amp fuse (12) in the junction block behind the instrument panel to the left of the steering column. (3) Test voltage at rear window defogger switch. If no voltage repair wire. Apply voltage to one wire and ground the other, refer to (Fig. 1) for pin numbers. Mirror should become warm to the touch. If not remove mirror glass and test the wires for continuity. If no continuity repair wires. If wires are OK, replace mirror glass. To test defogger switch refer to Group 8N, Electrically Heated Systems.
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POWER MIRRORS
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POWER MIRRORS
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GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING CHIME SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . DOME LAMP ON CHIME . . . . . . . . . . . . . . . . . . ENGINE TEMPERATURE CRITICAL CHIME . . . . EXTERIOR LAMPS ON CHIME . . . . . . . . . . . . . . GENERAL INFORMATION INTRODUCTION
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KEY-IN IGNITION CHIME . . . . . . . . . . . . . . . . . . LOW OIL PRESSURE CHIME OPERATION . . . . . SEAT BELT CHIME . . . . . . . . . . . . . . . . . . . . . . . SEAT BELT LAMP . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL ON CHIME . . . . . . . . . . . . . . . . . WARNING LAMP ANNOUNCEMENT CHIME . . .
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WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO GROUP 8M, RESTRAINT SYSTEMS FOR SAFETY PRECAUTIONS AND WARNINGS TO OBSERVE WHEN SERVICING AIRBAG RELATED COMPONENTS. The chime system provides the driver with warning chimes for: Seat Belt Exterior Lamps ON Key-In Ignition Engine Temperature Critical Turn Signals ON Dome Lamp ON Low Oil Pressure High Speed Warning Warning Lamp Announcement The Chime Warning/Reminder System is diagnosed using a scan tool (DRB). Refer to the proper Body Diagnostic Procedures manual for testing procedures and scan tool usage instructions.
(b) Pin 8 of the internal 32 way connector of the BCM for ignition feed. (c) If voltage OK, go to step Step 3 (d) If NO voltage repair as necessary. Refer to Group 8W, Wiring Diagrams for component locations and circuit information. (3) Check drivers seat belt buckle switch input for a closed circuit when not buckled. If input not seen, look for open in wiring or switch. The switch is grounded when belt is not buckled. (4) Repair as necessary.
NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON. (1) Check for burned out lamp. (2) Using a voltmeter check for voltage: (a) Pin 2 of the mechanical instrument cluster for battery feed. (b) Pin 11 of the mechanical instrument cluster for ignition voltage. (3) Repair as necessary. FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVERS DOOR IS CLOSED. (1) Check left door ajar switch for no ground when switch is depressed. (a) If continuity replace door ajar switch. (b) If NO continuity replace BCM for tone condition, or replace mechanical instrument panel for lamp condition. (c) Replace BCM for tone condition. (d) Replace mechanical instrument cluster for lamp condition. NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVERS DOOR IS OPEN. (1) Check left door ajar switch for good ground when drivers door is open. Repair as necessary.
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DIAGNOSIS AND TESTING (Continued)
instrument cluster for 6 seconds after the instrument cluster receives the message from the Body Control Module. The seat belt lamp is therefore illuminated for 6 seconds whenever the ignition switch is moved to run/start position. (1) While ignition is off, the seat belt lamp will not be illuminated. (2) The ignition power feed status will be updated every 250 milliseconds or on change. (3) This lamp will be checked by the instrument cluster for 6 seconds with every run/start cycle of the ignition switch.
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If hazard warning signals are pulsing, no chime will sound. If speed drops below 24 km/h (15 mph) before the warning is issued, the warning will not be issued and the distance counter will be reset. If turn signal lamps are not working properly, the chime will not sound. When using the scan tool, refer to the proper Body Diagnostic Manual for the procedure.
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GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING CATALYST OVERHEAT WARNING CHIME . . . . CHIME SYSTEM DIAGNOSIS . . . . . . . . . . . . . . DOME LAMP ON CHIME . . . . . . . . . . . . . . . . . ENGINE TEMPERATURE CRITICAL CHIME . . . GENERAL INFORMATION INTRODUCTION
1 1 1 2 2
EXTERIOR LAMPS ON CHIME . . . . . . . . . . . . . KEY-IN IGNITION CHIME . . . . . . . . . . . . . . . . . LOW OIL PRESSURE CHIME OPERATION . . . SEAT BELT CHIME . . . . . . . . . . . . . . . . . . . . . . SEAT BELT LAMP . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL ON CHIME . . . . . . . . . . . . . . . . WARNING LAMP ANNOUNCEMENT CHIME . .
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WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO GROUP 8M, RESTRAINT SYSTEMS FOR SAFETY PRECAUTIONS AND WARNINGS TO OBSERVE WHEN SERVICING AIRBAG RELATED COMPONENTS. The chime system provides the driver with warning chimes for: Seat Belt Exterior Lamps ON Key-In Ignition Engine Temperature Critical Turn Signals ON Dome Lamp ON Low Oil Pressure High Speed Warning Warning Lamp Announcement Catalyst Overheating The Chime Warning/Reminder System is diagnosed using a scan tool (DRB). Refer to the proper Body Diagnostic Procedures manual for testing procedures and scan tool usage instructions.
Ignition switch in the ON position Engine running at 420 to 480 rpm for 10 seconds CCD status and with a chime rate of one chime per second.
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DIAGNOSIS AND TESTING (Continued)
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the emergency flashers are turned on. This feature can also be disabled in EEPROM. Chime rate: 38 to 62 chimes per minute. For the turn signal warning system to operate: Must have input from either the right or left turn signal lamps. Creates a voltage change between 0 and battery voltage. The vehicle speed sensor sends a message to the Powertrain Control Module that vehicle has exceeded 24 km/h (15 mph) for 1.6 km (1.0 miles). When the above two conditions are met, the chime will sound. The chime will stop when no further voltage change is detected. If hazard warning signals are pulsing, no chime will sound. If speed drops below 24 km/h (15 mph) before the warning is issued, the warning will not be issued and the distance counter will be reset. If turn signal lamps are not working properly, the chime will not sound. When using the scan tool, refer to the proper Body Diagnostic Manual for the procedure.
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OVERHEAD CONSOLE
8V - 1
OVERHEAD CONSOLE
CONTENTS
page page
DESCRIPTION AND OPERATION COMPASS MINI-TRIP COMPUTER (CMTC) . . . . COMPASS/TEMPERATURE MINI TRIP COMPUTER SELF-DIAGNOSTIC TEST . . . . . . . THERMOMETER AND COMPASS . . . . . . . . . . . . UNIVERSAL TRANSMITTER . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING READING/DOME LAMP DIAGNOSIS . . . . . . . . . TRAVELER MESSAGES . . . . . . . . . . . . . . . . . . . . UNIVERSAL TRANSMITTER . . . . . . . . . . . . . . . . SERVICE PROCEDURES COMPASS CALIBRATION PROCEDURE (FAST METHOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPASS CALIBRATION PROCEDURE . . . . . . . DEMAGNETIZING PROCEDURE . . . . . . . . . . . . . DESCRIPTION AND OPERATION COMPASS/TEMPERATURE MINI TRIP COMPUTER SELF-DIAGNOSTIC TEST
1 1 2 2 3 3 3
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UNIVERSAL TRANSMITTER . . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION AMBIENT TEMPERATURE SENSOR . . . . . . . . . . COMPASS MINI-TRIP COMPUTER (CMTC) LAMP BULBS . . . . . . . . . . . . . . . . . . . . . . . . . COMPASS MINI-TRIP COMPUTER (CMTC) MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT HEADER READING/COURTESY LAMP . . OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . READING/COURTESY LAMP ASSEMBLY . . . . . . READING/COURTESY LAMP . . . . . . . . . . . . . . . UNIVERSAL TRANSMITTER . . . . . . . . . . . . . . . . SPECIAL TOOLS SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . COMPASS MINI-TRIP COMPUTER (CMTC)
5 5 6 6 6 6 7 6 7 9
The CMTC is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a scan tool (DRB) and the proper Body Diagnostic Procedures manual or by the following procedure. (1) With the ignition switch in the OFF position, press both the US/M and STEP button. (2) Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display. Upon completion of the internal check, the CMTC will display. PASS FAIL CCd If any segment of the CMTC fails to light replace the module. If FAIL is displayed, replace the module. If CCd is displayed, check the CCD and Body Control Module (BCM) for proper operation, refer to the appropriate diagnostic test procedures manual If the CCD and the BCM are OK, replace the CMTC module. For additional diagnostic information on the CMTC and for identifying CMTC problems, refer to the proper Body Diagnostic Procedures manual.
The Compass Mini-Trip Computer (CMTC) system is located in the overhead console. CMTC consists of a electronic control module with a vacuum fluorescent display (VFD) and function switches. The CMTC consists of a electronic module that displays compass, trip computer, and temperature features. Actuating the STEP switch will cause the CMTC to change mode of operation when ignition is ON. Example: Compass/Temperature Trip odometer (ODO) Average miles per gallon (ECO) Instant miles per gallon (ECO) Distance to empty (DTE) Elapsed time (ET) Off The CMTC module in the overhead console has three buttons used to select various functions. The CMTC selector buttons will not operate until the ignition is in the RUN position (Fig. 1). When the ignition switch is first turned to the RUN position the CMTC display; Blanks momentarily All segments of the VFD will light for one second Blanks momentarily Returns to the last mode setting selected before the ignition was last switched OFF.
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OVERHEAD CONSOLE
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UNIVERSAL TRANSMITTER
The Universal Transmitter, replaces the hand held remote controls that open the garage door, motorized gates, or home lighting in/outside the home. This device memorizes the activator codes for up to three remote controlled devices. It triggers those devices at the push of a button, located in a unit permanently mounted in your overhead console (if equipped).
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DESCRIPTION AND OPERATION (Continued)
OVERHEAD CONSOLE
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UNIVERSAL TRANSMITTER
Before proceeding in diagnosis, check the transmitter for battery voltage and a good ground at the transmitter harness connector. The unit may not have been trained correctly, try retraining the transmitter. The batteries in the hand-held transmitter may be dead.
TRAVELER MESSAGES
Traveler data is obtained from the Body Control Module (BCM) on the CCD bus wires. The CMTC will not display information for any of the screens for
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OVERHEAD CONSOLE
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DEMAGNETIZING PROCEDURE
A magnetic field can adversely affect the compass. Magnetic interference can magnetize the roof panel. Magnetizing can be caused by placing a permanent magnet in contact with the roof panel. Example: Magnetic Base Antenna Magnetic screwdriver Audio speakers Refrigerator magnets. Pizza Signs Bubble gum flasher lights
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SERVICE PROCEDURES (Continued)
Removing magnetic interfering objects will usually restore normal compass operation. If the compass display remains blank while the CAL label is illuminated, then the roof panel requires demagnetizing. To demagnetize use Special Tool 6029 for demagnetizing the roof panel. The demagnetizing procedure will demagnetize the roof and mounting screws in the overhead console. It is important that you follow the instructions below exactly. The mounting screws and the mounting brackets around the compass area are steel, and therefore aid in the demagnetizing of the roof panel. (1) Be sure the ignition switch is in the OFF position before you begin the demagnetize procedure. (2) Plug the demagnetizing tool into a standard 110/115 volt AC outlet, keeping the demagnetizing tool at least 12 inches away from the compass area when plugging it in. (3) Slowly approach and contact the console mounting screw with the plastic coated tip of the tool for at least two seconds. (4) With the demagnetizing tool still energized, slowly back it away from the screw until the tip is at least 12 inches from the screw head. (5) Repeat the last step with all the console mounting screws. (6) After you have pulled at least 12 inches from the last screw, remove the demagnetizing tool from inside vehicle and disconnect it from the electrical outlet. (7) Place an 8 1/2 X 11 inch piece of paper lengthwise on the roof of vehicle directly above compass. The purpose of the paper is to protect the roof panel from scratches and define the area to be demagnetized. (8) Plug in the demagnetizing tool, keeping it at least two feet away from the compass unit. (9) Slowly approach the center of the roof panel at the windshield with the demagnetizing tool plugged in. (10) Contact the roof panel with the tip of the tool. Using slow sweeping motions of 1/2 inch between sweeps. Move the tool approximately four inches either side of the center line and at least 11 inches back from the windshield. (11) With the demagnetizing tool still energized, slowly back away from the roof panel until the tip is at least two feet from the roof before unplugging the tool. (12) Recalibrate compass, refer to the compass calibration procedure in this section.
OVERHEAD CONSOLE
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(2) Erase the factory test codes by pressing the two outside buttons. Release the buttons when the red light begins to flash (about 20 seconds). (3) Choose one of the three buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and push the buttons on both transmitters. The red light on the universal transmitter will begin to flash slowly. (4) When the red light on the universal transmitter begins to flash rapidly (this may take as long as 60 seconds), release both buttons. Your universal transmitter is now trained. To train the other buttons, repeat Step 3 and Step 4. Be sure to keep your hand-held transmitter in case you need to retrain the universal transmitter.
UNIVERSAL TRANSMITTER
TRAINING (1) Turn off the engine.
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OVERHEAD CONSOLE
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OVERHEAD CONSOLE
Fig. 6 Compass Mini-Trip Computer
(4) Remove CMTC module from console.
REMOVAL (1) Open the transmitter bin door (Fig. 9). (2) Remove screw holding the overhead console to the headliner. With the screw removed the console is retained by one engagement tab located inside the eyeglass storage bin. (3) Open the eyeglass bin door. (4) Press the retaining tab which is located directly above the door latch. (5) Lower rear of console away from headliner. (6) Pull console rearward to disengage clips holding front of console to roof armature and lower console. (7) Disconnect wire connectors from back of CMTC and reading lamps. Ensure the connectors lock tabs are fully depressed before disconnecting. (8) Remove overhead console. INSTALLATION For installation, reverse the above procedures.
READING/COURTESY LAMP
Removal (1) Using a trim stick, lightly pry outward the forward end of reading lamp lens (Fig. 10). (2) Rotate reading/courtesy lamp socket one quarter turn counterclockwise. (3) Pull socket out of lamp (Fig. 11). (4) Pull lamp from socket.
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REMOVAL AND INSTALLATION (Continued)
OVERHEAD CONSOLE
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UNIVERSAL TRANSMITTER
REMOVAL The Universal Transmitter is serviced with the transmitter bin door, in the overhead console.
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OVERHEAD CONSOLE
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INSTALLATION For installation, reverse the above procedures. The Universal Transmitter will need to be retrained. Refer to SERVICE PROCEDURES in this section.
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OVERHEAD CONSOLE
8V - 9
Degausser 6029
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WIRING DIAGRAMS
8W - 1
WIRING DIAGRAMS
CONTENTS
page page
AIR CONDITIONING-HEATER . . . . . . . . . . AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . BODY CONTROL MODULE . . . . . . . . . . . . CHARGING SYSTEM . . . . . . . . . . . . . . . . . COMPONENT INDEX . . . . . . . . . . . . . . . . . CONNECTOR/GROUND LOCATIONS . . . . . CONNECTOR PIN-OUTS . . . . . . . . . . . . . . FRONT LIGHTING . . . . . . . . . . . . . . . . . . . FUEL/IGNITION SYSTEM . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . GROUND DISTRIBUTION . . . . . . . . . . . . . HORN/CIGAR LIGHTER/POWER OUTLET . INSTRUMENT CLUSTER . . . . . . . . . . . . . . INTERIOR LIGHTING . . . . . . . . . . . . . . . . . JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . MESSAGE CENTER . . . . . . . . . . . . . . . . . .
8W-42-1 8W-43-1 8W-35-1 8W-47-1 8W-45-1 8W-20-1 8W-02-1 8W-90-1 8W-80-1 8W-50-1 8W-30-1 8W-01-1 8W-15-1 8W-41-1 8W-40-1 8W-44-1 8W-12-1 8W-46-1
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . POWER DISTRIBUTION . . . . . . . . . . . . . . POWER DOOR LOCKS . . . . . . . . . . . . . . . POWER MIRRORS . . . . . . . . . . . . . . . . . . POWER SEAT . . . . . . . . . . . . . . . . . . . . . . POWER WINDOWS . . . . . . . . . . . . . . . . . . REAR LIGHTING . . . . . . . . . . . . . . . . . . . . SPLICE INFORMATION . . . . . . . . . . . . . . . SPLICE LOCATIONS . . . . . . . . . . . . . . . . . STARTING SYSTEM . . . . . . . . . . . . . . . . . TRAILER TOW . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION CONTROL SYSTEM . . . . TURN SIGNALS . . . . . . . . . . . . . . . . . . . . . VEHICLE SPEED CONTROL . . . . . . . . . . . VEHICLE THEFT SECURITY SYSTEM . . . . WINDOW DEFOGGERS . . . . . . . . . . . . . . . WIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . .
8W-49-1 8W-10-1 8W-61-1 8W-62-1 8W-63-1 8W-60-1 8W-51-1 8W-70-1 8W-95-1 8W-21-1 8W-54-1 8W-31-1 8W-52-1 8W-33-1 8W-39-1 8W-48-1 8W-53-1
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.... 9 Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only.
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CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 1).
CIRCUIT FUNCTIONS
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT A B C D E F G H I FUNCTION BATTERY FEED BRAKE CONTROLS CLIMATE CONTROLS DIAGNOSTIC CIRCUITS DIMMING ILLUMINATION CIRCUITS FUSED CIRCUITS MONITORING CIRCUITS (GAUGES) OPEN NOT USED OPEN POWERTRAIN CONTROL MODULE EXTERIOR LIGHTING INTERIOR LIGHTING NOT USED NOT USED POWER OPTION (BATTERY FEED) POWER OPTIONS (IGNITION FEED) PASSIVE RESTRAINT SUSPENSION/STEERING TRANSMISSION/TRANSAXLE/ TRANSFER CASE OPEN SPEED CONTROL, WIPER/WASHER OPEN AUDIO SYSTEMS OPEN GROUNDS
J K L M N O P Q R S T U V W X Y Z
COLOR CODE BL BK BR DB DG GY LB LG OR PK RD TN VT WT YL *
COLOR BLUE BLACK BROWN DARK BLUE DARK GREEN GRAY LIGHT BLUE LIGHT GREEN ORANGE PINK RED TAN VIOLET WHITE YELLOW WITH TRACER
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SECTION IDENTIFICATION
The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring.
GROUP 8W-01 thru 8W-09 8W-10 thru 8W-19 8W-20 thru 8W-29 8W-30 thru 8W-39 8W-40 thru 8W-49
TOPIC General Information and Diagram Overview Main Sources of Power and Vehicle Grounding Starting and Charging Powertrain/Drivetrain Systems Body Electrical items and A/C Exterior Lighting, Wipers, and Trailer Tow Power Accessories Splice Information Connector Pin Outs Connector Locations (including grounds) Splice Locations
SYMBOLS
International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world.
8W-50 thru 8W-59 8W-60 thru 8W-69 8W-70 8W-80 8W-90 8W-95
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TERMINOLOGY
This a list of terms with there definitions used in the wiring diagrams. Built-Up-Export . . . . . . . . .Vehicles Built For Sale In Markets Other Than North America Except-Built-Up-Export . . . . .Vehicles Built For Sale In North America LHD . . . . . . . . . . . . . . . . . .Left Hand Drive Vehicles RHD . . . . . . . . . . . . . . . . .Right Hand Drive Vehicles ATX . . . .Automatic Transmission-Front Wheel Drive MTX. . . . . .Manual Transmission-Front Wheel Drive AT . . . . . .Automatic Transmission-Rear Wheel Drive MT . . . . . . .Manual Transmission-Rear Wheel Drive SOHC. . . . . . . . . . . . .Single Over Head Cam Engine DOHC . . . . . . . . . . . . .Dual Over Head Cam Engine
CONNECTOR INFORMATION
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair.
SPLICE LOCATIONS
Splice Location charts in Section 8W-70 show the entire splice, and provide references to other sections the splice serves. Section 8W-95 contains illustrations that show the general location of the splices in each harness. The illustrations show the splice by number, and provide a written location.
IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. Connectors located on the instrument panel harness are C200 series numbers. Connectors located on the body harness are C300 series numbers. Jumper harness connectors are C400 series numbers. Grounds and ground connectors are identified with a G and follow the same series numbering as the in-line connector. Component connectors are identified by the component name instead of a number (Fig. 2). Multiple connectors on a component use a C1, C2, etc. identifier (Fig. 3).
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TAKE OUTS
The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component.
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TROUBLESHOOTING TESTS
Before beginning any tests on a vehicles electrical system use the Wiring Diagrams and study the circuit. Also refer to the Troubleshooting Wiring Problems in this section.
TESTING FOR VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 7). (2) Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure.
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TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS (1) Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. (2) Replace the blown fuse. (3) Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. (4) Start connecting the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. TESTING FOR A VOLTAGE DROP (1) Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). (2) Connect the other lead of the voltmeter to the other side of the switch or component. (3) Operate the item. (4) The voltmeter will show the difference in voltage between the two points.
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8W - 01 - 11
CONNECTOR REPLACEMENT
(1) Disconnect battery. (2) Disconnect the connector that is to be repaired from its mating half/component
8W - 01 - 12
NS/GS
NS/GS
8W - 01 - 13
TERMINAL REPLACEMENT
(1) Disconnect battery. (2) Disconnect the connector being repaired from its mating half. Remove connector locking wedge, if required (Fig. 19). (3) Remove connector locking wedge, if required (Fig. 19). (4) Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Fig. 20) (Fig. 21). (5) Cut the wire 6 inches from the back of the connector. (6) Remove 1 inch of insulation from the wire on the harness side.
8W - 01 - 14
NS/GS
DIODE REPLACEMENT
(1) Disconnect the battery. (2) Locate the diode in the harness, and remove the protective covering. (3) Remove the diode from the harness, pay attention to the current flow direction (Fig. 22).
NS/GS
8W - 02 COMPONENT INDEX
8W - 02 - 1
8W - 02 - 2
8W - 02 COMPONENT INDEX
NS/GS
Component Page Fuel Tank Module . . . . . . . . . . . . . . . . . . .8W-30, 45 Fuel Temperature Sensor . . . . . . . . . . . . . . . . .8W-30 Fuel Timing Solenoid . . . . . . . . . . . . . . . . . . . .8W-30 Fuses (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12 Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10 Fusible Link . . . . . . . . . . . . . . . . . . . . .8W-20, 21, 63 Fusible Link A0 . . . . . . . . . . . . . . . . . . . . . . . .8W-30 Fusible Link A11 . . . . . . . . . . . . . . . . . . . . . . .8W-10 Fusible Link A54 . . . . . . . . . . . . . . . . . . . . . . .8W-10 Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20 Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-44 Glow Plug Lamp . . . . . . . . . . . . . . . . . . . . .8W-30, 46 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30 Glow Plug Relay. . . . . . . . . . . . . . . . . . . . . . . .8W-30 Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50 Headlamp Dimmer Switch . . . . . . . . . .8W-10, 46, 50 Headlamp Leveling Motors . . . . . . . . . . . . . . .8W-50 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . .8W-50 Headlamp Washer . . . . . . . . . . . . . . . . . . . . . .8W-53 High Beam Indicator . . . . . . . . . . . . . . . . . . . .8W-46 High Beam Relay . . . . . . . . . . . . . . . . . . . .8W-10, 50 Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50 Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41 Hood Ajar Switch . . . . . . . . . . . . . . . . . . . .8W-39, 44 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . .8W-39, 41 Horn Switch . . . . . . . . . . . . . . . . . . . . .8W-10, 39, 41 HVAC Control . . . . . . . . . . . . . . . . . . . . . . . . .8W-42 Idle Air Control Motor . . . . . . . . . . . . . . . . . . .8W-30 Ignition Coil Pack. . . . . . . . . . . . . . . . . . . . . . .8W-30 Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . .8W-10 Instrument Cluster . . . . . . . . . . . . . . . . . . . . .8W-40 Intake Air Temperature Sensor . . . . . . . . . . . .8W-30 Intake Air Temperature/Manifold Absolute Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30 Interior Lamps On Switch . . . . . . . . . . . . . . . .8W-44 Junction Block . . . . . . . . . . . . . . . . . . . . . . . . .8W-12 Key-In Halo Lamp . . . . . . . . . . . . . . . . . . . . . .8W-44 Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30 Lamp Assemblies . . . . . . . . . . . . . . . . . . . . . . .8W-51 License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51 Liftgate Ajar Indicator Lamp . . . . . . . . . . . . . .8W-40 Liftgate Ajar Switch . . . . . . . . . . . . . . .8W-39, 40, 44 Liftgate Arm/Disarm Switch . . . . . . . . . . . .8W-39, 61 Liftgate Flood Lamps . . . . . . . . . . . . . . . . . . . .8W-44 Liftgate Lock Motor . . . . . . . . . . . . . . . . . . . . .8W-61 Low Beam Relay. . . . . . . . . . . . . . . . . . . . .8W-10, 50 Low Coolant Level Switch . . . . . . . . . . . . . . . .8W-45 Low Fuel Warning Indicator Lamp. . . . . . . . . .8W-40 Low Oil Pressure Lamp . . . . . . . . . . . . . . . . . .8W-46 Low Washer Fluid Level Indicator Lamp . . . . .8W-40 Low Washer Fluid Switch. . . . . . . . . . . . . . . . .8W-53 Low/Reverse Pressure Switch. . . . . . . . . . . . . .8W-31 Low/Reverse Solenoid . . . . . . . . . . . . . . . . . . . .8W-31
Component Page Manifold Absolute Pressure Sensor . . . . . . . . .8W-30 Memory Power Seat Switch . . . . . . . . . . . . . . .8W-63 Seat Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63 Memory Seat/Mirror Module . . . . . . . . . . .8W-62, 63 Memory Set Switch . . . . . . . . . . . . . . . . . .8W-62, 63 Message Center . . . . . . . . . . . . . . . . . . . . . . . .8W-46 Mid Reading Lamps . . . . . . . . . . . . . . . . . . . . .8W-44 Mode Door Actuator . . . . . . . . . . . . . . . . . . . . .8W-42 Name Brand Speaker Relay . . . . . . . . . . . . . . .8W-47 Needle Movement Sensor . . . . . . . . . . . . . . . . .8W-30 Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40 Output Shaft Speed Sensor . . . . . . . . . . . . . . .8W-31 Overdrive Pressure Switch . . . . . . . . . . . . . . . .8W-31 Overdrive Solenoid . . . . . . . . . . . . . . . . . . . . . .8W-31 Overhead Console. . . . . . . . . . . . . . . . . . . . . . .8W-49 Park Brake Switch . . . . . . . . . . . . . . . . . . .8W-46, 50 Park Lamp Relay. . . . . . . . .8W-10, 12, 44, 50, 51, 54 Park/Turn Signal Lamps . . . . . . . . . . . . . . . . .8W-50 Airbag Squibs. . . . . . . . . . . . . . . . . . . . . . . . . .8W-43 Power Distribution Center . . . . . . . . . . . . . . . .8W-10 Power Folding Mirror Switch . . . . . . . . . . . . . .8W-62 Power Mirror Fold Relay . . . . . . . . . . . . . . . . .8W-62 Power Mirror Switch . . . . . . . . . . . . . . . . . . . .8W-62 Power Mirror Unfold Relay . . . . . . . . . . . . . . .8W-62 Power Seat Circuit Breaker . . . . . . . . . . . .8W-62, 63 Powertrain Control Module . . . . . . . . . . . . . . .8W-30 PTCs (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12 Radiator Fan Disconnect . . . . . . . . . . . . . . . . .8W-42 Radiator Fan Relays. . . . . . . . . . . . . . . . . . . . .8W-42 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47 Radio Choke . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47 Reading Lamps . . . . . . . . . . . . . . . . . . . . . . . .8W-44 Rear A/C Heater Unit. . . . . . . . . . . . . . . . . . . .8W-42 Rear Blower Control Switches . . . . . . . . . . . . .8W-42 Rear Cigar Lighter/Power Outlet . . . . . . . . . . .8W-41 Rear Defogger On Indicator . . . . . . . . . . . . . . .8W-42 Rear Dome Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-44 Rear Fog Lamp. . . . . . . . . . . . . . . . . . . . . . . . .8W-51 Rear Fog Lamp Indicator . . . . . . . . . . . . . . . . .8W-51 Rear Washer Motor . . . . . . . . . . . . . . . . . . . . .8W-53 Rear Washer Switch . . . . . . . . . . . . . . . . . .8W-42, 53 Rear Window Defogger . . . . . . . . . . . . . . . . . . .8W-48 Rear Window Defogger Relay . . . . . . . . . . . . . .8W-48 Rear Window Defogger Switch . . . . . . . . . .8W-42, 48 Rear Wiper Delay On Indicator . . . . . . . . .8W-42, 53 Rear Wiper Delay Switch . . . . . . . . . . . . . .8W-42, 53 Rear Wiper Motor. . . . . . . . . . . . . . . . . . . . . . .8W-53 Rear Wiper On Indicator . . . . . . . . . . . . . .8W-42, 53 Rear Wiper On Switch . . . . . . . . . . . . . . . .8W-42, 53 Recirculate Mode Indicator. . . . . . . . . . . . . . . .8W-42 Recirculate Mode Switch . . . . . . . . . . . . . . . . .8W-42 Recirculation Door Actuator . . . . . . . . . . . . . . .8W-42 Remote Keyless Entry Module . . . . . . . . . . . . .8W-61 Repeater Lamps . . . . . . . . . . . . . . . . . . . . .8W-51, 52
NS/GS
8W - 02 COMPONENT INDEX
8W - 02 - 3
Component Page Seat Belt Indicator Lamp . . . . . . . . . . . . . . . . .8W-40 Seat Belt Switch. . . . . . . . . . . . . . . . . . . . . . . .8W-40 Sentry Key Immobilizer Module . . . . . . . . . . . .8W-39 Service Engine Soon Lamp . . . . . . . . . . . . .8W-30, 46 Sliding Door Contacts. . . . . . . . . . . . . . . . . . . .8W-61 Sliding Door Lock Motors . . . . . . . . . . . . . . . . .8W-61 Speed Control Switches . . . . . . . . . . . . . . .8W-30, 33 Speedometer. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40 Stop Lamp Switch . . . . . . . . . . . . . . . . . . .8W-33, 51 Stop/Turn Signal Relays . . . . . . . . . . . . . . . . . .8W-54 Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40 Tail/Stop Lamp. . . . . . . . . . . . . . . . . . . . . . . . .8W-51 Tail/Turn Signal Lamp . . . . . . . . . . . . . . . .8W-51, 52 Throttle Position Sensor. . . . . . . . . . . . . . . . . .8W-30 Traction Control Switch . . . . . . . . . . . . . . . . . .8W-35 Trailer Tow Connector . . . . . . . . . . . . . . . . . . .8W-54 Transmission Control Module. . . . . . . . . . . . . .8W-31 Transmission Control Relay . . . . . . . . . . . .8W-10, 31 Transmission Control Solenoids . . . . . . . . . . . .8W-31 Transmission Range Sensor . . . . . . . . . . . . . . .8W-31 Trip Odometer . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Component Page Turbine Speed Sensor. . . . . . . . . . . . . . . . . . . .8W-31 Turbo Boost Pressure Sensor . . . . . . . . . . . . . .8W-30 Turn Indicators. . . . . . . . . . . . . . . . . . . . . .8W-46, 52 Turn Signal/Hazard Switch . . . . . . . . . . . .8W-46, 52 Underdrive Solenoid. . . . . . . . . . . . . . . . . . . . .8W-31 Universal Garage Door Opener . . . . . . . . . . . .8W-49 Vacuum Solenoid . . . . . . . . . . . . . . . . . . . . . . .8W-33 Vehicle Speed Control Servo. . . . . . . . . . . . . . .8W-33 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . .8W-30 Vent Motors . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60 Vent Solenoids . . . . . . . . . . . . . . . . . . . . . . . . .8W-33 Visor/Vanity Mirror Lamps. . . . . . . . . . . . . . . .8W-44 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . .8W-20 Volts Indicator Lamp . . . . . . . . . . . . . . . . . . . .8W-40 VTSS Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-39, 46 Washer Module. . . . . . . . . . . . . . . . . . . . . . . . .8W-53 Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . .8W-35 Wiper High/Low Relay . . . . . . . . . . . . . . . . . . .8W-53 Wiper Module . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53 Wiper On Relay . . . . . . . . . . . . . . . . . . . . . . . .8W-53
NS/GS
8W - 10 POWER DISTRIBUTION
8W - 10 - 1
8W - 10 - 2
NS/GS
SPARE
86
30
30
1
85
87A 87
85
86
87A 87
HORN RELAY
86
30
30
3
85
87A 87
85
86
87A 87
30
30
5
85
86
87A 87
85
86
87A 87
SPARE
86
30
30
7
85
87A 87
85
86
87A 87
FRONT BLOWER MOTOR RELAY ENGINE STARTER MOTOR RELAY PARK LAMP RELAY
30
30
9
85
86
87A 87
85
86
87A 87
10
30
19
85
11
86
87A 87
20
12
21
30
13
85
86
TRANSMISSION CONTROL RELAY (GAS) FUEL PUMP RELAY (GAS) FUEL HEATER RELAY AUTOMATIC SHUT (DIESEL) DOWN RELAY (GAS) DIESEL POWER RELAY
87A 87
22
14
86 87A 85 87 30
23
15
24
16
86 87A 85 87 30
25
17
26
18
86 87A 85 87 30
27
28
IOD
J988W-1
GS001002
NS/GS
8W - 10 - 3
AMPS
10A 10A 10A 10A 20A 15A 20A 20A 20A 15A 25A 20A 20A 20A 20A 15A 30A 40A 40A 40A 40A 40A 40A 40A 40A 10A
FUSED CIRCUIT
F23 18DB/YL F23 20DB/YL F14 18LG/YL F14 20LG/YL SPARE L33 20RD L34 20RD/OR L34 20RD/OR L43 18VT
FEED CIRCUIT
A22 12BK/OR F87 18WT/BK A0 6RD
INTERNAL
INTERNAL L44 20VT/RD INTERNAL INTERNAL L9 18BK/WT INTERNAL A20 12RD/DB F32 18PK/DB SPARE A5 18RD/DB INTERNAL A14 18RD/WT* INTERNAL INTERNAL F41 20PK/VT INTERNAL A17 12RD/BK INTERNAL INTERNAL A1 12RD INTERNAL A16 12GY A10 12RD/DG A2 12PK/BK A4 12BK/RD M1 20PK A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD
8W - 10 - 4
NS/GS
CIRCUIT
INTERNAL C13 18DB/OR* C13 20DB/OR** F87 18WT/BK* A142 18DG/OR** C3 18DB/BK FUSED B (+)
FUNCTION
A/C COMPRESSOR CLUTCH RELAY CONTROL A/C COMPRESSOR CLUTCH RELAY CONTROL FUSED IGNITION (ST-RUN) FUSED IGNITION (ST-RUN) A/C COMPRESSOR CLUTCH RELAY OUTPUT -
CIRCUIT
INTERNAL K51 18DB/YL A0 6RD A142 18DG/OR FUSED B (+)
FUNCTION
CIRCUIT
INTERNAL Z1 18BK F1 20DB F30 16RD FUSED B (+) GROUND
FUNCTION
CIRCUIT
INTERNAL K51 20DB/YL A0 6RD A142 18DG/OR FUSED B (+)
FUNCTION
NS/GS
8W - 10 - 5
CIRCUIT
INTERNAL K90 18TN F45 18YL/RD T141 20YL/RD T40 12BR FUSED B (+)
FUNCTION
ENGINE STARTER MOTOR RELAY CONTROL FUSED IGNITION (ST) FUSED IGNITION (ST) ENGINE STARTER MOTOR RELAY OUTPUT -
CIRCUIT
INTERNAL Z1 18BK F20 20WT C71 12DB FUSED B (+) GROUND
FUNCTION
CIRCUIT
INTERNAL Z1 20BK INTERNAL A141 16DG/WT FUSED B (+) GROUND
FUNCTION
CIRCUIT
INTERNAL K31 18BR F87 18 WT/BK A141 16DG/WT FUSED B (+)
FUNCTION
FUEL PUMP RELAY CONTROL FUSED IGNITION (ST-RUN) FUEL PUMP RELAY OUTPUT EATX MTX
GS001005
J988W-1
8W - 10 - 6
NS/GS
CIRCUIT
A0 6RD L324 20WT/LG A0 6RD INTERNAL B (+)
FUNCTION
CIRCUIT
INTERNAL X4 20GY/OR A0 6RD X2 18DG/RD FUSED B (+)
FUNCTION
CIRCUIT
A0 6RD L94 20OR/WT L193 20OR/WT * A0 6RD INTERNAL B (+)
FUNCTION
LOW BEAM RELAY CONTROL LOW BEAM RELAY CONTROL B (+) LOW BEAM RELAY OUTPUT -
CIRCUIT
INTERNAL L97 18PK/DB INTERNAL L7 12BK/YL FUSED B (+)
FUNCTION
PARK LAMP RELAY CONTROL FUSED B (+) PARK LAMP RELAY OUTPUT -
NS/GS
8W - 10 - 7
CIRCUIT
INTERNAL Z16 18BK T15 18LG T16 18RD FUSED B (+) GROUND 12 V SUPPLY
FUNCTION
CIRCUIT
INTERNAL V16 20WT INTERNAL V4 12RD/YL V3 12BR/WT
FUNCTION
WIPER ON RELAY OUTPUT WIPER HIGH/LOW RELAY CONTROL WIPER ON RELAY OUTPUT WIPER HIGH/LOW RELAY OUTPUT (HIGH) WIPER HIGH/LOW RELAY OUTPUT (LOW)
CIRCUIT
INTERNAL V14 18RD/VT INTERNAL INTERNAL Z1 18BK
FUNCTION
WIPER ON RELAY OUTPUT WIPER ON RELAY CONTROL FUSED B(+) FUSED B(+) GROUND
GS001007
J988W-1
8W - 10 - 8
NS/GS
FUSIBLE LINK
A54 10 RD
ES09 ES11
GAS DIESEL A11 6 BK/GY
A0 6 RD
A0 2 RD A54 10 RD 1
ES28
BATTERY
(8W-20-2) (8W-20-3)
A0 6 RD
FUSIBLE LINK
A11 10 DG
GENERATOR
(8W-20-2) (8W-20-3)
C1
C4
C4
6 A16 12 GY GAS
C7
3 A1 12 RD
C4
A4 12 BK/RD TO
A2 12 PK/BK TO
A10 12 RD/DG TO
DIESEL TO
JUNCTION BLOCK
JUNCTION BLOCK
TO
TO
IGNITION SWITCH
86
87
86
C7
A17 12 RD/BK TO
J988W-1
GS001008
NS/GS
8W - 10 - 9
POWER DISTRIBUTION CENTER
5 M1 20 PK
C3
M1 20 PK
C2
F41 20 PK/VT
TO
TO
TO
JUNCTION BLOCK
JUNCTION BLOCK
C6
10
C8
A14 18 RD/WT
A5 18 RD/DB
TO
TO
8W - 10 - 10
FROM FUSE 15 (PDC) (8W-10-9) B
NS/GS
POWER DISTRIBUTION CENTER
C3
C3
C5
F32 18 PK/DB
A20 12 RD/DB
L9 18 BK/WT
TO
TO
TO
JUNCTION BLOCK
86
C3
BUILT-UP -EXPORT
C5
BUILT-UP -EXPORT
C5
CHRYSLER
C5
CHRYSLER
DODGE/ PLYMOUTH
L34 20 RD/OR
L33 20 RD
L33 20 RD
L44 20 VT/RD
L44 20 VT/RD
TO TO TO
L43 18 VT
TO TO
BS16
TO
RIGHT HEADLAMP
J988W-1
BS15
RIGHT HEADLAMP
TO
TO
TO
LEFT HEADLAMP
MESSAGE CENTER
GS001010
NS/GS
BATT A0
(8W-10-8)
8W - 10 - 11
FUSE 28 10A
C3
M1 M1 20 20 PK PK 16
13
C1
JUNCTION BLOCK
9 BODY CONTROL MODULE (8W-45-2) (8W-12-2)
C4
M1 20 PK M1 20 PK *8 12 2 M1 20 PK
13
C4
M1 20 PK
17
C4
M1 20 PK M1 20 PK 16
INSTRUMENT CLUSTER
(8W-40-2)
C3 IGNITION SWITCH
1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-14)
MESSAGE CENTER
(8W-46-2)
1 2 0 3
C1 RADIO
(8W-47-2)
2 3
C3
A81 20 DG/RD M1 22 PK 15
C4
D1
JUNCTION BLOCK
(8W-12-2)
D3 7
P50
NOT USED
* RHD
GS001011
J988W-1
8W - 10 - 12
BATT A0
(8W-10-8)
NS/GS
C1
C1 JUNCTION BLOCK
(8W-12-2)
C1
20
C4
C15 12 BK/WT 12
B17 LJ01
C16 20 LB/YL 4
C15 12 BK/WT 1
J03A L16
C16 20 LB/YL
C15 12 BK/WT 4
J988W-1
GS001012
NS/GS
BATT A0
(8W-10-8)
8W - 10 - 13
C4
A2 12 PK/BK 4
C1
WASHER MODULE (BUILT-UP -EXPORT (8W-53-5)
JUNCTION BLOCK
(8W-12-2)
PTC 3 9A (8W-12-14) (8W-12-15) 86 87 87A DRIVER DOOR UNLOCK RELAY (RKE) (8W-61-7) (8W-61-8) 4 86 87 87A DOOR UNLOCK RELAY (8W-61-3) (8W-61-4) (8W-61-7) (8W-61-8)
86
87
85
30
85
30
85
30
33
C1
HEATED SEATS
C4
OTHER
A2 12 PK/BK
B09 HS5D
A2 12 PK/BK
B09 S02
A2 12 PK/BK
C TO
A3 12 PK/BK
HS6D S02
IGNITION SWITCH
(8W-10-14)
8W - 10 - 14
NS/GS
JUNCTION BLOCK
(8W-12-2)
BATT A1
(8W-10-16) FROM
JUNCTION BLOCK
(8W-10-13) C
C3
BATT M1
(8W-10-11) A2 12 PK/BK 3 A1 12 RD 7 M1 20 PK G9 20 GY/BK 4 G26 20 LB 1
C2
C1
C1
C3
C1
C2
KEY-IN SWITCH
IGNITION SWITCH
1 START 2 RUN 0 OFF 3 LOCK 4 ACC
1 2 0 3
1 2 0 3
1 2 0 3
1 2 0 3
1 2 0 3
C1
10 A41 12 YL
C1
C1
9 A21 12 DB
C1
C3
1 Z1 20 BK 14
C1
2 Z1 20 BK
C2 INSTRUMENT CLUSTER
(8W-40-4) 13 Z1 20 BK
A22 12 BK/OR
A31 12 BK/WT
A81 20 DG/RD
ST A41
(8W-10-16)
ST-RUN A21
(8W-10-16)
G200
(8W-15-4)
RUN-ACC A31
(8W-10-16) 28
C4 JUNCTION BLOCK
(8W-12-19)
ST-RUN-OFF A81
2
C3
(8W-10-16)
JUNCTION BLOCK
(8W-12-2) FUSE 11 20A (8W-12-11) FUSE 12 10A (8W-12-12) 31
2 Z1 14 BK 8
C2
G300 C2
(8W-15-6) A22 12 BK/OR 1
* RHD GS001014
NS/GS
8W - 10 - 15
BATT A0
(8W-10-8)
C4
C7
A16 12 GY
DIESEL
A16 12 GY
25
GS001015
J988W-1
8W - 10 - 16
NS/GS
ST T141
(8W-12-16) T141 20 YL/RD MTX 3
BATT A0
(8W-10-8)
30 FUSE 23 40A 87 3 A1 12 RD B4 4 A1 12 RD
C4
3 T40 12 BR
C7 E95 B107
K90 20 TN 3
C6
GAS K90 18 TN
C8
BATT M1
(8W-12-20) M1 20 PK
B23 P18
K90 18 TN
F45 18 YL/RD 8
31
C1
C3 IGNITION SWITCH
1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-14) 2
1 2 0 3
1 2 0 3
1 2 0 3
10 A41 12 YL 7
C1
C1
9 A21 12 DB 31
C1
C3
A31 12 BK/WT
A81 20 DG/RD
C4
31
C3
C4
15
C4
D1
JUNCTION BLOCK
(8W-12-2)
PTC 8 9A (8W-12-16)
PTC 1 9A (8W-12-13)
PTC 7 9A (8W-12-16)
PTC 9 9A (8W-12-16)
GS001016
NS/GS
8W - 10 - 17
BATT A0
(8W-10-8)
86
85
87
10
C3
C1
L97 18 PK/DB
L7 12 BK/YL
C2
C1 JUNCTION BLOCK
(8W-12-2) FUSE 3 15A (8W-12-8) FUSE 5 15A (8W-12-8)
GS001017
J988W-3
8W - 10 - 18
RUN A22
NS/GS
(8W-10-14)
JUNCTION BLOCK
(8W-12-2) FUSE 12 10A (8W-12-12)
C2
F20 20 WT
C2
BATT A0
(8W-10-8)
86
85
87
C4
C1
Z1 18 BK
B23 P18
10
G300
(8W-15-7)
J988W-3
NS/GS
8W - 10 - 19
BATT A0
(8W-10-8)
FUSE 19 30A
86
87
85
30
86
85
87
87A
C7
C5
C5
C5
C5
C4
A17 12 RD/BK
V14 18 RD/VT
V16 20 WT
V4 12 RD/YL
V3 12 BR/WT
Z1 18 BK
B1 1
B23 P18
V16 20 WT 10
G300
(8W-15-7)
73
WIPER MODULE
(8W-53-2)
GS001019
J988W-3
8W - 10 - 20
BATT A0
(8W-10-8)
NS/GS
C2
F41 20 PK/VT 15
C2 JUNCTION BLOCK
D TO COURTESY LAMP RELAY (8W-10-21) (8W-12-2)
19
C2
16
C3
20
C3
F41 20 PK/VT 1
F41 20 PK/VT 2
F41 20 PK/VT 9
F41 20 PK/VT 1
B75 C20
OVERHEAD CONSOLE
OTHERS
4 F41 20 PK/VT
CS02
F41 20 PK/VT F41 20 PK/VT F41 20 PK/VT F41 20 PK/VT F41 20 PK/VT F41 20 PK/VT F41 20 PK/VT
F41 20 PK/VT
J988W-3
GS001020
NS/GS
8W - 10 - 21
JUNCTION BLOCK
(8W-12-2)
85
87 D4
10
C3
34
C3
28
C3
22
C2
C2
29
C2
M11 20 PK/LB
29
C3
M112 22 BR/LG 3
M111 22 BR/WT 9
M113 20 LB/PK 11
M113 20 LB/PK
C1
C1
C1 HEADLAMP SWITCH
(8W-50-9) (8W-50-10)
M11 20 PK/LB 2
B17 LJ01
CS01
M113 20 LB/PK 1 M113 20 LB/PK
M11 20 PK/LB
B01 D02
6
M113 20 LB/PK 1
M113 20 LB/PK
B03 D01P
M11 20 PK/LB 1
J02A L15
1
M11 20 PK/LB 1
8W - 10 - 22
NS/GS
JUNCTION BLOCK
(8W-12-2)
86
87
86
87
85
30
85
30
11
C4
11
C3
P159 20 DG
P159 20 DG
P160 20 LB
P160 20 LB
C2
C2
J988W-3
GS001022
NS/GS
BATT A0
(8W-10-8)
8W - 10 - 23
86
85 8
87
C6
K51 18 DB/YL 67
5 C6 A142 18 DG/OR
ES12
A142 18 DG/OR 2 A142 18 DG/OR 2 A142 18 DG/OR A142 18 DG/OR A142 18 DG/OR A142 18 DG/OR
E43 B70
A142 18 DG/OR 2
GENERATOR
(8W-20-2)
A142 18 DG/OR 2
A142 18 DG/OR 2
A142 18 DG/OR 2
A142 18 DG/OR 2
E78
(8W-10-24)
J988W-3
8W - 10 - 24
FROM (8W-10-23) E FROM (8W-10-23) G
NS/GS
ES12
A142 18 DG/OR 1
A142 18 DG/OR
E78 F02
ES99 (2.0L)
A142 18 DG/OR A142 18 DG/OR A142 18 DG/OR A142 18 DG/OR
A142 18 DG/OR
FS01 (3.3L/3.8L)
A142 18 DG/OR
A142 18 DG/OR
A142 18 DG/OR
A142 18 DG/OR
A142 18 DG/OR
A142 18 DG/OR
J988W-3
GS001024
NS/GS
BATT A0
(8W-10-8)
8W - 10 - 25
86
85 8
87
C6
C6
K51 20 DB/YL 3 42
A142 18 DG/OR
ES06
1 A142 18 DG/OR A142 18 DG/OR 7
E96 B108
A142 18 DG/OR 1 A142 18 DG/OR A142 18 DG/OR A142 18 DG/OR
A142 18 DG/OR
BS33
A142 16 DG/OR 68 A142 16 DG/OR 23 A142 16 DG/OR 45
EGR SOLENOID
(8W-30-29) 9 10
GENERATOR
(8W-20-3)
ES29
1 86 A/C COMPRESSOR CLUTCH RELAY (8W-42-9) 85
18 DG/OR
GS001025
8W - 10 - 26
NS/GS
(8W-10-16)
JUNCTION BLOCK
(8W-12-2) PTC 1 9A (8W-12-13)
30
C1
F87 18 WT/BK
C2
BATT A0
(8W-10-8)
86
85
87
3 K31 18 BR
C6
C2
C6
A141 16 DG/WT 4 4
A14 18 RD/WT
74
C2
(8W-30-6) (8W-30-20)
46
J988W-3
GS001026
NS/GS
8W - 10 - 27
JUNCTION BLOCK
(8W-12-2) PTC 1 9A (8W-12-13)
30
C1
F87 18 WT/BK
F87 18 WT/BK 6
C2
BATT A0
(8W-10-8)
38
85 6
87
C6
3 Z1 20 BK
C6
C2
F87 18 WT/BK 1
A141 16 DG/WT 4
B33 E120
A141 18 DG/WT
BATTERY
(8W-20-3) A141 18 DG/WT
ES40
A141 18 DG/WT
Z0 2 BK
Z0 8 BK
Z0 10 BK
FUEL HEATER
(8W-30-29)
G103
GS001027
G100
ES01 (DIESEL)
(8W-15-3) J988W-3
8W - 10 - 28
NS/GS
FUSE 15 20A
86
85
87
C8
C8
Z16 18 BK
C8
10
C8
T15 18 LG
T16 18 RD
A5 18 RD/DB
ES11
(8W-15-2)
BATTERY
Z0 10 BK (8W-20-2)
ES01
T16 18 RD Z0 8 BK Z0 6 BK
T16 18 RD
T16 18 RD
G103
G100
15
16
17
56
NS/GS
ST-RUN A21
8W - 10 - 29
BATT A0
(8W-10-8)
JUNCTION BLOCK
(8W-12-2) PTC 1 9A (8W-12-13) 30 F87 18 WT/BK 30 FUSE 17 20A (8W-10-25)
87 5
C6 ES06
(8W-10-25)
38
ES07
(8W-12-13) GAS F87 18 BK/WT GAS 1
ES29
(8W-10-25) A142 DIESEL 18DG/OR
BATT A0
(8W-10-8)
C2
C6
C6
BATT A0
(8W-10-8)
(8W-12-13)
FUSE 13 20A
FUSE 12 25A
C3
C3
C6
C6
C5
F32 18 PK/DB
A20 12 RD/DB 9
C3 18 DB/BK 1
L9 18 BK/WT
C2
1
JUNCTION BLOCK
(8W-12-2)
28
GS001029
J988W-3
8W - 10 - 30
NS/GS
BATT A0
(8W-10-8)
86
85
87
C2
C2
X4 20 GY/OR 4
X2 18 DG/RD
C2 JUNCTION BLOCK
(8W-12-2) X2 18 DG/RD A
BS19
X2 18 DG/RD A
18 HORN RELAY CONTROL HORN RELAY CONTROL 20 BODY CONTROL MODULE (8W-45-3)
C2
X3 20 BK/RD
C2 CLOCKSPRING
X3 20 BK/RD
HORN SWITCH
J988W-3
GS001030
NS/GS
8W - 10 - 31
RUN-ACC A31
(8W-10-16)
JUNCTION BLOCK
(8W-12-2) PTC 7 9A (8W-12-16)
16 F1 20 DB
C2
C2
BATT A0
(8W-10-8)
86
85
87
C4
10 F30 16 RD
C2
Z1 18 BK
A22 22
B23 P34
F30 16 RD
F30 16 RD
10
G300
(8W-15-7)
GS001031
8W - 10 - 32
NS/GS
85
87
85
87
C3
DODGE/ PYLMOUTH
C3
B23
9 L93 22 PK
33
C3 JUNCTION BLOCK
13 (8W-12-2) COMBINATION FLASHER/ DRL MODULE (8W-50-2)
76
C1
G200
(8W-15-4)
J988W-3
GS001032
NS/GS
8W - 10 - 33
FUSE 6 20A
FUSE 7 15A
FUSE 4 10A
FUSE 5 10A
C5
C3
1 L33 20 RD
C5
C5
L34 20 RD/OR
L44 20 VT/RD CHRYSLER L43 18 VT DODGE/ PYLMOUTH L44 20 VT/RD CHRYSLER L44 20 VT/RD DODGE/ PYLMOUTH L33 20 RD
B18 18
B23 P18
L34 20 RD/OR 1
TO
TO
TO
TO
BS15
(8W-50-6)
RIGHT HEADLAMP
(8W-50-6) (8W-50-8)
LEFT HEADLAMP
(8W-50-6)
MESSAGE CENTER
(8W-46-4)
TO
TO
DODGE/ PYLMOUTH
CHRYSLER
L34 20 RD/OR
L34 20 RD/OR
TO
TO
RIGHT HEADLAMP
(8W-50-6) (8W-50-8) GS001033
8W - 10 - 34
NS/GS
FUSE 6 20A
FUSE 7 15A
FUSE 4 10A
FUSE 5 10A
8 L43 18 VT
C5
C3
1 L33 20 RD
C5
C5
L34 20 RD/OR
L44 20 VT/RD
L34 20 RD/OR
LEFT HEADLAMP
(8W-50-6)
B18 18
B23 P18
L34 20 RD/OR *6 1
BS16
L44 20 VT/RD L44 20 VT/RD
MESSAGE CENTER
(8W-46-4)
B3 3
B23 P18
L44 20 VT/RD
L44 20 VT/RD
L44 20 VT/RD 2 1
C1 HEADLAMP SWITCH
(8W-50-10)
RIGHT HEADLAMP
(8W-50-8)
J988W-3
* RHD
GS001034
NS/GS
8W - 10 - 35
ST-RUN A21
(8W-10-16)
RUN A22
(8W-10-14)
JUNCTION BLOCK
(8W-10-14) PTC 1 9A (8W-12-13) (8W-12-2)
30
C1
31
C2
F87 18 WT/BK
A22 12 BK/OR
C2
FUSE 2 10A
FUSE 1 10A
(8W-10-8)
C5
10
C5
B24 24
B23 P18
F23 18 DB/YL 2
C2
GS001035
J988W-3
NS/GS
8W - 12 JUNCTION BLOCK
8W - 12 - 1
8W - 12 - 2
NS/GS
1 8
2 9
3 10
4 11
5 12
6 13
7 14
1 8
2 9
3 10
4 11
5 12
6 13
7 14
C1
23 30
15 19
16 20
17 21
18 22
15 19
16 20
17 21
18 22
C2
29 36
24 31
25 32
26 33
27 34
28 35
29 36
23 30
24 31
25 32
26 33
27 34
28 35
1 8
2 9
3 10
4 11
5 12
6 13
7 14
1 8
2 9
3 10
4 11
5 12
6 13
7 14
C4
23 30
15 19
16 20
17 21
18 22
15 19
16 20
17 21
18 22
C3
29 36
24 31
25 32
26 33
27 34
28 35
29 36
23 30
24 31
25 32
26 33
27 34
28 35
10
PTCS
D3
1
85
87A
86
85
D4
2
30 2
30
D1
1
WASHER MODULE
P 56
D2
1
85 2
86
31
85
86
85
86 2
30
30
30
30
87A
87
30
87A
87
30
87A
87
30
85
85
85
10
11
12
FUSES
J988W-3
GS001202
NS/GS
8W - 12 - 3
AMPS
10A 10A 15A 15A 15A 20A 10A 10A 15A 10A 20A 10A
FUSED CIRCUIT
INTERNAL F11 20RD/WT L78 20DG/YL L78 20DG/YL F39 18PK/LG F39 18PK/LG INTERNAL INTERNAL C16 20LB/YL C16 20LB/YL INTERNAL V20 18RD F45 20YL/RD C40 12BR/WT INTERNAL
FEED CIRCUIT
L78 20DG/YL L78 20DG/YL A81 20DG/RD A21 12DB L7 12BK/YL L7 12BK/YL L7 12BK/YL A21 12DB INTERNAL INTERNAL INTERNAL A41 12YL A22 12BK/OR A22 12BK/OR
AMPS
9A 9A 9A 9A 9A -
FUSED CIRCUIT
INTERNAL INTERNAL INTERNAL INTERNAL F21 12TN -
FEED CIRCUIT
INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL -
8W - 12 - 4
NS/GS
CIRCUIT
L9 18BK/WT L61 18LG L60 18TN INTERNAL INTERNAL INTERNAL L305 22LB/WT L302 22LB/YL L91 20DB/PK L91 22DB/PK INTERNAL INTERNAL INTERNAL FUSED B (+)
FUNCTION
LEFT FRONT TURN SIGNAL RIGHT FRONT TURN SIGNAL LEFT REAR TURN SIGNAL RIGHT REAR TURN SIGNAL FUSED IGNITION (RUN) LEFT TURN SIGNAL SENSE RIGHT TURN SIGNAL SENSE COMBINATION FLASHER SWITCHED GROUND RED BRAKE WARNING LAMP SENSE GROUND HIGH/LOW BEAM RELY CONTROL
CIRCUIT
INTERNAL M111 22BR/WT INTERNAL INTERNAL FUSED B (+)
FUNCTION
COURTESY LAMP RELAY CONTROL FUSED B (+) COURTESY LAMP RELAY OUTPUT -
CIRCUIT
INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL
FUNCTION
DOOR LOCK RELAY OUTPUT DOOR LOCK RELAY CONTROL FUSED B (+) FUSED B (+) GROUND
J988W-3
GS001204
NS/GS
8W - 12 - 5
CIRCUIT
INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL
FUNCTION
DOOR UNLOCK RELAY OUTPUT DOOR UNLOCK RELAY CONTROL FUSED B (+) FUSED B (+) GROUND
CIRCUIT
F131 20BK/PK INTERNAL INTERNAL INTERNAL INTERNAL
FUNCTION
LEFT FRONT DOOR UNLOCK RELAY OUTPUT LEFT FRONT DOOR UNLOCK RELAY CONTROL FUSED B (+) FUSED B (+) GROUND
CIRCUIT
INTERNAL L94 20OR/WT INTERNAL INTERNAL -
FUNCTION
FUSED LOW BEAM RELAY OUTPUT FOG LAMP RELAYCONTROL FUSED LOW BEAM RELAY OUTPUT FOG LAMP RELAY OUTPUT -
CIRCUIT
INTERNAL INTERNAL X60 20RD/DG X1 16DG/RD -
FUNCTION
FUSED IGNITION (RUN-ACC) GROUND NAME BRAND SPEAKER RELAY DRIVER NAME BRAND SPEAKER RELAY OUTPUT -
8W - 12 - 6
NS/GS
CIRCUIT
P160 20LB P160 20LB P171 20VT/WT INTERNAL INTERNAL INTERNAL
FUNCTION
POWER MIRROR FOLD OUTPUT POWER MIRROR FOLD OUTPUT FUSED B (+) FUSED B (+) GROUND
CIRCUIT
P159 20DG P159 20DG P174 20YL/RD INTERNAL INTERNAL INTERNAL
FUNCTION
POWER MIRROR UNFOLD OUTPUT POWER MIRROR UNFOLD OUTPUT FUSED B (+) FUSED B (+) GROUND
CIRCUIT
A4 12BK/RD C14 22WT/RD INTERNAL INTERNAL FUSED B (+)
FUNCTION
REAR WINDOW DEFOGGER RELAY CONTROL FUSED IGNITION (RUN) REAR WINDOW DEFOGGER RELAY OUTPUT -
J988W-3
GS001206
NS/GS
8W - 12 - 7
CIRCUIT
V53 18RD/YL INTERNAL INTERNAL INTERNAL INTERNAL
FUNCTION
WASHER MODULE OUTPUT WASHER MODULE CONTROL FUSED PARK LAMP RELAY OUTPUT FUSED B(+) FUSED IGNITION (RUN-ACC)
DIODES D1 CAVITY
1 2
CIRCUIT
INTERNAL INTERNAL
ORIENTATION
ANODE (+) CATHODE
CIRCUIT
-
ORIENTATION
ANODE (+) CATHODE
D3 CAVITY
1 2
CIRCUIT
INTERNAL INTERNAL
ORIENTATION
ANODE (+) CATHODE
D4 CAVITY
1 2 GS001207
CIRCUIT
INTERNAL INTERNAL
ORIENTATION
ANODE (+) CATHODE J988W-3
8W - 12 - 8
BATT A0
(8W-10-8)
NS/GS
86
F39 18 PK/LG
1 85 10 87 F39 18 PK/LG
C3
C1
L97 18 PK/DB 9
L7 12 BK/YL 2
C2
C1
C1 JUNCTION BLOCK
(8W-12-2)
FUSE 1 10A
FUSE 3 15A
16
C1
C1
L77 18 BR/YL B28 28
18
C1
L77 20 BR/LB TRAILER TOW 4 OTHERS
L77 20 BR/YL
L77 20 BR/LB
4 L78 18 BR 2 *1 2
B98 T08
B17 LJ01
L77 20 BR/LB
B99 T05
L77 20 BR/LB *3 4
L78 20 DG/YL *3 4
*1 2
J02A L15
L77 20 BR/LB 2
NS/GS
8W - 12 - 9
ST-RUN-OFF A81
D1
(8W-10-16)
ST-RUN A21
(8W-10-16)
JUNCTION BLOCK
(8W-12-2) D3
FUSE 2 10A
FUSE 6 20A
11
12
20
C1
10
C4
F11 20 RD/WT
14
C4
14
C1
C1
F11 20 RD/WT
F11 20 RD/WT
V23 18 BR/PK
V23 18 BR/PK 11
V23 18 BR/PK 8
P50
V23 18 BR/PK 1
B17 LJ01
NOT USED
C19 EC1
V23 18 BR/PK 3
B33 E36
11
V23 18 BR/PK 1
J03A L16
INSTRUMENT CLUSTER
(8W-40-2)
V23 18 BR/PK
F11 18 RD/WT
11
MESSAGE CENTER
(8W-46-2)
OVERHEAD CONSOLE
(8W-49-2)
GS001209
J988W-3
8W - 12 - 10
NS/GS
BATT A4
(8W-10-12)
JUNCTION BLOCK
30 REAR WINDOW DEFOGGER RELAY (8W-48-2) 87 (8W-12-2)
FUSE 7 10A
C1
20
C4
C16 20 LB/YL
C15 12 BK/WT 12
C16 20 LB/YL
B17 LJ01
C15 12 BK/WT
J03A L16
C15 12 BK/WT 4
J988W-3
GS001210
NS/GS
8W - 12 - 11
RUN-ACC A31
(8W-10-16)
RUN A22
(8W-10-14)
JUNCTION BLOCK
(8W-12-2) FUSE 8 10A FUSE 9 15A FUSE 11 20A
86
85 (8W-12-19)
87
13
C3
C2
Z1 14 BK
22
C1
X12 20 RD/WT 6
24
C3
15
C3
V20 18 RD
12
C2
X60 20 RD/DG
X1 16 DG/RD
X12 18 RD/WT
C40 12 BR/WT
P50
NOT USED 1
RADIO CHOKE
(8W-47-4) 8
G300
(8W-15-6)
C2
C1 RADIO
(8W-47-2) (8W-47-4)
GS001211
J988W-3
8W - 12 - 12
RUN A22
(8W-10-14)
NS/GS
JUNCTION BLOCK
(8W-12-2) FUSE 12 10A
32
C4
14
C2
F20 18 WT 23
18
C2
C2
C14 22 WT/RD
F20 20 WT
F20 20 WT
F20 20 WT
F20 20 WT
B09 HS5D
F20 20 WT
HS2
F20 20 WT D B F20 20 WT
5 F20 20 WT
B33 E120
B33 E36
5 F20 18 WT
B33 E36
5 86
BACK-UP SWITCH
(8W-51-5)
J988W-3
GS001212
NS/GS
8W - 12 - 13
ST-RUN A21
(8W-10-16)
JUNCTION BLOCK
(8W-12-2) PTC 1 9A
F87 18 WT/BK 38 30
3 F87 20 WT/BK
C1
19
C4
F87 18 WT/BK 6
86 FUEL HEATER RELAY (DIESEL) (8W-30-29) 85 85 A/C COMPRESSOR CLUTCH RELAY (8W-42-7) (8W-42-9) DIESEL 86
GAS
86
C6
C6
C6
BUILT-UP -EXPORT
C5
EXCEPT BUILTUP-EXPORT
F87 18 WT/BK
F87 18 BK/WT
A142 18 DG/OR
F87 18 WT/BK
F87 18 WT/BK 3
ES07 (GAS)
F87 18 WT/BK TO
F14 18 LG/YL
F14 20 LG/YL
ES29
(8W-10-25)
B23 23
B23 P18
C1
(8W-30-18) (8W-30-26) 2
F14 18 LG/YL
EGR SOLENOID
(8W-30-20)
8W - 12 - 14
BATT A2
(8W-10-13)
NS/GS
JUNCTION BLOCK
(8W-12-2) PTC 3 9A
(8W-10-13)
86
87
86
87
85
30
85
30
C1
19
C1
15
C1
F131 20 BK/PK
F136 20 VT/YL
F136 20 VT/YL
F136 20 VT/WT 10
F136 20 VT/WT
B17 LJ01
B02 D01D
B03 D01P
F136 20 VT/WT
J02A L15
F136 20 VT/WT
NS/GS
8W - 12 - 15
BATT A2
(8W-10-13)
JUNCTION BLOCK
(8W-12-2) PTC 3 9A
(8W-10-13) 86 87 87A DOOR LOCK RELAY (8W-61-3) (8W-61-4) (8W-61-7) (8W-61-8) P WASHER MODULE (BUILTUP-EXPORT) (8W-53-5)
30
32
C1
11
C1
26
C1
F133 20 BR
F133 20 BR
F133 20 BR/RD
F133 20 BR/YL
F133 20 BR/YL 15
12
B02 D01D
10
B03 D01P
B17 LJ01J01A
B75 C20
F133 20 BR/YL 1
F133 20 BR
F133 20 BR
F133 20 BR/RD
4 2
J02A L15
(8W-61-4) (8W-61-8)
GS001215
J988W-3
8W - 12 - 16
RUN-ACC A31
NS/GS
(8W-10-16)
(8W-10-16)
JUNCTION BLOCK
PTC 7 9A S WASHER MODULE (BUILTUP-EXPORT) (8W-53-5) (8W-12-2) PTC 9 9A PTC 8 9A FUSE 10 10A
C2
F1 20 DB F1 20 DB
C3
F1 20 DB
16
C2
F1 20 DB
34
C2
17
C2
13 12
C2 B03 D01P
10
C2
EATX F45 20 YL/RD 1
F21 16 TN
F55 12 TN/DG
F55 12 TN/DG
14 F21 16 TN
B02 D01D
1
F55 14 TN/DG
11
PASSENGER T141 POWER 20 WINDOW YL/RD SWITCH DRIVER POWER WINDOW SWITCH
(8W-60-3)
C2
(8W-60-2) 3
85 7
C8
F45 18 YL/RD 8
NS/GS
8W - 12 - 17
POWER DISTRIBUTION CENTER
(8W-10-10)
85 4
C2
X4 20 GY/OR
BATT L9
(8W-10-29)
C2 JUNCTION BLOCK
(8W-12-2)
10
EATX
MTX
26
C3
C3
22
C3
C2
C3
C2
C3
L305 22 LB/WT
TO 5
P50
NOT USED
TO
TO
TO
IGNITION SWITCH
(8W-10-14) TO
MESSAGE CENTER
(8W-46-3) J988W-3
GS001217
8W - 12 - 18
FROM
NS/GS
L93 22 PK 33
C3 JUNCTION BLOCK
(8W-12-2)
12
21
19
5 L60 18 TN
C2
11 L61 18 LG
C2
L63 18 DG/RD TRAILER TOW L63 18 DG/RD
28
C2
36
C2
14
C3
21
C3
L63 18 DG/RD
L62 18 BR/RD
L63 18 DG/RD
TO
TO
L62 18 BR/RD
L63 18 DG/RD
L62 18 BR/RD
TO
MESSAGE CENTER
(8W-46-5)
TO
TO
B99 T05
1
TO
L63 18 DG/RD
L63 18 DG/RD
B98 T08
L62 18 BR/RD
L62 18 BR/RD
TO
TO
TO
TO
TO
TO
J988W-3
NS/GS
8W - 12 - 19
MESSAGE CENTER
(8W-46-4) 3 *4
INSTRUMENT CLUSTER
(8W-40-4)
13
IGNITION SWITCH
(8W-10-14) 2 Z1 20 BK Z1 20 BK
C2
FROM
Z1 20 BK
22
C4
30 DOOR LOCK RELAY (8W-61-3) (8W-61-4) (8W-61-7) (8W-61-8) 30 DOOR UNLOCK RELAY (8W-61-3) (8W-61-4) (8W-61-7) (8W-61-8)
28
C4
35
C4
36
C4 JUNCTION BLOCK
(8W-12-2)
30 DRIVER DOOR UNLOCK RELAY (RKE) (8W-61-7) (8W-61-8) 86 NAME BRAND SPEAKER RELAY (8W-47-4) 85 3 4 COMBINATION FLASHER/ DRL MODULE (8W-50-13) 11
87
87A
87
87A
87
87A
C2
21
C4
29
C4
10
C2
14
C2
Z1 14 BK
Z1 18 BK
Z1 20 BK
Z2 20 BK/LG
Z2 20 BK/LG
C2
C1 HEADLAMP SWITCH
(8W-50-9) (8W-50-10) * RHD
G300
(8W-15-6)
GS001219
J988W-3
8W - 12 - 20
NS/GS
BATT M1
(8W-10-11)
JUNCTION BLOCK
9 BODY CONTROL MODULE (8W-45-2) (8W-12-2)
C4
13
C4
17
C4
M1 20 PK
M1 20 PK
M1 20 PK
M1 20 PK
M1 20 PK
M1 20 PK
C3 IGNITION SWITCH
1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-14)
16
INSTRUMENT CLUSTER
(8W-40-2) *8 12 1 2 0 3 4
MESSAGE CENTER
(8W-46-2) 2
C1 RADIO
(8W-47-2)
C3
M1 22 PK 7
A81 20 DG/RD
P50
NOT USED 15
C4
D1
JUNCTION BLOCK
(8W-12-2)
* RHD
J988W-3
GS001220
NS/GS
8W - 12 - 21
BATT F41
(8W-10-20)
JUNCTION BLOCK
(8W-12-2)
19
C2
16
C3
20
C3
F41 20 PK/VT
F41 20 PK/VT
F41 20 PK/VT
F41 20 PK/VT
B75 C20
OTHERS
OVERHEAD CONSOLE
F41 20 PK/VT
F41 20 PK/VT
9 TO
CS02
(8W-10-20)
TO
GS001221
J988W-3
8W - 12 - 22
NS/GS
JUNCTION BLOCK
(8W-12-2)
85
87 D4
10
C3
34
C3
28
C3
22
C2
C2
29
C2
29
C3
M112 22 BR/LG
M111 22 BR/WT
M113 20 LB/PK
M113 20 LB/PK 4
M11 20 PK/LB
B75 C20
3
M11 20 PK/LB
M11 20 PK/LB
M11 20 PK/LB
TO
HEADLAMP SWITCH
(8W-50-9) (8W-50-10)
B17 LJ01
M11 20 PK/LB 3 3
TO
TO
CS01
(8W-44-4)
CS1
(8W-44-4)
B01 D02
B03 D01P
J02A L15
M11 20 PK/LB M11 20 PK/LB 1
M11 20 PK/LB 1
M11 20 PK/LB 1
NS/GS
8W - 12 - 23
TO TO TO TO
TO TO
V10 20 BR
E2 20 OR 4
E2 20 OR
E2 20 OR
E2 20 OR 11 E2 20 OR
V10 20 BR
D01D B02
E2 20 OR
D01P B03
21
C2
18
C3
C1 JUNCTION BLOCK
(8W-12-2)
30
C4
C4
23
C4
C4
C1
E2 20 OR
E2 20 OR
E2 20 OR
E2 20 OR
E2 20 OR
E2 18 OR
E2 20 OR
E2 20 OR
E2 20 OR 17
E2 20 OR
TO
B75 C20
TO
TO
TO
TO
E2 20 OR
HEADLAMP SWITCH
(8W-50-9) (8W-50-10)
RADIO
(8W-47-2)
TO
TO
TO
TO
TO
TO
INSTRUMENT CLUSTER
(8W-40-4)
J988W-3
8W - 12 - 24
NS/GS
C1
L7 12 BK/YL
RUN-ACC A31
(8W-10-16)
C1
BATT A4
(8W-10-12)
JUNCTION BLOCK
(8W-12-2) PTC 7 9A (8W-12-16) FUSE 5 15A (8W-12-8) PTC 3 9A (8W-12-15)
56
P WASHER MODULE
LOGIC
30
18 V10 20 BR 11
C3
21 V10 20 BR
C2
34
C1
V53 18 RD/YL B
HEADLAMP WASHER
(8W-53-5)
GS001224
NS/GS
BATT A0
8W - 12 - 25
C5
C1
30 FOG LAMP RELAY (8W-50-5)
JUNCTION BLOCK
(8W-12-2)
L43 18 VT 85 12 87
C1
31
C1
25 L39 18 LB
C1
B23 P18
B23 P18
L39 18 LB
L94 20 OR/WT
C2 HEADLAMP SWITCH
(8W-50-9)
10
GS001225
J988W-3
8W - 12 - 26
BATT A0
(8W-10-8)
NS/GS
C2
F41 20 PK/VT 15
C2 JUNCTION BLOCK
(8W-12-2)
86
87
87A
87
85 30
30
30
85
(8W-12-19)
C2
11
C3
P160 20 LB 6
11
C4
36 P159 20 DG
C1
36
C4
FROM
2 Z1 14 BK
C2
P171 20 VT/WT 6
P160 20 LB
P159 20 DG
C2
M
C2
M
C2
C2
1 1
P174 20 YL/RD
P136 20 YL
G300
(8W-15-6)
71
C1
74
C1
39
J988W-3
GS001226
NS/GS
8W - 15 GROUND DISTRIBUTION
8W - 15 - 1
8W - 15 - 2
NS/GS
C1
50
C2
86 TRANSMISSION CONTROL RELAY (8W-31-2)
P34 B23
Z12 18 BK/TN Z12 18 BK/TN 85 4 Z16 18 BK
Z11 20 BK/WT 9
B70 E43
C8
Z11 18 BK/WT
ES18 BATTERY
(8W-20-2)
Z1 12 BK
1 Z1 14 BK
RF3 E40
Z1 12 BK
Z1 18 BK
ES23
Z0 8 BK Z0 6 BK Z1 10 BK Z1 12 BK
G100
J988W-3
G103
G101
G102
GS001502
NS/GS
8W - 15 - 3
NEEDLE MOVEMENT SENSOR
(8W-30-35)
ES31
Z122 18 BK 2
E97 B106
Z12 16 BK/TN
Z12 16 BK/TN
Z12 16 BK/TN
BS40
Z1 18 BK Z1 18 BK
BS41
G301
(8W-15-12)
BS31
86 FUEL HEATER RELAY (8W-30-29) 85 1 Z12 14 BK/TN 3 Z1 16 BK 3
Z12 14 BK/TN A TO
G300
(8W-15-5)
C6
B107 E95
Z1 20 BK Z1 12 BK
ES12
ES01
G102
BATTERY
Z0 10 BK (8W-20-3)
Z1 18 BK
FUEL HEATER
(8W-30-29) 2 Z0 6 BK Z0 2 BK Z1 16 BK Z1 18 BK 2 Z1 20 BK
Z1 18 BK
GS001503
G100
G103
ES02
J988W-3
8W - 15 - 4
LEFT SPEED CONTROL SWITCH
(8W-33-2) (8W-33-4) Z2 22 BK Z2 20 BK
NS/GS
CONTROLLER ANTI-LOCK BRAKE
(8W-35-2) 8 24
Z1 12 BK 6 Z1 12 BK
Z7 12 BK
Z7 12 BK
C2
CLOCKSPRING
G201
3
Z2 20 BK/LG
C1
C1
C2
IGNITION SWITCH
(8W-10-14) 1
Z2 18 BK/LG
G204
C1
INSTRUMENT CLUSTER
(8W-40-2) 7
Z2 20 BK 3 12 14
Z1 20 BK 13
Z2 20 BK/LG Z1 18 BK 11 9
Z1 20 BK Z1 20 BK 7 6 Z1 20 BK 10
G200
J988W-3
GS001504
NS/GS
LEFT DOOR SPEAKER (PREMIUM)
2 X15 16 BK/DG 1 (8W-47-6) (8W-47-7) 2 X15 16 BK/DG 1
8W - 15 - 5
RIGHT REAR SPEAKER
(8W-47-5) 2 X15 16 BK/DG
RADIO
(8W-47-2)
D02 B01
D01P B03
X15 16 BK/DG
X15 16 BK/DG
B23 P34
X15 16 BK/DG
WIPER MODULE
(8W-53-2) 4 Z1 20 BK 1
X15 16 BK/DG
C2
(8W-62-3) (8W-63-4)
EC1 C19
Z1 20 BK
Z1 14 BK
Z1 14 BK
12 Z1 18 BK
C20 B75
FROM
BS31 (DIESEL)
(8W-15-3) A
S02 B56
Z12 14 BK/TN 1 Z12 20 BK/TN 3
S02 B09
Z1 20 BK 14 12
Z1 14 BK 7
Z1 12 BK
G300
GS001505
J988W-3
8W - 15 - 6
NS/GS
MESSAGE CENTER
(8W-46-4) 3 *4
INSTRUMENT CLUSTER
(8W-40-4)
13
IGNITION SWITCH
(8W-10-14) 2 Z1 20 BK Z1 20 BK
C2
FROM
Z1 20 BK
22
C4
30 DOOR LOCK RELAY (8W-61-3) (8W-61-4) (8W-61-7) (8W-61-8) 30 DOOR UNLOCK RELAY (8W-61-3) (8W-61-4) (8W-61-7) (8W-61-8)
28
C4
35
C4
36
C4 JUNCTION BLOCK
(8W-12-2)
30 DRIVER DOOR UNLOCK RELAY (RKE) (8W-61-7) (8W-61-8) 86 NAME BRAND SPEAKER RELAY (8W-47-4) 85 3 4 COMBINATION FLASHER/ DRL MODULE (8W-50-13) 11
87
87A
87
87A
87
87A
C2
21
C4
29
C4
10
C2
14
C2
Z1 14 BK
Z1 18 BK
Z1 20 BK
Z2 20 BK/LG
Z2 20 BK/LG
C2
C1 HEADLAMP SWITCH
(8W-50-9) (8W-50-10) * RHD
G300
J988W-3
GS001506
NS/GS
8W - 15 - 7
86 FRONT BLOWER MOTOR RELAY (8W-42-2) 85 30 WIPER ON RELAY (8W-53-2) (8W-53-3) 87 87A
FROM
Z1 20 BK
Z1 20 BK
Z1 12 BK
3 *2 Z1 20 BK
D01P B03
Z1 18 BK
10
D01D B02
Z1 12 BK
10
11
G300
GS001507
* BUILT-UP-EXPORT
J988W-3
8W - 15 - 8
NS/GS
LEFT HEADLAMP
(8W-50-6)
Z1 20 BK
CHRYSLER
OTHER
LEFT HEADLAMP
(8W-50-6) 3
Z1 20 BK
Z1 20 BK
EXCEPT BUILTUP-EXPORT
BUILT-UP -EXPORT 2 Z1 20 BK Z1 20 BK
Z1 20 BK
Z1 20 BK
EXCEPT BUILTUP-EXPORT
BUILT-UP-EXPORT 1
G300
J988W-3
GS001508
NS/GS
DRIVER HEATED SEAT MODULE
F (8W-63-7)
8W - 15 - 9
Z1 20 BK
Z1 18 BK
Z1 18 BK
Z1 18 BK
Z1 18 BK
C2
HS3
S02 HS6D
Z1 14BK
HS5D B09
Z1 12 BK Z1 12 BK
HS5P B56
G300
GS001509
J988W-3
8W - 15 - 10
NS/GS
Z2 20 BK/LG
Z2 20 BK/LG
Z2 20 BK/LG
RIGHT HEADLAMP
(8W-50-8) 3
Z1 20 BK
Z1 20 BK
Z1 20 BK
Z1 20 BK
Z1 20 BK
Z2 20 BK/LG
EXCEPT BUILTUPEXPORT
BUILT-UP -EXPORT
D01P B03
Z2 20 BK/LG
13
10
12
11
G301
J988W-3
GS001510
NS/GS
8W - 15 - 11
Z1 18 BK
Z2 20 BK/LG
Z2 20 BK/LG
Z2 20 BK/LG
OVERHEAD CONSOLE
(8W-49-2)
Z2 20 BK/LG
3 Z2 18 BK/LG
Z1 18 BK
Z2 18 BK/LG
D01D B02
Z1 20 BK
Z2 20 BK/LG
CS06
9
C20 B75
Z2 18 BK/LG
14
G301
GS001511
J988W-3
8W - 15 - 12
NS/GS
OTHER
Z2 20 BK/LG
Z2 20 BK/LG
Z2 20 BK/LG 3
OVERHEAD CONSOLE
(8W-49-2)
Z2 20 BK/LG
3 Z2 18 BK/LG
D01D B02
Z2 18 BK/LG
CS06
FROM (8W-15-3) B
B106
S02 B56
Z1 12 BK
24 A24
P34 B23
Z1 18 BK
9 Z11 20 BK/WT
C20 B75
Z12 18 BK
Z2 18 BK/LG 3 6
14
G301
J988W-3
GS001512
NS/GS
LEFT COMBINATION RELAY
(8W-54-3) 2 Z1 18 BK 2
8W - 15 - 13
LEFT REAR LAMP ASSEMBLY
6 *1 (8W-51-4) (8W-51-5)
2 Z1 18 BK
Z1 18 BK 6 *1 Z1 20 BK 6
Z1 18 WT 6 *1 Z1 20 BK 6
Z1 20 BK 6 *1 Z1 20 BK
Z1 18 BK 2
T05 B99
T08 B98
OTHERS
TRAILER TOW
Z1 16 BK
AWS1
Z1 18 BK Z1 18 BK 1 1 Z1 16 BK
4 Z1 16 BK 1 Z1 14 BK
1 Z1 18 BK Z1 18 BK
AW4 B13
Z1
AW4 B13
3 Z1 20 BK Z1 20 BK Z1 18 BK Z1 16 BK
C1
C2
3.8L
OTHER
14
12
11
G302
10 Z1 12 BK C TO * BUILT-UP-EXPORT
B17
(8W-15-14) GS001513 J988W-3
8W - 15 - 14
NS/GS
FROM (8W-15-13) C
G302
LICENSE LAMP
(8W-51-2)
11
B17 LJ01
Z1 12 BK
J02A L15
Z1 12 BK
Z2 20 BK/LG
Z1 20 BK
Z1 20 BK
Z1 20 BK
Z1 20 BK
Z1 20 BK
Z1 18 BK
Z1 12 BK
11
G400
J988W-3
GS001514
NS/GS
8W - 20 CHARGING SYSTEM
8W - 20 - 1
8W - 20 - 2
NS/GS
FUSIBLE LINK
A11 10 DG
ES09
30 AUTOMATIC SHUT DOWN RELAY (8W-30-2) 87
A0 6 RD
A0 6 RD
FUSED B(+)
C6
A142 18 DG/OR
ES12
(8W-10-23) FROM A11 6 BK/GY
BATTERY
ES11
(8W-15-2)
A142 18 DG/OR 1
Z0 10 BK
GENERATOR
G103
C1
Z0 8 BK
G100
J988W-3
GS002002
NS/GS
8W - 20 - 3
FUSIBLE LINK
A11 10 DG
ES11
C6
ES28
A54 10 RD 1
A142 18 DG/OR
ES06
(8W-10-25) A142 18 DG/OR A11 6 BK/GY
A0 2 RD A0 6 RD A0 10 RD
GENERATOR
BATTERY
FROM
ES01
(8W-15-3) DF Z0 10 BK 1 Z0 2 BK A142 18 DG/OR 7 D+ + VOLTAGE REGULATOR
E96 B108
A142 18 DG/OR
G103
Z0 8 BK A142 16 DG/OR 23 DIESEL POWER RELAY OUTPUT A142 16 DG/OR 45 DIESEL POWER RELAY OUTPUT
BS33
A142 16 DG/OR 68 DIESEL POWER RELAY OUTPUT
G100
GS002003
NS/GS
8W - 21 STARTING SYSTEM
8W - 21 - 1
8W - 21 - 2
ST A41
(8W-10-16)
NS/GS
10
C2
A0 6 RD
C6
C7
T40 12 BR
A0 6 RD
BATTERY
(8W-20-2)
31
J988W-3
GS002102
NS/GS
ST A41
(8W-10-16)
8W - 21 - 3
C2
F45 20 YL/RD 1
A0 6 RD
ES28
C6
3 T40 12 BR
C7
A0 2 RD
BATTERY
(8W-20-3)
6 K90 20 TN 3
E95 B107
A54 10 RD
FUSED B(+)
G103
TO
ES01
(8W-15-3)
Z0 6 BK
G100
GS002103 J988W-3
NS/GS
8W - 30 FUEL/IGNITION SYSTEM
8W - 30 - 1
8W - 30 - 2
ST-RUN A21
(8W-10-16)
NS/GS
30
C1
F87 18 WT/BK 6
C2
BATT A0
(8W-10-8)
86
85 6
87
C6 GENERATOR
(8W-20-2)
C6
C6
C6
F87 18 WT/BK
A142 18 DG/OR
ES07
(8W-12-13) F87 18 WT/BK 20
ES12
(8W-10-23) A142 18 DG/OR 6 A14 18 RD/WT 46
C1
C1
67
C2
C1
FUSED B (+)
ES11
(8W-15-2) Z0 10 BK J988W-3
Z0 8 BK
Z0 6 BK
G100
G103
GS003002
NS/GS
BATT A0
8W - 30 - 3
C3
M1 20 PK 13
C1
(8W-12-20)
16
JUNCTION BLOCK
(8W-12-2)
FUSED B(+)
17 M1 20 PK
C4
M1 20 PK 7
C1 RADIO
(8W-47-2)
FUSED B(+)
16
4 Z2 20 BK/LG
P18 B23
1
P34 B23
B33 E36
G200
(8W-15-4)
Z11 20 BK/WT 9
B70 E43
Z11 18 BK/WT
ES24
D20 18 LG 75 D21 18 PK Z0 10 BK
ES11
(8W-15-2)
BATTERY
(8W-20-2)
D21 18 PK
C2
65
7 SCI TRANSMIT
SCI RECEIVE
SCI TRANSMIT
Z0 8 BK
Z0 6 BK
G100
GS003003
G103
J988W-3
8W - 30 - 4
DATA LINK CONNECTOR
14 11 D2 20 WT/BK 3 D1 20 VT/BR
NS/GS
AIRBAG CONTROL MODULE
(8W-43-3)
INSTRUMENT CLUSTER
(8W-40-2)
C2 TWISTED PAIR
C2
TWISTED PAIR
TWISTED PAIR
D2 20 WT/BK
D1 20 VT/BR
PS02
D2 20 WT/BK
PS01
D1 20 VT/BR 12 D2 20 WT/BK D1 20 VT/BR D1 20 VT/BR 6 CCD BUS (+) D2 20 WT/BK 5 CCD BUS (-) D2 20 WT/BK D1 20 VT/BR
D6 20 PK/LB 14 B14
13 B13
B12
P18 B23
34
TWISTED PAIR C2
CCD BUS (-) 3
D2 18 WT/BK
C2
CCD BUS (+)
D1 18 VT/BR
TWISTED PAIR
2
C3
CCD BUS (-)
C3 RADIO
(8W-47-2)
BS05 BS06
D2 18 WT/BK D1 18 VT/BR
TWISTED PAIR
D2 18 WT/BK
D1 18 VT/BR
D6 20 PK/LB 6 EATX
D1 18 VT/BR 7
B33 E36
MTX
5 D2 18 WT/BK
B75 C20
D1 18 VT/BR
ES13 ES14
D6 18 PK/LB 46 SCI RECEIVE D2 18 WT/BK 4 CCD BUS (-) 43 CCD BUS (+) D1 18 VT/BR D2 18 WT/BK D2 18 WT/BK D1 18 VT/BR
D1 18 VT/BR
TWISTED PAIR
1 CCD BUS (-) 6 CCD BUS (+)
OVERHEAD CONSOLE
(8W-49-2)
C2
CCD BUS (-)
59
C2
CCD BUS (+)
J988W-3
NS/GS
8W - 30 - 5
RIGHT SPEED CONTROL SWITCH 1 RESUME/ACCEL 2 CANCEL 3 COAST
ST-RUN F87
86
C6
V37 22 WT
V37 20 WT
V37 20 WT
C1
1 2
Z2 22 BK
P18 B23
Z2 20 BK
RADIATOR
CLOCKSPRING
C2
C2
B70 E43
K173 14 LG/DB
Z2 20 BK/LG
P34 B23
3
C13 18 DB/OR
C103 18 DG/LB
V37 20 RD/LG 8
B70 E43
G200
(8W-15-4)
V37 18 RD/LG 64
C2
38
C1
73
C2
41
GS003005
J988W-3
8W - 30 - 6
ST-RUN A21 ST T141
(8W-12-16) PTC 1 9A (8W-12-13) 30
NS/GS
TRANSMISSION RANGE SENSOR
(8W-31-3) BACKUP LAMP FEED 2 L1 18 VT/BK 10 L1 20 VT/BK
JUNCTION BLOCK
(8W-12-2)
ST F45
(8W-12-16) T141 20 YL/BK F45 20 YL/BK
BACK-UP SWITCH
(8W-51-5)
C1
MTX 3
EATX
F87 18 WT/BK 6
C2
C2
BATT A0
10 (8W-10-8)
E36 B33
86 ENGINE STARTER MOTOR RELAY (8W-21-2) 85 86 30 FUEL PUMP RELAY (8W-12-13) FUSE 16 20A (8W-10-26)
E36 B33
L1 20 VT/BK
MTX
BS02
(8W-70-2) L1 20 VT/BK
C1
G4 18 DB
85 4
87
C6
C6
C2
3
B13 AW4
G4 18 DB
B13 AW4
B13 AW4
3
K90 18 TN
K31 18 BR
AW4 B13
Z1 14 BK
31
C1
74
G302
(8W-15-13) GS003006
J988W-3
NS/GS
BATT A0
8W - 30 - 7
ES12
A142 18 DG/OR (8W-10-23) A142 18 DG/OR 2 4 2
E43 B70
A142 18 DG/OR 2 4
K4 18 BK/LB
Z1 18 BK
ES18
(8W-15-2) Z1 10 BK
G300
(8W-15-5)
B33 E36
10
G101
(8W-15-2)
K4 18 BK/LB
B70 E43
ES21
K41 18 BK/DG 30 (8W-70-4) K4 (8W-70-5) 18 BK/LB 43 K141 18 TN/WT 51
C1
C2
SENSOR GROUND
GS003007
J988W-3
8W - 30 - 8
NS/GS
BATT A0
ES17
(8W-70-9)
K7 18 OR
K7 18 OR
C6
A142 18 DG/OR
ES12
(8W-10-23) A142 18 DG/OR
ES02
(8W-70-4) 1 2 8V SUPPLY
ES21
K17 18 DB/TN K19 18 GY/RD K7 18 OR K24 18 GY/BK (8W-70-4) K4 18 BK/LB K44 18 TN/YL
C1
11
C1
44
C2
32
C1
43
C2
33
8V SUPPLY
SENSOR GROUND
J988W-3
GS003008
NS/GS
BATT A0
(8W-10-8)
8W - 30 - 9
C6
A142 18 DG/OR
ES12
(8W-10-23) A142 18 DG/OR
ES99
A142 18 DG/OR 2
A142 18 DG/OR 2
A142 18 DG/OR 2
A142 18 DG/OR 2
K11 18 WT/DB
K12 18 TN/WT
K13 18 YL/WT
K14 18 LB/BR
13
C1
17
C1
C1
16
GS003009
J988W-3
8W - 30 - 10
NS/GS
ES02
(8W-70-4) K4 18 BK/LB K4 18 BK/LB K4 18 BK/LB 1
KNOCK SENSOR
K6 18 VT/WT
K21 18 BK/RD
K1 18 DG/RD
K4 18 BK/LB
K42 18 DB/LG
K2 18 TN/BK
C18 18 DB
61
C2
37
C1
36
C1
43
C2
25
C1
26
C1
42
5V SUPPLY
SENSOR GROUND
J988W-3
GS003010
NS/GS
8W - 30 - 11
K6 18 VT/WT
ES03
(8W-70-7) 3
SENSOR GROUND 2
8V SUPPLY 1 K7 18 OR
K4 18 BK/LB
K4 18 BK/LB
ES02
(8W-70-4)
K4 18 BK/LB
ES21
(8W-70-4)
ES17
(8W-70-9)
K6 18 VT/WT
K22 18 OR/DB
K4 18 BK/LB
K7 18 OR
G7 18 WT/OR
61
C2
35
C1
43
C2
44
C2
66
5V SUPPLY
SENSOR GROUND
8V SUPPLY
GS003011
J988W-3
8W - 30 - 12
NS/GS
K70 18 VT/RD
K52 18 PK/BK K39 18 GY/RD 68 K60 18 YL/BK 49 K40 18 BR/WT 48 K59 18 VT/BK 58
C2
70
C2
57
C2
C2
C2
J988W-3
GS003012
NS/GS
ST-RUN V23
(8W-12-9) SERVICE ENGINE SOON LAMP 7 *13 G3 20 BK/PK 2 A2
8W - 30 - 13
GENERATOR
(8W-20-2) GENERATOR FIELD DRIVER 2
P34 B23
G3 20 BK/PK 5
G3 18 BK/PK 22
B70 E43
K20 18 DG
C1
SEVICE ENGINE SOON INDICATOR LAMP DRIVER STOP LAMP SWITCH SENSE 62
C2
C1
C2
C2
V32 18 YL/RD 3
V35 18 LG/RD
V36 18 TN/RD
E43 B70
V32 20 YL/RD 3
Z1 20 BK 6
Z1 20 BK
B70 E43
G300
(8W-15-7) TO
JUNCTION BLOCK
(8W-12-19) GS003013
* RHD J988W-3
8W - 30 - 14
NS/GS
BATT A0
ES17
(8W-70-9)
C6
A142 18 DG/OR
ES12
(8W-10-23) A142 18 DG/OR
ES02
(8W-70-5)
ES21 ES05
(8W-70-8) (8W-70-5)
K17 18 DB/TN
K19 18 GY/RD
K7 18 OR
K24 18 GY/BK
K4 18 BK/LB
K44 18 TN/YL
C1
11
C1
44
C2
32
C1
43
C2
33
8V SUPPLY
SENSOR GROUND
J988W-3
GS003014
NS/GS
BATT A0
(8W-10-8)
8W - 30 - 15
C6
A142 18 DG/OR
ES12
(8W-10-23) A142 18 DG/OR 10
A142 18 DG/OR 2
A142 18 DG/OR 2
A142 18 DG/OR 2
A142 18 DG/OR 2
F09 E69
K14 18 LB/BR 16
C1
C1
C1
GS003015
J988W-3
8W - 30 - 16
NS/GS
K6 18 VT/WT
K6 18 VT/WT B
K6 18 VT/WT 2
SENSOR GROUND 1
K1 18 DG/RD
K4 18 BK/LB
K4 18 BK/LB
FS01
(8W-70-5) K4 18 BK/LB 1
8 K6 18 VT/WT
11
F09 E69
K4 18 BK/LB
ES03
(8W-70-7) 2
K4 18 BK/LB 2
K4 18 BK/LB
K2 18 TN/BK
KNOCK SENSOR
ES21
(8W-70-5) 12 9
F09 E69
C18 18 DB
61
C2
36
C1
25
C1
43
C2
26
C1
42
5V SUPPLY
SENSOR GROUND
J988W-3
GS003016
NS/GS
8W - 30 - 17
K6 18 VT/WT
ES03
(8W-70-7)
K4 18 BK/LB
K22 18 OR/DB
K4 18 BK/LB
ES08 (EATX)
(8W-70-8)
ES02
(8W-70-5)
K4 18 BK/LB 1
K4 18 BK/LB
G7 18 WT/OR
MTX
EATX
ES21
(8W-70-5)
ES17
(8W-70-9)
K6 18 VT/WT
K22 18 OR/DB
K21 18 BK/RD
K4 18 BK/LB
K7 18 OR
G7 18 WT/OR
61
C2
35
C1
37
C1
43
C2
44
C2
66
5V SUPPLY
SENSOR GROUND
8V SUPPLY
GS003017
J988W-3
8W - 30 - 18
ST-RUN A21
NS/GS
JUNCTION BLOCK
PTC 1 9A (8W-12-13) 30 (8W-12-2)
C1
F87 18 WT/BK 6
C6
F87 18 WT/BK
ES07
(8W-12-13) F87 18 WT/BK 2 F87 18 WT/BK
K70 18 VT/RD 2 1
3 FUSE IGN. (ST-RUN) LEAK DETECTION PUMP SOLENOID CONTROL 2 K106 18 WT/DG 77 K39 18 GY/RD 57 K60 18 YL/BK 49 K40 18 BR/WT 48 K59 18 VT/BK 58
F09 E69
K52 18 PK/BK 68
C2
C2
C1
C2
C2
C2
C2
C2
GS003018
NS/GS
8W - 30 - 19
(8W-12-9) SERVICE ENGINE SOON LAMP 7 *13 G3 20 BK/PK 2 A2
ST-RUN V23
MESSAGE CENTER
(8W-46-3)
GENERATOR
(8W-20-2) GENERATOR FIELD DRIVER 2
P34 B23
ES05
(8W-70-8)
ES08
(8W-70-8)
K24 18 GY/BK
K22 18 OR/DB
G3 18 BK/PK
B70 E43
32
C1
35
C1
63
C2
C1
22
GENERATOR FIELD DRIVER SPEED CONTROL VENT SOLENOID CONTROL 80 SPEED CONTROL VACUUM SOLENOID CONTROL 56
SERVICE ENGINE SOON INDICATOR LAMP DRIVER TRANSMISSION RANGE SWITCH T41 SENSE 76
C2
C1
C2
C2
C2
V32 18 YL/RD 3
V35 18 LG/RD
V36 18 TN/RD
E43 B70
V32 20 YL/RD 3
T41 18 BK/YL
LHD
RHD
B70 E43
P/N
JUNCTION BLOCK
(8W-12-19)
G300
(8W-15-7)
* RHD J988W-3
GS003019
8W - 30 - 20
NS/GS
BACKUP LAMP FEED 6 L1 18 VT/BK BACKUP LAMP FEED 2 L1 18 VT/BK 10
JUNCTION BLOCK
PTC 1 9A (8W-12-13) 30 (8W-12-2)
BACK-UP SWITCH
(8W-51-5)
C1 E36 B33
ST F45
C2
BATT A0
(8W-10-8)
10
86 ENGINE STARTER MOTOR RELAY (8W-21-2) 85 86 30 FUEL PUMP RELAY FUSE 16 20A (8W-10-26)
E36 B33
20 VT/BK
L1 20 VT/BK
EATX
MTX L1 20 VT/BK
BODY
FUEL CONTROL LEVEL SENSOR MODULE SIGNAL (8W-45-7) 46
85 4
87
C1
G4 18 DB 2
BS02
(8W-70-2)
C6
C6
C6
F87 18 WT/BK
B13 AW4
ES07
(8W-12-13)
F87 18 WT/BK 2
GROUND 1
EGR SOLENOID
3.3L Z1 16 BK
3.8L Z1 16 BK
AWS1
C1
40
C1
AW4 B13
Z1 14BK 5
G302
(8W-15-13) GS003020
J988W-3
NS/GS
BATT A0
8W - 30 - 21
ES12
A142 18 DG/OR (8W-10-23) A142 18 DG/OR 2 4 2
E43 B70
A142 18 DG/OR 2 4
K4 18 BK/LB
Z1 18 BK
ES18
(8W-15-2) Z1 10 BK
G300
(8W-15-5)
B33 E36
10
G101
(8W-15-2)
K4 18 BK/LB
B70 E43
ES02
K41 18 BK/DG 30 (8W-70-6) K4 18 BK/LB 43 K141 18 TN/WT 51
C1
C2
SENSOR GROUND
GS003021
J988W-3
8W - 30 - 22
NS/GS
K7 18 OR
K7 18 OR
E78 F02
K7 18 OR
C6
A142 18 DG/OR
ES12
(8W-10-23)
K50 18 YL/WT
K4 18 BK/LB
A142 18 DG/OR 3
FS02
(8W-70-6) 14 K4 18 BK/LB
F02 E78
8
K4 18 BK/LB
F02 E78
2 4 1
ES02 ES05
(8W-70-8) (8W-70-6) K19 18 GY/RD K17 18 DB/TN K18 18 RD/YL
K7 18 OR 44
K24 18 GY/BK
K4 18 BK/LB 54
K44 18 TN/YL 33
C2
32
C1
C2
43
C2
C1
11
C1
C1
SENSOR GROUND
J988W-3
GS003022
NS/GS
BATT A0
(8W-10-8)
8W - 30 - 23
ES12
(8W-10-23) A142 18 DG/OR 1
E78 F02
A142 18 DG/OR
FS01
A142 18 DG/OR A142 18 DG/OR 1 A142 18 DG/OR A142 18 DG/OR 1 A142 18 DG/OR (8W-10-24) A142 18 DG/OR 1
13
F02 E78
K58 18 BR/DB
C1
C1
C1
C1
C1
14
GS003023
8W - 30 - 24
NS/GS
E78 F02
K6 18 VT/WT
K6 18 VT/WT B 2
10
14
F02 E78
ES21
(8W-70-6) K4 18 BK/LB
K4 18 BK/LB
ES02
(8W-70-6)
K4 18 BK/LB 2
11
F02 E78
K6 18 VT/WT
K1 18 DG/RD
K2 18 TN/BK
K42 18 DB/LG
K4 18 BK/LB
C18 18 DB
61
C2
36
C1
26
C1
25
C1
43
C2
42
5V SUPPLY
SENSOR GROUND
J988W-3
GS003024
NS/GS
8W - 30 - 25
K6 18 VT/WT 3
K22 18 OR/DB
K24 18 GY/BK
K4 18 BK/LB
K22 18 OR/DB
ES08
ES03
(8W-70-7)
ES02
(8W-70-6)
ES05
(8W-70-8)
K6 18 VT/WT
K4 18 BK/LB
K22 18 OR/DB
G7 18 WT/OR
K24 18 GY/BK
61
C2
43
C2
35
C1
66
C2
32
5V SUPPLY
SENSOR GROUND
GS003025
J988W-3
8W - 30 - 26
ST-RUN A21
NS/GS
JUNCTION BLOCK
PTC 1 9A (8W-12-13) 30 (8W-12-2)
C1
F87 18 WT/BK 6
C6
IDLE AIR CONTROL MOTOR NO. 1 DRIVER 4 IDLE AIR CONTROL MOTOR NO. 2 DRIVER 3 IDLE AIR CONTROL MOTOR NO. 3 DRIVER 2 IDLE AIR CONTROL MOTOR NO. 4 DRIVER 1
F87 18 WT/BK
ES07
(8W-12-13) F87 18 WT/BK
FUSE IGN. (ST-RUN) LEAK DETECTION PUMP SWITCH SENSE 1 LEAK DETECTION PUMP SOLENOID CONTROL 2 K106 18 WT/DG
K52 18 PK/BK
K70 18 VT/RD
K107 18 DB/WT
K39 18 GY/RD
K60 18 YL/BK
K40 18 BR/WT
K59 18 VT/BK
68
C2
70
C2
72
C2
77
C2
57
C2
49
C2
48
C2
58
J988W-3
GS003026
NS/GS
ST-RUN V23
8W - 30 - 27
GENERATOR
GENERATOR FIELD DRIVER 2 (8W-20-2)
MESSAGE CENTER
(8W-46-3)
K20 18 DG
G3 18 BK/PK 22
B70 E43
T10 18 YL/DG
C1
63
C2
SERVICE ENGINE SOON INDICATOR LAMP DRIVER SPEED CONTROL ON/OFF SWITCH SENSE 5
C2
C1
C2
C2
C2
V32 18 YL/RD 3
V35 18 LG/RD
V36 18 TN/RD
E43 B70
V32 20 YL/RD 3
T41 18 BR/YL
P/N
B70 E43
V30 18 DB/RD
G300
(8W-15-7) TO
2 VENT SOLENOID
1 VACUUM SOLENOID
JUNCTION BLOCK
(8W-12-19) GS003027
* RHD J988W-3
8W - 30 - 28
ST-RUN A21
(8W-10-16)
NS/GS
JUNCTION BLOCK
PTC 1 9A (8W-12-13) (8W-12-2) FUSE 17 20A (8W-10-25) 86 30 30 DIESEL POWER RELAY
C1
85 8 F87 18 WT/BK 86
87
C6
C6 ES06
(8W-10-25)
85 TO
A142 18 DG/OR 7
E96 B108
A142 18 DG/OR
E95 B107
K90 20 TN 42 DIESEL POWER RELAY K51 20 DB/YL A142 16 DG/OR 23 DIESEL POWER RELAY OUTPUT GROUND 46 Z12 16 BK/TN A142 16 DG/OR 45 DIESEL POWER RELAY OUTPUT
BS33
A142 16 DG/OR 68 DIESEL POWER RELAY OUTPUT
BS31
(8W-15-3) Z12 14 BK/TN 7
G300
(8W-15-5)
J988W-3
GS003028
NS/GS
ST-RUN A21
8W - 30 - 29
JUNCTION BLOCK
PTC 1 9A (8W-12-13) 30 F87 18 WT/BK (8W-12-2)
C1
F87 18 WT/BK 6
C2
BATT A0
(8W-10-8)
TO
85 3 Z1 20 BK
87
C6
C2
C6
A141 16 DG/WT 4
B33 E120
A142 18 DG/OR
BATTERY
(8W-20-3) A141 18 DG/WT 1 Z0 2 BK Z0 6 BK Z0 10 BK 2 Z1 18 BK
A141 18 DG/WT
ES06
A142 18 DG/OR 1
ES40
A141 18 DG/WT 1
FUEL HEATER
2 Z1 18 BK
2 K35 20 GY/YL 2
E96 B108
G100
ES02
(8W-15-3) Z1 16 BK 25
K35 20 GY/YL
G103
GS003029
ES01
(8W-15-3)
8W - 30 - 30
BATT A0
(8W-10-8)
NS/GS
C3
M1 20PK
C1
(8W-12-20)
16
JUNCTION BLOCK
(8W-12-2)
FUSED B(+)
17 M1 20 PK
C4
M1 20 PK 7
C1 RADIO
(8W-47-2)
FUSED B(+)
16
D21 20 PK
Z11 20 BK/WT
17 B17
P18 B23
24 A24
P34 B23
D21 20 PK
Z2 20 BK/LG
Z11 20 BK/WT
61 SCI TRANSMIT
G200
(8W-15-4)
G301
(8W-15-12)
J988W-3
GS003030
NS/GS
8W - 30 - 31
CONTROLLER ANTI-LOCK BRAKE
(8W-35-3)
OVERHEAD CONSOLE
(8W-49-2)
TWISTED PAIR
D2 18 WT/BK
TWISTED PAIR
TWISTED PAIR
D1 18 VT/BR B12 12
D2 18 WT/BK B13 13
B23 P18
11
TWISTED PAIR
D1 20 VT/BR
D2 20 WT/BK
TWISTED PAIR
D1 20 VT/BR
D2 20 WT/BK
INSTRUMENT CLUSTER
(8W-40-2)
D1 20 VT/BR 3
D2 20 WT/BK 4
C2
CCD BUS (+)
C2
CCD BUS (-)
C2
CCD BUS (+)
C2
CCD BUS (-)
GS003031
8W - 30 - 32
ST-RUN A21
NS/GS
BATT A0
(8W-10-8)
JUNCTION BLOCK
FUSE 6 20A (8W-12-9) (8W-12-2) FUSE 17 20A (8W-10-25) 30 14 DIESEL POWER RELAY (8W-30-28) V23 18 BR/PK 87 5
BATTERY
(8W-20-3) A0 10 RD
C4
V23 18 BR/PK
C6
10
A142 18 DG/OR
ES28
ES06
(8W-10-25) A142 18 DG/OR A54 10 RD
10
7 G85 20 OR/BK
K152 18 WT/DG
ES37
K154 12 BK K154 12 BK K154 12 BK K154 12 BK
17 A17
P34 B23
E95 B107
G85 20 OR/BK
K152 20 WT/DG
J988W-3
GS003032
NS/GS
8W - 30 - 33
C6
A142 18 DG/OR
ES06
(8W-10-25) A142 18 DG/OR 9 FUEL TEMPERATURE SENSOR 7 K156 18 GY 4 K4 20 BK/LB 8 K140 18 TN/WT 8 FUEL QUANTITY ACTUATOR 5 K126 18 LG 1 A142 18 DG/OR 10 FUEL TIMING SOLENOID 6 K153 18 OR/DG 4 FUEL SHUTDOWN SOLENOID
ES05
(8W-70-11) K4 20 BK/LB 6
E96 B108
E97 B106
E95 B107
E97 B106
E96 B108
K4 18 BK/LB
K140 18 TN/WT
BS32
BS34
K156 20 GY 63 FUEL TEMPERATURE SENSOR SIGNAL 33 SENSOR GROUND (8W-70-11) K4 20 BK/LB K140 18 TN/WT 4 K140 18 TN/WT 5 K140 18 TN/WT 49 51 SIGNAL TIMING SOLENOID CONTROL K126 20 LG K153 18 OR/DG 53 FUEL SHUTDOWN SOLENOID CONTROL
GS003033
J988W-3
8W - 30 - 34
NS/GS
SENSOR GROUND 1
5V SUPPLY 3
K57 18 LG/OR
K134 18 LB/BK
K135 18 WT/BK
K4 18 BK/LB
K9 18 LB
K21 18 BK/RD
K1 18 DG/RD
ES05
(8W-70-11) K4 20 BK/LB
E95 B107
E97 B106
K4 18 BK/LB
BS34
(8W-70-11)
E120 B33
E96 B108
K4 20 BK/LB
K134 20 LB/BK
K9 20 LB 64
K21 20 BK/RD
5V SUPPLY
J988W-3
GS003034
NS/GS
8W - 30 - 35
ENGINE SPEED SENSOR
ES31
Z122 18 BK
ES30
Z122 18 BK
2 Z12 18 BK 6
E97 B106
E120 B33
G301
Z1 18 BK (8W-15-12) Z1 18 BK K3 20 BK/VT
BS41
Z1 18 BK K67 20 BR/BK K68 20 LG/YL Z1 18 BK
BS40
BS31
(8W-15-3) Z12 14 BK/TN 7
G300
(8W-15-5) K24 18 GY/BK 8 ENGINE SPEED SENSOR 21 ENGINE SPEED SENSOR RETURN
GS003035
J988W-3
8W - 30 - 36
ST-RUN A21
(8W-10-16)
NS/GS
PTC 1 9A (8W-12-13) 30
(8W-12-2)
C1
F87 18 WT/BK 6
C6
F87 18 WT/BK 1 VEHICLE SPEED SENSOR SIGNAL 3 G7 18 WT/OR 4 COOLANT TEMPERATURE SENSOR SIGNAL 3 G58 20 BK/YL 3 G7 18 WT/OR 42 FUSED IGNITION (ST-RUN)
SENSOR GROUND
K4 20 BK/LB
G58 20 BK/YL 60
E120 B33
K4 20 BK/LB
ES05
(8W-70-11)
C1
VEHICLE SPEED SENSOR SIGNAL ENGINE SPEED SENSOR SIGNAL 75 C1 K159 20 VT/RD 2 ENGINE SPEED SENSOR SIGNAL
COOLANT TEMPERATURE SENSOR SIGNAL ENGINE DISABLE SIGNAL 72 C1 G55 20 OR/BK 59 ENGINE DISABLE SIGNAL
E97 B106
K4 18 BK/LB
BS34
(8W-70-11) K2 20 TN/BK 14 33 K4 20 BK/LB
J988W-3
GS003036
NS/GS
ST-RUN F87
86 A/C COMPRESSOR CLUTCH RELAY (8W-42-9) 85 7 (8W-10-29)
8W - 30 - 37
C6
LOW SPEED RADIATOR FAN RELAY CONTROL 6
C13 20 DB/OR
C24 20 DB/PK
C137 20 YL
C137 20 YL
C1
C137 20 YL
10
E97 B106
E95 B107
P18 B23
C137 20 YL
GS003037
J988W-3
8W - 30 - 38
NS/GS
ACCELERATOR PEDAL POSITION SENSOR
SENSOR GROUND 3
5V SUPPLY 10
K4 20 BK/LB
K4 20 BK/LB
BS34
(8W-70-11)
K7 20 OR
C18 20 DB
K4 20 BK/LB
K151 20 WT
K22 20 OR/DB
K167 20 BR/YL
K6 20 VT/WT
19 5V OUTPUT
33 SENSOR GROUND
65
15
57 5V SUPPLY
J988W-3
GS003038
NS/GS
BATT A0
(8W-10-8)
8W - 30 - 39
BS01
(8W-70-2) F32 18 PK/DB 6 L50 18 WT/TN 5 3 1
V38 20 LB/RD
A21 21
B23 P34
V37 20 RD/LG
56
C1 BODY
C2 CLOCKSPRING
(8W-33-4)
CLUTCH SWITCH
FROM
V37 20 WT
FROM
Z1 18 BK 6
Z1 20 BK
Z1 20 BK 1
Z1 20 BK
V37 20 WT
G300
(8W-15-7) (8W-15-8)
GS003039
NS/GS
8W - 31 - 1
8W - 31 - 2
BATT A0
NS/GS
(8W-10-8)
86
85
87
10
C8
C8
4 Z16 18 BK
C8
C8
T16 18 RD
ES01
(8W-10-28)
A5 18 RD/DB
T15 18 LG
T16 18 RD
T16 18 RD
Z16 18 BK
Z13 16 BK/RD
Z14 16 BK/YL
BATTERY
(8W-20-2)
ES11
(8W-15-2) Z0 10 BK
Z0 8 BK
Z0 6 BK
J988W-3
G100
G103
GS003102
NS/GS
8W - 31 - 3
JUNCTION BLOCK
FUSE 12 10A (8W-12-12) 18 (8W-12-2)
C2
F20 20 WT
5 F20 18 WT
B33 E36
F20 18 WT
E36 B33
L1 20 VT/BK
BS02
(8W-70-2) L1 20 VT/BK 2
ES10
(8W-70-8)
L1 18 VT/BK
B13 AW4
C1
T14 18 LG/WT
T13 18 DB/BK
T52 18 RD/BK
1 Z1 18 BK
C1
1 Z1 18 BK
Z1 16 BK 1
AW4 B13
Z1 14 BK
G302
(8W-15-13) J988W-3
8W - 31 - 4
NS/GS
POWERTRAIN CONTROL MODULE
SENSOR GROUND 43 (8W-30-14) (8W-30-17) (8W-30-22) (8W-30-25)
C2
C1
C1
C2
G7 18 WT/OR
K24 18 GY/BK
K22 18 OR/DB
K4 18 BK/LB
3.3L/3.8L
2.4L
ES05
ES08
ES02
(8W-70-6)
ES21
(8W-70-5)
K24 18 GY/BK
K22 18 OR/DB
K4 18 BK/LB
K4 18 BK/LB
THROTTLE
ES21
(8W-70-6)
ES02
(8W-70-5)
K24 18 GY/BK
K22 18 OR/DB
K4 18 BK/LB
51 SENSOR GROUND
J988W-3
GS003104
NS/GS
ST A41
8W - 31 - 5
(8W-10-16)
(8W-10-16)
JUNCTION BLOCK
(8W-12-2)
C2
20
C1
F11 20 RD/WT
B33 E36
F11 18 RD/WT
C2
7
C8
F45 18 YL/RD 8 FUSED IGNITION (ST) TRANSMISSION RANGE SWITCH T41 SENSE 41 TRANSMISSION RANGE SWITCH T42 SENSE 42 TRANSMISSION RANGE SWITCH T3 SENSE 3 11 FUSED IGNITION (ST-RUN-OFF) TRANSMISSION TRANSMISSION RANGE TEMPERATURE SWITCH SENSOR T1 SIGNAL SENSE 1 54
T41 18 BR/YL
T41 18 BK/WT
T42 18 VT/WT
T3 18 VT
T1 18 LG/BK
T54 18 VT/LG
ES10
(8W-70-8) T13 18 DB/BK 3
10
PN
PRNL
P3L
NOL
GS003105
J988W-3
8W - 31 - 6
NS/GS
(8W-10-8)
2 T16 18 RD
C8
ES01
(8W-10-28) T16 18 RD 4
T50 18 DG
T47 18 YL/BK
T9 18 OR/BK
J988W-3
GS003106
NS/GS
8W - 31 - 7
(8W-10-8)
2 T16 18 RD
C8
ES01
(8W-10-28) T16 18 RD 4
2-4 SOLENOID
UNDERDRIVE SOLENOID
OVERDRIVE SOLENOID
T20 18 LB
T19 18 WT
T59 18 PK
T60 18 BR
GS003107
J988W-3
8W - 31 - 8
NS/GS
C2
C2
ES24
(8W-30-3) D21 18 PK 4 D21 20 PK B17 17 7 11 D2 20 WT/BK 3
E36 B33
14
TWISTED PAIR
D1 20 VT/BR
PS02
(8W-30-4) D2 20 WT/BK 13 B13 D2 18 WT/BK
PS01
(8W-30-4) D1 20 VT/BR 12 B12 D1 18 VT/BR 14 B14
P18 B23
D6 20 PK/LB
BS06
(8W-30-4) 2 7
BS05
(8W-30-4) 6
B33 E36
ES14
(8W-30-4) D21 18 PK 7 SCI TRANSMIT D2 18 WT/BK 4 CCD BUS (-)
ES13
(8W-30-4) D1 18 VT/BR 46 CCD BUS (+) SCI RECEIVE D6 18 PK/LB
TWISTED PAIR
43
J988W-3
GS003108
NS/GS
8W - 33 - 1
8W - 33 - 2
NS/GS
POWERTRAIN CONTROL MODULE
(8W-30-11) (8W-30-17) (8W-30-25)
C2
C2
V37 18 RD/LG 8
E43 B70
MTX
G7 18 WT/OR EATX
G7 18 WT/OR 58
TRANSMISSION
V37 20 WT
V37 22 WT
V37 20 WT
Z2 22 BK Z2 20 BK
CLOCKSPRING
C2
Z2 20 BK/LG 3
G200
(8W-15-4)
J988W-3
GS003302
NS/GS
8W - 33 - 3
POWERTRAIN CONTROL MODULE
(8W-30-13) (8W-30-19) (8W-30-27)
7 K29 20 WT/PK
E43 B70
V32 20 YL/RD
B70 E43
V30 18 DB/RD 3 2 1
LHD
RHD
VENT SOLENOID
VACUUM SOLENOID
TO
DUMP SOLENOID
JUNCTION BLOCK
6 (8W-12-19) 4 Z1 18 BK
G300
(8W-15-7)
ES18
(8W-15-2) Z1 10 BK
G101
(8W-15-2) GS003303 J988W-3
8W - 33 - 4
NS/GS
B23 P34
BS30
G7 18 WT/OR
V37 20 RD/LG 4
C2 CLOCKSPRING
C1
42
B108 E96
V37 20 WT
V37 22 WT
G7 18 WT/OR 3
Z2 20 BK
Z2 22 BK
CLOCKSPRING
C2
Z2 20 BK/LG 3
G200
(8W-15-4)
J988W-3
GS003304
NS/GS
BATT A0
(8W-10-8)
8W - 33 - 5
ACCELERATOR
5V SUPPLY 10 ACCELERATOR PEDAL SENSOR SIGNAL 7 ACCELERATOR PEDAL PEDAL POSITION SENSOR SENSOR GROUND (8W-30-38) 8
C3
K6 20 VT/WT
K22 20 OR/DB
K167 20 BR/YL
57 5V SUPPLY STOP LAMP SWITCH SIGNAL 44 F32 18 PK/DB L50 18 WT/TN BRAKE SWITCH SENSE 20 K29 20 WT/PK CLUTCH SWITCH SIGNAL 17 K119 20 LG/BK
FUEL QUANTITY ACTUATOR SIGNAL 4 K140 18 TN/WT 5 K140 18 TN/WT 49 K140 18 TN/WT
BS01
(8W-70-2) L50 18 WT/TN 6 5 3 1 1
TWISTED PAIR
TWISTED PAIR
BS32
CLUTCH SWITCH
K140 18 TN/WT
GROUND 1
B108 E96
Z1 20 BK
Z1 20 BK
Z1 20 BK
FUEL
G300
(8W-15-7) (8W-15-8)
GS003305
J988W-3
NS/GS
8W - 35 ANTI-LOCK BRAKES
8W - 35 - 1
8W - 35 - 2
BATT A0
(8W-10-8)
NS/GS
JUNCTION BLOCK
FUSE 12 10A (8W-12-12) (8W-12-2) BODY CONTROL MODULE (8W-45-5) (8W-12-23)
C3
C4
18 F20 18 WT 23 FUSED IGNITION (RUN) TRACTION CONTROL SWITCH SENSE 22 B27 18 RD/YL
A20 12 RD/DB
A10 12 RD/DG
C2
30 E2 20 OR
C4
9 FUSED B (+)
25 FUSED B (+)
GROUND 8
GROUND 24
Z7 12 BK
Z7 12 BK
A1 1
B23 P34
B27 20 RD/YL 2 3
C4
(8W-12-19)
JUNCTION BLOCK
(8W-12-2)
2 Z1 14 BK 8
C2
G300 G104
(8W-15-6)
J988W-3
GS003502
NS/GS
BATT A0
8W - 35 - 3
(8W-10-8)
(8W-10-16)
JUNCTION BLOCK
FUSE 6 20A (8W-12-9) (8W-12-2)
C3
14
C4
11
F32 18 PK/DB
TWISTED PAIR
V23 18 BR/PK D2 20 WT/BK D1 20 VT/BR
10
MESSAGE CENTER
(8W-46-2)
PS02
(8W-30-4) (8W-30-31) D2 20 WT/BK
PS01
(8W-30-4) (8W-30-31) D1 20 VT/BR
5 *2
13 B13
12 B12
BS01
(8W-70-2)
C2
G19 20 LG/OR 3 A3
P18 B23
D2 18 WT/BK
D1 18 VT/BR
P34 B23
BS06
(8W-30-4) (8W-30-31) D2 18 WT/BK
BS05
(8W-30-4) (8W-30-31) D1 18 VT/BR
G19 18 LG/OR
TWISTED PAIR
12 STOP LAMP SWITCH SENSE 16 ABS WARNING LAMP DRIVER 19 CCD BUS (-) 20 CCD BUS (+)
8W - 35 - 4
NS/GS
B8 18 RD/DB
B9 18 RD
B7 18 WT
B6 18 WT/DB
B4 18 LG
B3 18 LG/DB
B2 18 YL
B1 18 YL/DB
J988W-3
GS003504
NS/GS
8W - 39 - 1
8W - 39 - 2
BATT A0
NS/GS
86
30 HORN RELAY
85 4
87
FUSED B (+)
C2
C2
5 M1 20 PK
C3
16 M1 20 PK
C1
X4 20 GY/OR
X2 18 DG/RD
C2
13
C1
(8W-12-20)
JUNCTION BLOCK
(8W-12-2)
18 HORN RELAY CONTROL HORN RELAY CONTROL 20 C2 X3 20 BK/RD PASSENGER DOOR AJAR SWITCH SENSE 48 C1 G74 18 TN/RD DRIVER DOOR AJAR SWITCH SENSE 79 C1 G75 18 TN
9 FUSED B (+) VTSS LAMP DRIVER 16 C2 G69 22 BK/OR BODY CONTROL MODULE (8W-45-3) (8W-45-7) 6
C4
NOT USED 7 P50 M1 22 PK
BS19
1 X2 18 DG/RD A X2 18 DG/RD
M1 20 PK
M1 20 PK
B Z1 18 BK 13
B Z1 18 BK 1
MESSAGE CENTER
VTSS LAMP (8W-46-2)
G301
(8W-15-10) (8W-15-11)
HORN SWITCH
13 *7 * RHD
J988W-3
GS003902
NS/GS
8W - 39 - 3
BODY CONTROL MODULE
LIFTGATE MUX SIGNAL 44 (8W-45-6) (8W-45-8)
C1
C1
C1
P97 18 WT/DG 11
P96 20 WT/LG 4
P98 20 WT/RD 6 6
B02 D01D
B03 D01P
P96 20 WT/LG 2
P98 20 WT/RD 2
GROUND (8W-61-6) 3
P96 20 WT/LG 2
1 Z2 20 BK/LG Z2 20 BK/LG
D01D B02
D01P B03
Z2 20 BK/LG 3
Z2 20 BK/LG 2 9
G301
(8W-15-10) (8W-15-11)
G400
(8W-15-14)
GS003903
J988W-3
8W - 39 - 4
NS/GS
BODY CONTROL MODULE
(8W-45-7) (8W-45-8)
C1
C1
C1
C1
B17 LJ01
G78 18 TN/BK 4
J03A L16
G78 18 TN/BK 2 2 1 3
Z1 18 BK
Z1 18 BK
Z1 18 BK
Z1 20 BK
14
12
11
G302
(8W-15-13)
G301
(8W-15-10)
G400
(8W-15-14)
J988W-3
GS003904
NS/GS
BATT A0
(8W-10-8)
8W - 39 - 5
C2
F41 20 PK/VT
15
C2
ST-RUN A21
(8W-10-16)
JUNCTION BLOCK
PTC 1 9A (8W-12-13) (8W-12-2)
20
C3
19
C4
F41 20 PK/VT
F87 20 WT/BK
1 FUSED B(+)
GROUND 2
Z2 20 BK
12
G200
TO TO (8W-15-4)
PS01
(8W-30-4)
PS02
(8W-30-4)
GS003905
J988W-3
NS/GS
8W - 40 INSTRUMENT CLUSTER
8W - 40 - 1
8W - 40 - 2
NS/GS
ST-RUN-OFF A81
(8W-10-16)
D1
JUNCTION BLOCK
(8W-12-2)
5 M1 20 PK 13
C3
10
C4
C1
(8W-12-20)
JUNCTION BLOCK
(8W-12-2)
M1 20 PK
F11 20 RD/WT
13
C4
M1 20 PK
16
FUSED B (+)
AW4 B13
2
M1 20 PK
TO
IGNITION SWITCH
(8W-10-14)
FUSED B (+) CCD BUS (+) CCD BUS (-) FUEL GAUGE CONTROL
INSTRUMENT CLUSTER
FUEL GAUGE
10
TWISTED PAIR
G4 18 DB
D1 20 VT/BR
D2 20 WT/BK
Z2 20 BK/LG
PS01
(8W-30-4) (8W-30-31) 46
PS02
(8W-30-4) (8W-30-31) 34
C1
C2
CCD BUS (+)
C2
CCD BUS (-)
G200
(8W-15-4)
GS004002
NS/GS
ST-RUN-OFF A81
(8W-10-16)
8W - 40 - 3
JUNCTION BLOCK
(8W-12-2)
10
C4
F11 20 RD/WT 11 FUSED IGNITION (ST-RUN-OFF) CCD BUS (+) CCD BUS (-)
INSTRUMENT CLUSTER
DOOR AJAR INDICATOR LAMP CONTROL DOOR AJAR INDICATOR LAMP LIFTGATE AJAR INDICATOR LAMP CONTROL LIFTGATE AJAR INDICATOR LAMP
10 D1 20 VT/BR
TWISTED PAIR
D2 20 WT/BK
PS01
(8W-30-4) 3 DRIVER DOOR AJAR SWITCH SENSE 79 G75 18 TN
PS02
(8W-30-4) 34
B17 LJ01
C2
CCD BUS PASSENGER (+) DOOR AJAR SWITCH SENSE 48 G74 18 TN/RD
C2
CCD BUS (-)
C1
RIGHT REAR DOOR AJAR SWITCH SENSE 77
G78 18 TN/BK
J03A L16
C1
C1
C1
C1
G78 18 TN/BK 3
G77 18 TN/OR
G76 18 TN/YL 2
1 Z1 18 BK 14
G302
(8W-15-13)
G400
(8W-15-14) J988W-3
8W - 40 - 4
ST-RUN-OFF A81
D1 (8W-10-16)
NS/GS
JUNCTION BLOCK
(8W-12-2)
C4
F11 20 RD/WT 11 FUSED IGNITION (ST-RUN-OFF) CCD BUS (+) CCD BUS (-)
INSTRUMENT CLUSTER
SEAT BELT INDICATOR LAMP CONTROL SEAT BELT INDICATOR LAMP CLUSTER ILLUMINATION LAMPS
10 D1 20 VT/BR
9 D2 20 WT/BK FROM
13
IGNITION SWITCH
(8W-10-14) GROUND 2 Z1 20 BK
C2
Z1 20 BK
PS02
(8W-30-4) D2 (8W-30-31) 20 WT/BK
C4
(8W-12-23) BODY CONTROL MODULE (8W-45-3) (8W-45-5) (8W-45-7)
28
C4 JUNCTION BLOCK
(8W-12-2)
C2
CCD BUS (+)
34
C2
CCD BUS (-)
(8W-12-19)
C1
2 G10 18 LG/RD 1 2 Z1 20 BK Z1 14 BK 8
C2
G300
(8W-15-6) (8W-15-8) GS004004
NS/GS
8W - 40 - 5
JUNCTION BLOCK
(8W-12-2)
C4
INSTRUMENT CLUSTER
ODOMETER CONTROL ODOMETER TRIP ODOMETER CONTROL TRIP ODOMETER
PS01
(8W-30-4) (8W-30-31)
TWISTED PAIR
(8W-30-4) (8W-30-31)
D2 20 WT/BR 13 B13
TWISTED PAIR
P18 B23
D1 18 VT/BR D2 18 WT/BK
D2 18 WT/BK
BS05
(8W-30-4) (8W-30-31) 7 2
BS06
(8W-30-4) (8W-30-31)
D1 20 VT/BR 3
D2 20 WT/BK 34
C2
CCD BUS (+)
C2
CCD BUS (-)
D1 18 VT/BR 59
D2 18 WT/BK 60
C2
CCD BUS (+)
C2
CCD BUS (-)
GS004005
8W - 40 - 6
NS/GS
JUNCTION BLOCK
(8W-12-2)
C4
F11 20 RD/WT 11 FUSED IGNITION (ST-RUN-OFF) SPEEDOMETER CONTROL SPEEDOMETER TACHOMETER CONTROL TACHOMETER
INSTRUMENT CLUSTER
10 D1 20 VT/BR
9 D2 20 WT/BK
PS01
(8W-30-4)
PS02
(8W-30-4) D2 20 WT/BK
D1 20 VT/BR
TWISTED PAIR
TWISTED PAIR
12 B12 D1 18 VT/BR
13 B13
P18 B23
D2 18 WT/BK
G7 18 WT/OR
BS05
(8W-30-4) 7 2
BS06
(8W-30-4)
D1 20 VT/BR 3
D2 20 WT/BK 34
ES13 (EATX)
D1 (8W-30-4) 18 VT/BR 59
EATX G7 18 WT/OR 66
MTX
D2 (8W-30-4) 18 WT/BK 60
C2
CCD BUS (+)
C2
CCD BUS (-)
C2
CCD BUS (+)
C2
CCD BUS (-)
J988W-3
GS004006
NS/GS
BATT M1
(8W-10-11)
8W - 40 - 7
INSTRUMENT CLUSTER
FUSED B(+) CCD BUS (+) CCD BUS (-) FUSED IGN. (ST-RUN-OFF) SPEEDOMETER CONTROL SPEEDOMETER TACHOMETER CONTROL TACHOMETER
10 D1 20 VT/BR
9 D2 20 WT/BK
TWISTED PAIR
SHIELD
PS01
(8W-30-31)
PS02
(8W-30-31) FROM Z122 18 BK
BS40
(8W-15-3)
E96 B108
ES30
Z1 18 BK (8W-15-3) Z122 18 BK 7
K24 20 GY/BK
G7 18 WT/OR
TWISTED PAIR
E97 B106
G7 18 WT/OR 43 VEHICLE SPEED SENSOR SIGNAL
BS30
K24 18 GY/BK 8 Z12 18 BK 6 ENGINE SPEED SENSOR SIGNAL 2 ENGINE SPEED SENSOR SIGNAL
G301
(8W-15-12)
D1 20 VT/BR 3
D2 20 WT/BK 34
K159 20 VT/RD 75
G7 18 WT/OR 42
C2
CCD BUS (+)
C2
CCD BUS (-)
C1
GS004007
8W - 40 - 8
ST-RUN-OFF A81
D1 (8W-10-16)
NS/GS
10
C4
F11 20 RD/WT 11 FUSED IGNITON (ST-RUN-OFF) CCD BUS (+) CCD BUS (-)
INSTRUMENT CLUSTER
ENGINE COOLANT TEMPERATURE GAUGE CONTROL ENGINE COOLANT TEMPERATURE GAUGE CHARGING SYSTEM INDICATOR CONTROL VOLTS INDICATOR LAMP
10 D1 20 VT/BR
9 D2 20 WT/BK
PS01
(8W-30-4)
D1 20 VT/BR
TWISTED PAIR
TWISTED PAIR
12 B12 D1 18 VT/BR
13 B13
P18 B23
2.0L 2.4L 12
OTHERS 3.3L/3.8L
D2 18 WT/BK
BS05
(8W-30-4) 7 D1 20 VT/BR 3 D2 20 WT/BK 34 2
BS06
(8W-30-4)
F09 E69
11
F02 E78
ES13 (EATX)
D1 (8W-30-4) 18 VT/BR
C2
CCD BUS (+)
C2
CCD BUS (-)
D2 (8W-30-4) 18 WT/BK 60
K2 18 TN/BK 26
59
C2
CCD BUS (+)
C2
CCD BUS (-)
J988W-3
NS/GS
BATT M1
(8W-10-11)
8W - 40 - 9
INSTRUMENT CLUSTER
FUSED B(+) CCD BUS (+) CCD BUS (-) ENGINE COOLANT TEMPERATURE GAUGE CONTROL FUSED IGNITION (ST-RUN-OFF) CHARGING SYSTEM INDICATOR CONTROL ENGINE COOLANT TEMPERATURE GAUGE 10 D1 20 VT/BR 9 D2 20 WT/BK SCI TRANSMIT 61 D21 20 PK VOLTS INDICATOR LAMP
TWISTED PAIR
B17 17 D21 20 PK 7
B23 P18
G58 20 BK/YL
3 D1 20 VT/BR
11 D2 20 WT/BK 3
TWISTED PAIR
E120 B33
PS01
(8W-30-31)
TWISTED PAIR
D1 20 VT/BR 3 D2 20 WT/BK 34
PS02
(8W-30-31) G58 20 BK/YL 60
C2
CCD BUS (+)
C2
CCD BUS (-)
GS004009
8W - 40 - 10
ST-RUN-OFF A81
D1 (8W-10-16)
NS/GS
10
C4
F11 20 RD/WT 11 FUSED IGNITION (ST-RUN-OFF) CCD BUS (+) CCD BUS (-)
LOW WASHER FLUID LEVEL INDICATOR CONTROL LOW WASHER FLUID LEVEL INDICATOR LAMP
INSTRUMENT CLUSTER
10 D1 20 VT/BR
9 D2 20 WT/BK
PS01
(8W-30-4)
PS02
(8W-30-4) D2 20 WT/BK 4
CLOCKSPRING
D1 20 VT/BR
TWISTED PAIR
12 B12 D1 18 VT/BR
13 B13
P18 B23
C2
D2 18 WT/BK
BS05
(8W-30-4) D1 20 VT/BR 3 D2 20 WT/BK 34 G29 20 BK/TN 58 7 2
BS06
(8W-30-4)
P34 B23
V37 20 RD/LG 8
B70 E43
C2
CCD BUS (+)
C2
CCD BUS (-)
C1
D2 (8W-30-4) 18 WT/BK 60
V37 18 RD/LG 41
C2
CCD BUS (+)
C2
CCD BUS (-)
J988W-3
NS/GS
BATT M1
(8W-10-11)
8W - 40 - 11
INSTRUMENT CLUSTER
FUSED B(+) CCD BUS (+) CCD BUS (-) CRUISE INDICATOR LAMP CONTROL CRUISE INDICATOR LAMP FUSED IGNITION (ST-RUN-OFF) LOW WASHER FLUID LEVEL INDICATOR CONTROL LOW WASHER FLUID LEVEL INDICATOR LAMP
10 D1 20 VT/BR
9 D2 20 WT/BK
TWISTED PAIR
PS01
(8W-30-31)
PS02
(8W-30-31) V37 20 WT
LOW
WASHER WASHER FLUID FLUID SWITCH SENSE SWITCH (8W-53-3) B 4
CLOCKSPRING
C2
TWISTED PAIR
P34 B23
D1 20 VT/BR 3
D2 20 WT/BK 34
G29 20 BK/TN 58
V38 20 LB/RD 56
V38 20 LB/RD 27
C2
CCD BUS (+)
C2
CCD BUS (-)
C1
GS004011
NS/GS
8W - 41 - 1
8W - 41 - 2
BATT A0
(8W-10-8)
NS/GS
85 4
87
C2
C2
X4 20 GY/OR 4 18 HORN RELAY CONTROL HORN RELAY CONTROL 20 C2 X3 20 BK/RD BODY CONTROL MODULE (8W-45-3)
X2 18 DG/RD
C2 JUNCTION BLOCK
(8W-12-2)
BS19
X2 18 DG/RD X2 18 DG/RD
C2
A
CLOCKSPRING
Z1 18 BK 13 1
Z1 18 BK
HORN SWITCH
G301
(8W-15-10) (8W-15-11)
J988W-3
GS004102
NS/GS
RUN-ACC A31
8W - 41 - 3
JUNCTION BLOCK
PTC 7 9A (8W-12-16) (8W-12-2)
16 F1 20 DB 9
C2
C2
BATT A0
(8W-10-8)
85 2
87
10 F30 16 RD
C2
C1
A22 22
B23 P34
Z1 18 BK *2
E2 20 OR 1
F30 16 RD
F30 16 RD
G300
(8W-15-7)
G200
(8W-15-4)
G302
(8W-15-13)
GS004103
* BUILT-UP-EXPORT
J988W-3
NS/GS
8W - 42 AIR CONDITIONING-HEATER
8W - 42 - 1
8W - 42 - 2
NS/GS
10
C2
C2
BATT A0
(8W-10-8)
C4
3 C71 12 DB
C1
B32 32
B34 34
B33 33
B30 30
B31 31
B23 P18
Z1 18 BK
B35 35 1
C4 16 TN
C5 16 LG
C6 14 LB
C104 12 RD/WT
C107 12 TN/BK
M 10
B23 P18 FRONT BLOWER MOTOR REAR BLOWER FRONT CONTROL SWITCH
(8W-42-6)
G300
(8W-15-7)
2 C7 12 BK/TN GROUND 7
C2
C2
C2
2 1 0
3 3 4
C2
C2
10
GROUND
6 Z1 12 BK
C2
Z1 12 BK
G201
J988W-3 (8W-15-4) GS004202
NS/GS
8W - 42 - 3
POWERTRAIN CONTROL MODULE
(8W-30-37)
JUNCTION BLOCK
(8W-12-2)
C4
(8W-40-4)
E2 20 OR
V26 22 YL/WT
E2 20 OR
11
C1
C1
B23 P18 C1
2 1
4 5
MODE SELECT
GROUND RIGHT LEFT TEMP. TEMP. CONTROL CONTROL REAR SENSE SENSE WASHER WIPER ON SWITCH WIPER ON INDICATOR GROUND SENSE SWITCH DRIVER
ELECTRIC A/C ON-OFF WIPER DE-ICE SWITCH DRIVER SIGNAL DELAY ON DELAY INDICATOR SWITCH DRIVER SENSE
ILLUMINATION LAMP
6 Z1 12 BK TO
21
C1
Z2 18 BK/LG 5
GROUND 7 (8W-42-6) Z1 12 BK
G200
(8W-15-4)
G201
(8W-15-4) J988W-3
8W - 42 - 4
MESSAGE CENTER
(8W-46-2)
NS/GS
JUNCTION BLOCK
86 (8W-12-2) REAR WINDOW DEFOGGER RELAY (8W-48-2) 85
14
C4
32
C4
V23 18 BR/PK 10
C14 22 WT/RD 1
C1
A/C SWITCH
A/C ON INDICATOR
21
C1
Z2 18 BK/LG 5
G200
(8W-15-4)
J988W-3
GS004204
NS/GS
8W - 42 - 5
BLEND DOOR ACTUATOR
M 1
C61 20 DB 9 A TO
J01D P30
P34
(8W-42-6)
C36 22 RD/WT
P34
(8W-42-6)
C1
15
C1
C1
C1
C1
C1
C1
SENSOR GROUND
5V SUPPLY
BLEND DOOR FEEDBACK SIGNAL EVAP. TEMP. SENSOR SENSOR SIGNAL GROUND
HVAC CONTROL
19
C1
12
C1
18
C1
C1
6 C37 22 YL 8 C37 20 YL
C1
20
C1
C1
C35 22 DG/YL 6
C21 22 DB/OR 12
P30 J01D
JS03
(8W-70-9) C34 20 DB/WT 5 1 C34 20 DB/WT 1 C35 20 DG/YL 5 2
JS01B JS02B
(8W-70-10) C57 C57 20 20 DB/GY DB/GY 2 (8W-70-10) C21 20 DB/OR 1
GS004205
J988W-3
8W - 42 - 6
NS/GS
JUNCTION BLOCK
(8W-12-2) FUSE 11 20A (8W-12-11) (8W-12-23)
1 E2 20 OR 8
C1
30 E2 20 OR 8
C4
12
C2
C40 12 BR/WT
0 1 1 C60 16 BK/LB 2 2
0 1 2 3
C60 16 BK/LB
G302
(8W-15-13) 31 A31 33 A33
G201
35 A35
P34 B23
(8W-15-4)
FROM
FROM
C61 20 DB
P34 B23
C61 20 DB C60 16 BK/LB 5 C70 12 DG 4 6 3
J988W-3
GS004206
NS/GS
ST-RUN A21
(8W-10-16)
8W - 42 - 7
30
C1 ES07
(8W-12-13) F87 18 BK/WT 1
F87 18 WT/BK
F87 18 WT/BK 6
C2
C6
C6
BATT A0
(8W-10-8)
(8W-12-13)
86
85 7
87
C6
C3 18 DB/BK 1
C13 18 DB/OR
K6 18 VT/WT
ES03
(8W-70-7)
ES02
(8W-70-4) 5
FS01
(8W-70-5)
ES21
(8W-70-6)
ES23
(8W-15-2) Z1 12 BK K6 18 VT/WT
ES21
(8W-70-4)
ES21 G102
(8W-15-2) (8W-70-5)
64
C2
61
C2
42
C2
43
5V SUPPLY
SENSOR GROUND
8W - 42 - 8
NS/GS
6 A16 12 GY 4
C7
FUSED B (+) RADIATOR FAN RELAY OUTPUT 3 C23 12 DG 1 C23 12 DG RADIATOR FAN RELAY CONTROL 2
GROUND 1 Z1 14 BK
E40 RF3
K173 14 LG/DB
RFS1
C23 12 DG 1 1 C23 12 DG
M 2 Z1 12 BK
Z1 12 BK
RFS2
Z1 12 BK 2 Z1 12 BK
RF3 E40
ES23
Z1 12 BK (8W-15-2)
73
G102
(8W-15-2) J988W-3
NS/GS
8W - 42 - 9
ES29
(8W-10-25) A142 18 DG/OR 1
A142 18 DG/OR
C6
BATT A0
(8W-10-8)
C6
BATT A0
(8W-10-8)
C6
C6
C13 20 DB/OR
C3 18 DB/BK 1
E97 B106
Z1 16 BK
BATTERY ES02
(8W-15-3) (8W-20-3)
ES01
(8W-15-3)
Z0 6 BK
Z0 2 BK
K7 20 OR
C18 20 DB
K4 20 BK/LB
G103 G100
19 5V SUPPLY 13 A/C PRESSURE SWITCH SIGNAL 33
BS34
(8W-70-11) SENSOR GROUND
8W - 42 - 10
NS/GS
6 A16 12 GY
C7 BATT A17
(8W-10-19)
ES29
A142 18 DG/OR 4 C116 12 LG/WT 8 A142 18 DG/OR 4 8 (8W-10-25) A142 18 DG/OR 4 A17 12 RD/BK 8
ES07 ES09
C27 12 DB/PK 4 DRIVERS M SIDE RADIATOR FAN 3 1 Z1 12 BK 2 PASSENGERS M SIDE RADIATOR FAN
ES12
1
E95 B107
10
E97 B106
(8W-15-3) Z1 12 BK
G102
(8W-15-3)
J988W-3
GS004210
NS/GS
8W - 43 AIRBAG SYSTEM
8W - 43 - 1
8W - 43 - 2
ST-RUN F87
(8W-10-26)
NS/GS
C5
C5
BUILT-UP -EXPORT
EXCEPT BUILTUP-EXPORT
F14 18 LG/YL
F14 20 LG/YL
BUILT-UP -EXPORT
EXCEPT BUILTUP-EXPORT
F23 18 DB/YL
F23 20 DB/YL
CLOCKSPRING
C1
C1
B23 23
B24 24
B23 P18
TWISTED PAIR
F14 18 LG/YL
F23 18 DB/YL
R43 18 BK/LB
R45 18 DG/LB
C2
C2
C1
C2
Z2 18 BK/LG
G204
(8W-15-4) J988W-3 GS004302
NS/GS
ST-RUN A21
8W - 43 - 3
(8W-10-16)
JUNCTION BLOCK
(8W-12-2) FUSE 6 20A (8W-12-9) PASSENGER AIRBAG LINE NO. 1 2 14 PASSENGER AIRBAG LINE NO. 2 1
C4
V23 18 BR/PK
MESSAGE CENTER
AIRBAG INDICATOR LAMP (8W-46-2)
R42 18 BK/YL 11
R44 18 DG/YL
D1 20 VT/BR 11 *9
D2 20 WT/BK
TWISTED PAIR
R41 18 BK/TN
TWISTED PAIR
PS01
(8W-30-4) (8W-30-31) D1 20 VT/BR
PS02
(8W-30-4) (8W-30-31) D2 20 WT/BK
C2
C2
CCD BUS (+)
C2
CCD BUS (-)
C1
NS/GS
8W - 44 INTERIOR LIGHTING
8W - 44 - 1
8W - 44 - 2
BATT A0
(8W-10-8)
NS/GS
C2
F41 20 PK/VT 15
C2 JUNCTION BLOCK
86 30 COURTESY LAMP RELAY (8W-12-2)
85
87 D4
20
C3
F41 20 PK/VT 1
34 C3 M111 22 BR/WT 9
19
C2
C1
C1
FRONT READING LAMP DEFEAT SWITCH
F41 20 PK/VT
HEADLAMP SWITCH
(8W-50-9) (8W-50-10)
B75 C20
C1
10
C1
OVERHEAD CONSOLE
2 M20 20 BR
M112 22 BR/LG
M13 20 BK/YL
10 17
C3
BODY CONTROL MODULE (8W-45-4) (8W-45-8) READING LAMP GROUND 80
CS02
(8W-10-20) 1 4 3
5 B5
P18 B23
C1
M20 20 BR 6 OVERHEAD CONSOLE 2 OTHERS
M20 20 BR
1 J988W-3
B75 C20
M20 20BR
CS03
(8W-70-3) GS004402
NS/GS
BATT A0
(8W-10-8)
8W - 44 - 3
C2
F41 20 PK/VT 15
C2
86 30 COURTESY LAMP RELAY (8W-44-2) 85 87
JUNCTION BLOCK
(8W-12-2)
19
C2
29
C3
29
C2
M11 20 PK/LB
F41 20 PK/VT 2
M11 20 PK/LB
M11 20 PK/LB 3
B01 D02
M1 20 PK/LB 2 1
B03 D01P
(8W-10-20)
M11 20 PK/LB
1 Z1 20 BK
Z1 20 BK
A M20 20 BR
A M20 20 BR (8W-12-19)
36
C4 JUNCTION BLOCK
(8W-12-2) Z1 12 BK 10 Z1 12 BK 5
CS03
1
C2
Z1 14 BK
D01D B02
Z1 18 BK 11
D01P B03
TO
5 2
80
G300
(8W-15-6) (8W-15-7)
GS004403
J988W-3
8W - 44 - 4
BATT A0
(8W-10-8)
NS/GS
C2
F41 20 PK/VT 15
C2
86 30 COURTESY LAMP RELAY (8W-44-2) 85 87 D4
JUNCTION BLOCK
(8W-12-2)
19
C2
22
C2
C2
F41 20 PK/VT 2
M113 20 LB/PK 4
M11 20 PK/LB 3
F41 20 PK/VT
B75 C20
2 M20 20 BR 2
2 M20 20 BR 2
M2 20 BR
CS03
1 M2 20BR 5 80
G400
(8W-15-14) GS004404
NS/GS
8W - 44 - 5
C1
C1
C1
C1
C1
C1
G70 18 BR/TN
G77 18 TN/OR
G74 18 TN/RD
G76 18 TN/YL
G78 18 TN/BK 4
B17 LJ01
G78 18 TN/BK 4
J03A L16
G78 18 TN/BK 2 3
G400
(8W-15-14)
G301
(8W-15-10)
G302
(8W-15-13)
GS004405
J988W-3
8W - 44 - 6
ST-RUN A21 BODY CONTROL MODULE
(8W-45-8)
NS/GS
RUN A22
(8W-10-14)
JUNCTION BLOCK
FUSE 6 20A (8W-12-9) FUSE 12 10A (8W-12-12) (8W-12-2)
C1
14
C1
C2
L24 20 WT/LG 18
V23 18 BR/PK 11
L24 20 WT/LG
MTX F20 20 WT
V23 18 BR/PK 1
B33 E36
DIESEL 5 F20 20 WT
GAS 5 F20 18 WT
6 L24 20 WT/LG 7 AUTOMATIC HEADLAMP SIGNAL POWER MIRROR B(-) 4 P112 20 YL/WT 4 POWER MIRROR B(-) 5 P114 20 YL/BK 5
C19 EC1
F20 18 WT
B33 E120
B33 E36
V23 18 BR/PK 1 FUSED IGNITION (ST-RUN) BACK-UP LAMP GROUND FEED 2 Z1 20 BK 3 L1 20 VT/BK
R 6
BACK-UP SWITCH
EC1 C19
L1 18 VT/BK DIESEL 10
GAS 10
E120 B33
E36 B33
19
20
Z1 20 BK
L1 20 VT/BK
10
E36 B33
EATX MTX L1 20 VT/BK
A18 18
13 Z1 20 BK
P114 20 YL/BK 4
C20 B75
L1 20 VT/BK
BS02
(8W-70-2)
C1
G300
(8W-15-5)
J988W-3
GS004406
NS/GS
BATT A0
(8W-10-8)
8W - 44 - 7
85 10
87
C3
C1
L97 18 PK/DB 9
L7 12 BK/YL 2
C2
C1 JUNCTION BLOCK
(8W-12-2) FUSE 3 15A (8W-12-8) FUSE 1 10A (8W-12-8) 1 FUSED PARK LAMP COURTESY LAMP RELAY OUTPUT SWITCH SENSE 2 BODY CONTROL MODULE (8W-45-4) (8W-45-5)
C2
C2
C2
C2
C2
C4
E2 20 OR M32 22 BK/LB
E17 20 YL/BK 5
C2
C1
C1
C1 HEADLAMP SWITCH
(8W-50-9) (8W-50-10)
C1 RADIO
(8W-47-2)
FROM
MESSAGE CENTER
(8W-46-4)
2 Z2 20 BK/LG Z2 20 BK/LG Z1 18 BK
C2
6 Z1 20 BK
C1
Z1 14 BK 8 2
OTHER 22 (8W-12-19)
OVERHEAD
C4
29
C4
21
C4
C2 JUNCTION BLOCK
(8W-12-2) * RHD
G300
(8W-15-6)
GS004407
J988W-3
8W - 44 - 8
NS/GS
JUNCTION BLOCK
(8W-12-2)
C4
30
C4
E2 20 OR E2 20 OR 11
C4
2 E2 20 OR
1 E2 20OR
C1
E2 20 OR 5
E2 20 OR
11 3
(8W-42-3)
C2
Z1 12 BK
CS06
(8W-49-3) 9
Z2 18 BK/LG 5
C20 B75
G200
(8W-15-4)
G301
(8W-15-11)
E2 20 OR
Z1 20 BK
Z1 20 BK 7 Z1 12 BK 35
INSTRUMENT CLUSTER
(8W-40-4)
G302
(8W-15-13)
IGNITION SWITCH
(8W-10-14) GROUND 2 Z1 20BK 28
C2
C4
G201
C4 JUNCTION BLOCK
(8W-12-2)
(8W-12-19)
2 5
C2
Z1 14 BK
C1 RADIO
(8W-47-2) 8
G300
(8W-15-6)
J988W-3
GS004408
NS/GS
8W - 44 - 9
C1
E2 20 OR
B02 D01D
E2 20 OR 6
11 E2 20 OR 1
B03 D01P
E2 20 OR
14 3 Z2 20 BK/LG
7 Z1 20 BK
3 Z2 20 BK/LG
13 Z1 12 BK
GROUND (8W-44-3) 2 Z1 20 BK
DS01
(8W-15-7) 3 10 5 Z2 20 BK/LG 3
5 Z1 18 BK 11
D01P B03
D01D B02
Z2 20 BK/LG
G300
(8W-15-7)
G301
(8W-15-10) (8W-15-11)
GS004409
J988W-3
NS/GS
8W - 45 - 1
8W - 45 - 2
BATT A0
(8W-10-8)
NS/GS
BATT A1
(8W-10-16)
IGNITION SWITCH
1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-14)
C3
FUSED B (+) 16 M1 20 PK
M1 20 PK
C3
C1
C1
A21 12 DB
C1
A81 20 DG/RD
A31 12 BK/WT
13
C1
15
C4
D1
31
C3
31
C4 JUNCTION BLOCK
(8W-12-2) FUSE 6 20A (8W-12-9)
(8W-12-20)
(8W-10-16)
FUSE 2 10A (8W-12-9) 9 FUSED B (+) GROUND 10 C2 GROUND 14 C2 29 Z2 20 BK/LG Z2 20 BK/LG Z1 20 BK 6 Z1 18 BK 7 FUSED IGN. (ST-RUN-OFF) 14 FUSED IGN. (RUN-ACC) GROUND 4 11 12 FUSED IGN. (ST-RUN)
C4
21
C4
C2
Z1 14 BK
C1
C2 HEADLAMP SWITCH
(8W-50-9) (8W-50-10)
GROUND
GROUND
G300
(8W-15-6)
J988W-3
GS004502
NS/GS
BATT A0
(8W-10-8)
8W - 45 - 3
86
85 4
85
87
C2
10
C3
C1
X4 20 GY/OR 4
L97 18 PK/DB 9
L7 12 BK/YL 2
C2
C2
C1 JUNCTION BLOCK
(8W-12-2) FUSE 3 15A (8W-12-8) FUSE 1 10A (8W-12-8) 1 FUSED PARK LAMP RELAY OUTPUT BODY CONTROL MODULE
16 PARK LAMP RELAY CONTROL WIPER PARK SWITCH SENSE 41 WASHER FLUID SWITCH SENSE 58 G29 20 BK/TN
C2
C1
C1
C1
C2
C2
E92 22 OR/BK
D1 20 VT/BR
TWISTED PAIR
D2 20 WT/BK
WIPER MODULE
(8W-53-2)
PS01
(8W-30-4) (8W-30-31) D1 20 VT/BR 3
PS02
(8W-30-4) (8W-30-31) D2 20 WT/BK 11
C2
TWISTED PAIR
12
C1
HORN CLOCKSPRING RELAY (8W-41-2) CONTROL
8W - 45 - 4
BATT A0
(8W-10-8)
NS/GS
REAR
C5
V14 18 RD/VT
REAR
L16 J03A
V13 18 BR/LG 7
LJ01 B17
V13 18 BR/LG 49
C3
(8W-53-5) BODY CONTROL MODULE
73
C1
50
C1
C1
C2
JUNCTION BLOCK
(8W-12-2)
GROUND 4
C2
C2
C2
C2
C2
10
C3
21
C4
RADIO
STEP (8W-47-2) DIMMER SWITCH SENSE M112 4 C1 22 BR/LG E17 20 YL/BK
L307 20 LG/OR
L308 20 LG/WT
L110 22 BK/YL
M32 22 BK/LB
E17 20 YL/BK
Z1 18 BK
Z1 20 BK
C2
C2
C2
C1
C1
C1
C2
C1 HEADLAMP SWITCH
(8W-50-9) (8W-50-10)
J988W-3
GS004504
NS/GS
8W - 45 - 5
86
L93 22 PK
MESSAGE
L193 20 OR/WT VTSS CENTER INDICATOR (8W-46-2) LAMP DRIVER 13 *7 G69 22 BK/OR 33
C3
HIGH/LOW BEAM RELAY CONTROL 12 LEFT REAR TURN SIGNAL 4 19 LEFT REAR TURN SIGNAL PANEL LAMPS FEED 2 RIGHT REAR TURN SIGNAL 5 21 RIGHT REAR TURN SIGNAL BODY CONTROL MODULE COMBINATION FLASHER/ DRL MODULE (8W-50-2) (8W-50-12) (8W-51-3)
JUNCTION BLOCK
(8W-12-2)
76
C1
16
C2
C2
8 E2 20 OR 6 PANEL LAMPS FEED E2 20 OR
C4
30
C4
E2 20 OR 3 PANEL LAMPS FEED E2 20 OR E2 18 OR
23 E2 20 OR
C4
1 E2 20 OR
C4
E2 20 OR 5 PANEL LAMPS FEED
INSTRUMENT CLUSTER
(8W-40-4)
G26 20 LB
TO
E2 20 OR
C1 RADIO
(8W-47-2)
IGNITION SWITCH
(8W-10-14)
11
C2 HEADLAMP SWITCH
(8W-50-9) (8W-50-10) J988W-3
8W - 45 - 6
MESSAGE ENGINE ENGINE OIL TEMPERATURE CENTER PRESSURE WARNING (8W-46-2) LAMP SWITCH DRIVER SENSE
8 *12 6 *1
NS/GS
LIFTGATE
LIFTGATE ARM/ LOCK/ DISARM UNLOCK SWITCH MUX (8W-39-3) 2 P98 20 WT/RD 6
RKE INTERFACE 19
C1
G96 20 LG/RD B23 A23 23 P34 G96 20 LG/RD 6 RKE INTERFACE RKE PROGRAM SIGNAL 5 G6 22 GY 33 G2 22 VT D9 22 GY/BK G96 20 LG/RD 1
L16 J03A
P98 20 WT/RD
C1
LJ01 B17
P98 20 WT/RD 44
V26 22 YL/WT 38
C2
C2
37
C2
C2
C1
C2
BODY CONTROL MODULE
JUNCTION BLOCK
(8W-12-2)
ENGINE ENGINE OIL TEMPERATURE PRESSURE WARNING LAMP SWITCH DRIVER SENSE ABS WARNING LAMP DRIVER 17
RKE INTERFACE
C2
1 ABS WARNING CENTER (8W-46-2) LAMP DRIVER 5 *2 G19 20 LG/OR TO
C1
E2 20 OR
C1
E2 20 OR E2 20 OR
MESSAGE
8 E2 20 OR
G19 20 LG/OR
4 E2 20 OR
B02 D01D
11 E2 20 OR 1
B03 D01P
3 A3
P34 B23
G19 18 LG/OR 16
E2 20 OR
* RHD
NS/GS
8W - 45 - 7
BATT A2
(8W-10-13)
JUNCTION BLOCK
(8W-12-2) PTC 3 9A (8W-12-14) (8W-12-15)
85
85
85
6 DOOR UNLOCK RELAY CONTROL DRIVER DOOR AJAR SWITCH SENSE 79 PASSENGER DOOR AJAR SWITCH SENSE 48
5 DRIVER UNLOCK RELAY CONTROL FUEL LEVEL SENSOR SIGNAL 46 LIFTGATE AJAR SWITCH SENSE 59 HOOD AJAR SWITCH SENSE 43 BODY CONTROL MODULE
C1
G6 20 GY
C1
C1
G75 18 TN
C1
C1 B13 AW4
G4 18 DB
C1
C1
G10 18 LG/RD
G74 18 TN/RD
G78 18 TN/BK 4
G70 18 BR/TN
B17 LJ01
1 HOOD AJAR SWITCH SENSE
B33 E36
1 SEAT BELT SWITCH SENSE
G78 18 TN/BK
J03A L16
G78 18 TN/BK 3
LIFTGATE
J988W-3
8W - 45 - 8
LEFT MID READING LAMP
(8W-44-4)
NS/GS
RIGHT REAR READING LAMP
(8W-44-4)
1 M20 20 BR 5 B5 M20 20 BR
C20 B75
OTHER
(8W-70-3)
PASSENGER PASSENGER PASSENGER DOOR DOOR DOOR SWITCH ARM/ LOCK DISARM MUX SWITCH SWITCH 2 (8W-61-2)
(8W-61-6) P96 20 WT/LG (8W-39-3)
OTHER
RKE
P18 B23
M20 20 BR
11
BS10
M20 20 BR
D01D B02
P96 20 WT/LG 4
D01P B03
P97 20 WT/DG
P96 20 WT/LG
45
C1
RIGHT REAR DOOR AJAR SWITCH SENSE 77
55
C1
C1
G76 18 TN/YL 2
NS/GS
8W - 45 - 9
C1
C1
C1
C1
C1
C1
C1
BS30
(8W-30-36) G7 18 WT/OR 43 VEHICLE SPEED SENSOR SIGNAL
G58 20 BK/YL
B33 E120
BACK-UP SWITCH
(8W-51-5)
2 Z1 20 BK
ES02
(8W-15-3) L1 18 VT/BK 10 Z1 16 BK
E120 B33
ES01
(8W-15-3)
L1 20 VT/BK
BATTERY
(8W-20-3) Z1 10 BK
BS02
(8W-70-2) L1 20 VT/BK 2 2 BACK-UP LAMP FEED GS004509
B13 AW4
1 G4 18 DB Z1 16 BK 1 GROUND 5
B13 AW4
Z1 14 BK
Z0 6 BK
Z0 2 BK
B13 AW4
3
G100 G302
(8W-15-13)
G103
J988W-3
8W - 45 - 10
NS/GS
BATT F41
(8W-10-20)
JUNCTION BLOCK
(8W-12-2) 86 87 87A POWER MIRROR FOLD RELAY (8W-62-8) 85 30 30 30 85 87A 87 86 POWER MIRROR UNFOLD RELAY (8W-62-8)
(8W-12-19)
C2
11
C3
11
C4
36
C1
36
C4
C2
P171 20 VT/WT
P160 20 LB
P160 20 LB
P159 20 DG
P159 20 DG
FROM
C2
M
C2
M
Z1 14 BK
C2
C2
1 1
P174 20 YL/RD
P136 20 YL
G300
(8W-15-6)
71
C1
74
C1
39
J988W-3
GS004510
NS/GS
8W - 46 MESSAGE CENTER
8W - 46 - 1
8W - 46 - 2
NS/GS
POWER DISTRIBUTION CENTER
(8W-10-9)
ST-RUN A21
(8W-10-16)
13
C1 JUNCTION BLOCK
(8W-12-2) NOT USED 7 P50 M1 20 PK 5 M1 20 PK 16 3 FUSED B (+) FUSE 28 10A (8W-10-11)
(8W-12-20)
C3
14
C4
V23 18 BR/PK 10
6 M1 20 PK
C4
M1 20PK
M1 22 PK
V23 18 BR/PK
FUSED B (+)
10
MESSAGE CENTER
ABS WARNING LAMP 5 *2 G19 20 LG/OR 3 A3 6 *1 ENGINE COOLANT TEMPERATURE LAMP 8 *12 LOW OIL PRESSURE LAMP 11 *9 R41 18 BK/TN 7 AIRBAG WARNING LAMP 13 *7 G69 22 BK/OR VTSS LAMP
P34 B23
G2 22 VT G19 20 LG/OR
G6 22 GY
17
C2
C2
33
C2
ENGINE OIL PRESSURE SWITCH SENSE 52 C1 G6 20GY GAS 9
G19 18 LG/OR
DIESEL
B33 E36
G6 16 GY
B33 E36
NS/GS
ST-RUN A21
(8W-10-16)
8W - 46 - 3
JUNCTION BLOCK
FUSE 6 20A (8W-12-9) (8W-12-2)
14
C4
V23 18 BR/PK
V23 18 BR/PK 10 GAS SERVICE ENGINE SOON LAMP 7 *13 G3 20 BK/PK 7 G85 20 OR/BK DIESEL GLOW PLUG LAMP 9 *11 G9 20 GY/BK 8 BRAKE WARNING LAMP
MESSAGE CENTER
10
C3
10 BRAKE LAMP SENSE COMBINATION FLASHER/ DRL MODULE (8W-50-13)
2 A2
17 A17
JUNCTION BLOCK
(8W-12-2)
P34 B23
G3 20 BK/PK
G85 20 OR/BK
EATX
MTX
C3
C2
C2
G9 20 GY/BK 2
B70 E43
G3 18 BK/PK
G9 20 GY/BK A
C1 IGNITION SWITCH
1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-14)
1 2 0 1 Z1 20 BK 14 3
22
C1
SERVICE POWERTRAIN ENGINE CONTROL SOON MODULE INDICATOR (8W-30-13) LAMP (8W-30-19) DRIVER (8W-30-27)
C1
Z1 20 BK
G300
(8W-15-8)
G200
(8W-15-4)
GS004603
J988W-3
8W - 46 - 4
BATT A0
(8W-10-8)
NS/GS
86
85
87
C3
C5
L324 20 WT/LG
L34 20 RD/OR
B21 21
B18 FROM 18
B23 P18
L324 22 WT/LG
MESSAGE CENTER
12
10
9 L93 22 PK 33 12
3 *4 Z1 20 BK
C3
15 COMBINATION FLASHER/ DRL MODULE (8W-50-2) HIGH/ LOW BEAM RELAY CONTROL BODY CONTROL MODULE (8W-45-5) (8W-12-19)
22
C4 JUNCTION BLOCK
(8W-12-2)
2 Z1 18 BK 13 8 Z1 14 BK
C2
G200
(8W-15-4)
G300
(8W-15-6)
NS/GS
8W - 46 - 5
LEFT REAR TURN SIGNAL 19 COMBINATION FLASHER/ DRL MODULE (8W-51-3) (8W-52-2)
JUNCTION BLOCK
(8W-12-2)
26
C3
C3
22
C3
21
C3
14
C3
28
C2
36
C2
L91 20 DB/PK
L91 22 DB/PK
L305 22 LB/WT
L302 22 LB/YL
L63 18 DG/RD
L62 18 BR/RD
MESSAGE CENTER
L63 18 DG/RD
L62 18 BR/RD
3 *4
1 RIGHT REAR TURN SIGNAL Z1 20 BK **1 5 RIGHT REAR TURN SIGNAL 1 LEFT REAR TURN SIGNAL **1 5 LEFT REAR TURN SIGNAL
C4 JUNCTION BLOCK
(8W-12-2)
2 Z1 18 BK 13 8 Z1 14 BK
C2
G200
(8W-15-4)
G300
(8W-15-6)
GS004605
J988W-3
NS/GS
8W - 47 AUDIO SYSTEM
8W - 47 - 1
8W - 47 - 2
NS/GS
C3
RUN-ACC A31
(8W-10-16)
C1 JUNCTION BLOCK
(8W-12-2)
FUSED B (+) 9
24
C3
1 E2 20 OR X12 20 RD/WT
C4
E2 20 OR
X12 18 RD/WT
17 M1 20 PK
C4
M1 20 PK
E17 20 YL/BK
16
HEADLAMP
STEP SWITCH DIMMER (8W-50-9) SWITCH (8W-50-10) SENSE 5 C1
TO
TO
PS01
(8W-30-4)
PS02
(8W-30-4)
E17 20 YL/BK 6
D1 20 VT/BR 7
D2 20 WT/BK 2
C1
C1
C1
C1
C3
C3
CCD BUS (-)
RADIO
G202
J988W-3 (8W-15-5) GS004702
NS/GS
8W - 47 - 3
X51 20 BR/YL
X57 20 BR/LB
X52 20 DB/WT
X58 20 DB/OR
A9 9
A7 7
A10 10
A8 8
B23 P34
X55 20 BR/RD
X53 20 DG
X51 20 BR/YL
X57 20 BR/LB
X52 20 DB/WT
X58 20 DB/OR
X54 20 VT
X56 20 DB/RD
C1
C2
C2
C2
C2
C2
C2
C1 RADIO
GS004703
J988W-3
8W - 47 - 4
NS/GS
JUNCTION BLOCK
(8W-12-2) FUSE 8 10A (8W-12-11)
86
85
87
(8W-12-19)
13
C3
C2
Z1 14 BK
22
C1
X60 20 RD/DG
X1 16 DG/RD
G300
(8W-15-6)
RADIO CHOKE
X13 16 RD/DG
BS03
X13 16 RD/DG 2 X13 16 RD/DG 14
B01 D02
B03 D01P
X13 16 RD/DG 1
X13 16 RD/DG 5
X13 16 RD/DG
X13 16 RD/DG
C2 RADIO
J988W-3
NS/GS
8W - 47 - 5
BS03
(8W-47-4) X151 20 BR/YL X157 20 BR/LB X13 16 RD/DG X13 16 RD/DG X158 20 DB/OR X152 20 DB/WT
X57 20 BR/LB
X51 20 BR/YL
X15 16 BK/DG
X52 20 DB/WT
X58 20 DB/OR
X15 16 BK/DG
BS08
(8W-15-5) X15 16 BK/DG
A7 7 X57 20 BR/LB
A9 9 X51 20 BR/YL
A8 8 X58 20 DB/OR
A11 11
B23 P34
X15 16 BK/DG
G202
(8W-15-5) 6
C2
C2
C2
C2 RADIO
J988W-3
8W - 47 - 6
NS/GS
RADIO CHOKE
(8W-47-4)
1 X13 16 RD/DG
X153 20 WT/BR 2 B2
BS03
(8W-47-4)
X154 20 WT/VT 6 B6
P18 B23
X13 16 RD/DG 2 X13 16 RD/DG 14
P18 B23
10
B01 D02
B01 D02
B03 D01P
X154 20 WT/VT
B120 D02
X153 20 WT/BR
X155 20 BR/WT
X13 16 RD/DG 5
X13 16 RD/DG
X156 20 VT/WT
6 8
3 9
2 1
6 7
2 1
D02 B01
D01P B03
X54 20 VT
X56 20 DB/RD
X15 16 BK/DG
BS08
(8W-15-5) X15 16 BK/DG
A12 12 X53 20 DG
A13 13 X54 20 VT
A11 11
B23 P34
X15 16 BK/DG
C1
C2
C2
C1 RADIO G202
(8W-15-5)
GS004706
NS/GS
8W - 47 - 7
RADIO CHOKE
1 X13 16 RD/DG
X154 20 WT/VT 6 B6
BS03
(8W-47-4)
X153 20 WT/BR 2 B2
P18 B23
X13 16 RD/DG 14 X13 16 RD/DG 2
P18 B23
10
B01 D02
B03 D01P
B01 D02
X153 20 WT/BR
B120 D02
X154 20 WT/VT
X156 20 VT/WT
X13 16 RD/DG 5
X13 16 RD/DG
X155 20 BR/WT
6 8
3 9
2 1
6 7
2 1
D02 B01
D01P B03
X53 20 DG
X55 20 BR/RD
X15 16 BK/DG
BS08
(8W-15-5) X15 16 BK/DG
A13 13 X54 20 VT
A12 12 X53 20 DG
A11 11
B23 P34
X15 16 BK/DG
C1
C2
C2
C1 RADIO G202
(8W-15-5)
J988W-3
NS/GS
8W - 48 WINDOW DEFOGGERS
8W - 48 - 1
8W - 48 - 2
NS/GS
ST-RUN A21
(8W-10-16)
RUN A22
(8W-10-14)
JUNCTION BLOCK
(8W-12-2) FUSE 6 20A (8W-12-9) FUSE 12 10A (8W-12-12)
C1
A4 12 BK/RD 35
C1
86
85
14
C4
32
V23 18 BR/PK 10 C1
C14 22 WT/RD 1
C4
C16 20 LB/YL
20
C4
C1
C16 20 LB/YL 4
C15 12 BK/WT 12
C1
(8W-42-4)
C1
(8W-62-2) (8W-62-5)
21
C1
5 Z1 20 BK 6
Z2 18 BK/LG 5
C1
(8W-62-2) (8W-62-4)
G400
(8W-15-14)
G200
(8W-15-4)
J988W-3
GS004802
NS/GS
8W - 48 - 3
RUN-ACC A31
(8W-10-16)
JUNCTION BLOCK
(8W-12-2) FUSE 9 15A (8W-12-11) 15
C3
V20 18 RD
C2
C66 18 BK/WT
GS004803
J988W-3
NS/GS
8W - 49 OVERHEAD CONSOLE
8W - 49 - 1
8W - 49 - 2
ST-RUN A21
NS/GS
JUNCTION BLOCK
FUSE 6 20A (8W-12-9) (8W-12-2) 2 G31 20 VT/LG G32 20 BK/LB
14
C1
V23 18 BR/PK 11
CS04
(8W-12-9) V23 18 BR/PK 4 FUSED IGN. (RUN) CCD BUS (+) 6
G32 20 BK/LB 2 SENSOR GROUND CCD BUS (-) 1 COMPASS/ MINI-TRIP COMPUTER
OVERHEAD CONSOLE
GROUND 3
Z2 18 BK/LG
D1 18 VT/BR
D2 18 WT/BK
CS06
(8W-49-3) 6 5
C20 B75
Z2 18 BK/LG
D1 18 VT/BR
D2 18 WT/BK
C20 B75
TO TO
Z2 18 BK/LG *3 5
BS05
(8W-30-4) (8W-30-31)
BS06
(8W-30-4) (8W-30-31)
G301
(8W-15-11)
J988W-3
*DIESEL
GS004902
NS/GS
BATT A0
(8W-10-8)
8W - 49 - 3
C2
F41 20 PK/VT 15
JUNCTION BLOCK
(8W-12-2)
C2 JUNCTION BLOCK
(8W-12-2)
1 19
C1
E2 20 OR
C2
F41 20 PK/VT 2
17
B75 C20
E2 18 OR
OVERHEAD CONSOLE
Z2 18 BK/LG
CS06
Z2 18 BK/LG 9
C20 B75
Z2 18 BK/LG *3 5
G301
(8W-15-11) (8W-15-12) * DIESEL GS004903 J988W-3
NS/GS
8W - 50 FRONT LIGHTING
8W - 50 - 1
8W - 50 - 2
NS/GS
85
87
85
87
C3
DODGE/ PYLMOUTH
C3
C5
C3
C5
C5
B23 P18
L324 22 WT/LG 12
9 L93 22 PK
33
C3 JUNCTION BLOCK
13 (8W-12-2) COMBINATION FLASHER/ DRL MODULE
76
C1
G200
(8W-15-4)
J988W-3
GS005002
NS/GS
8W - 50 - 3
C5
C3
1 L33 20 RD
C5
C5
L34 20 RD/OR
L44 20 VT/RD CHRYSLER L43 18 VT DODGE/ PYLMOUTH L44 20 VT/RD CHRYSLER L44 20 VT/RD DODGE/ PYLMOUTH L33 20 RD
B18 18
B23 P18
TO
TO
TO
TO
BS15
(8W-50-6)
RIGHT HEADLAMP
(8W-50-6)
LEFT HEADLAMP
(8W-50-6)
MESSAGE CENTER
(8W-46-4)
TO
TO
DODGE/ PYLMOUTH
CHRYSLER
L34 20 RD/OR
L34 20 RD/OR
TO
TO
RIGHT HEADLAMP
(8W-50-6)
GS005003
J988W-3
8W - 50 - 4
NS/GS
C5
C3
L34 20 RD/OR
L44 20 VT/RD
Z1 20 BK
Z1 20 BK
G301
(8W-15-10)
J988W-3
GS005004
NS/GS
8W - 50 - 5
C5
C5
C1
30 FOG LAMP RELAY
86
JUNCTION BLOCK
(8W-12-2)
85
87
12
C1
31
C1
L39 18 LB 1 L39 18 LB
25
C1
1 L33 20 RD A L43 18 VT 2
L94 20 OR/WT
B19 19 Z39 18 BK
B3 3 L39 18 LB
B23 P18
Z1 20 BK 1 9
G300
(8W-15-8)
A TO
B TO
HEADLAMP SWITCH
(8W-50-6) (8W-50-9)
HEADLAMP SWITCH
(8W-50-6) (8W-50-9) J988W-3
GS005005
8W - 50 - 6
BATT A0
30
NS/GS
87
C5
C5
C5
C3
BUILT-UP -EXPORT
L33 20 RD
L44 20 VT/RD
BS15
L39 18 VT/RD 1 L39 18 VT/RD L39 18 LB
L43 18 VT
EXCEPT BUILTUP-EXPORT
2 Z39 20 BK
L43 18 VT
2 Z39 20 BK
C TO
L44 20 VT/RD
D TO
B3 3 L39 18 LB
B23 P18
*2 1 *1 3
RIGHT HEADLAMP
(8W-50-8) L34 20 RD/OR
BS16
(8W-50-8)
LEFT HEADLAMP
2 *3 1
B19 19 Z39 18 BK A TO
B23 P18
B TO
Z1 20 BK
RIGHT HEADLAMP
2 Z1 20 BK
HEADLAMP SWITCH
(8W-50-5) (8W-50-9) 9
G300
(8W-15-8) 7
HEADLAMP SWITCH
(8W-50-5) (8W-50-9)
G301
(8W-15-10) * BUILT-UP-EXPORT
J988W-3
GS005006
NS/GS
BATT A0
(8W-10-8)
8W - 50 - 7
C1
L7 12 BK/YL 2
C1 JUNCTION BLOCK
(8W-12-2) FUSE 4 15A (8W-12-8)
C1
F39 18 PK/LG 1
F39 18 PK/LG 1
2 Z39 20 BK
2 Z39 20 BK
B19 19
B23 P18
Z39 18 BK 6
Z39 18BK
C2 HEADLAMP SWITCH
(8W-50-10)
GROUND
F TO
HEADLAMP SWITCH
(8W-50-10) J988W-3
GS005007
8W - 50 - 8
NS/GS
JUNCTION BLOCK
(8W-50-6) C L44 20 VT/RD
BS16
L44 20 VT/RD L44 20 VT/RD L44 20 VT/RD 2 B3 3 L44 20 VT/RD 1
L34 20 RD/OR
B23 P18
RIGHT HEADLAMP
3
L44 20 VT/RD 2
C1 HEADLAMP SWITCH
(8W-50-10) Z1 20 BK
C1
C1
P34 B23
L13 18 BR/YL 2 3
L13 20 BR/YL 3 2
1 Z1 20 BK 1
Z1 20 BK 7
G300
(8W-15-8)
G200
(8W-15-4)
G301
(8W-15-10)
J988W-3
GS005008
NS/GS
8W - 50 - 9
JUNCTION BLOCK
(8W-12-2)
P18
FROM (8W-50-5) (8W-50-6) B
P18
(8W-50-5) (8W-50-6) A
23
C4
C2
C3
34
C3
28
C3
Z39 18 BK 6
E2 20 OR 1
E92 22 OR/BK
M112 22 BR/LG 3
M111 22 BR/WT 9
M113 20 LB/PK 11
L39 18 LB
C2
12
C1
C1
C1
C1
C2
C2
FOG LAMP INDIC.
HEADLAMP SWITCH
0 OFF 1 PARK 2 HEAD 3 AUTO 4 ON
ILLUM. LAMP
0 1 2 Z1 18 BK 2
0 1 2 7
C1
C1
C2
6 Z1 20 BK
C1
10
C1
C2
C2
C2
M32 22 BK/LB
E17 20 YL/BK
P18 B23
Z2 20 BK/LG 10 Z2 20 BK/LG 14
L308 20 LG/WT
L307 20 LG/OR
L110 22 BK/YL
M13 20 BK/YL
C2
C2
40
C2
13
C2
12
21
C4
29
C4 JUNCTION BLOCK
(8W-12-2)
GROUND
GROUND
3 2
C2
11
C2
C2
Z1 14 BK 8
B75 C20
G300
(8W-15-6)
GS005009
8W - 50 - 10
NS/GS
BATT F41
(8W-10-20)
JUNCTION BLOCK
30 COURTESY LAMP RELAY (8W-12-2) FROM FROM
(8W-12-23)
P18
(8W-50-7) F
P18
(8W-50-11) E
23
C4
E2 20 OR
85
87 (8W-12-22) D4 (8W-12-22)
C2
C2
C2
10 C3 M112 22 BR/LG 3 C1
34 C3 M111 22 BR/WT 9 C1
Z39 18 BK
L77 18 BR/YL
C2
C2 HEADLAMP SWITCH
FOG LAMP INDIC. 0 OFF 1 PARK 2 HEAD 3 REAR 4 ON
3 1 2 8
0 1 2 3
C2
C1
6 Z1 20 BK
C1
10
C1
C2
C2
C2
L308 20 LG/WT
L307 20 LG/OR 13
C2
40
C2
GROUND 10
C2
C2
C4
29
C4 JUNCTION BLOCK
(8W-12-2)
2 Z1 14 BK 8
C2
E17 20 YL/BK
C1
G300
(8W-15-5)
J988W-3
NS/GS
BATT A0
(8W-10-8)
8W - 50 - 11
85 10
87
C3
C1
C5
L97 18 PK/DB 9 16 PARK LAMP RELAY CONTROL FUSED PARK LAMP RELAY OUTPUT 1 BODY CONTROL MODULE (8W-45-3)
L7 12 BK/YL 2
L9 18 BK/WT 27 1 LEFT FRONT TURN SIGNAL 2 FUSED B(+) RIGHT FRONT TURN SIGNAL 3 COMBINATION FLASHER/ DRL MODULE
C2
C1
C2 JUNCTION BLOCK
(8W-12-2)
C1
11 L61 18 LG
C2
23
C1
5 L60 18 TN *1 2 *3 1
C2
L77 20 BR/YL *1 2 *3 1
B23 P18
L77 18 BR/YL
3 *2 Z1 18 BK 6
*3 4 FUSED B(+)
BUILT-UP -EXPORT
3 *2
E TO
HEADLAMP SWITCH
(8W-50-10)
Z1 18 BK 8
G300
(8W-15-7)
G301
(8W-15-10) * BUILT-UP-EXPORT
GS005011
J988W-3
8W - 50 - 12
BATT A0
(8W-10-8)
NS/GS
85 10
87
C3
C1
C5
L97 18 PK/DB 9 16 FUSED PARK LAMP RELAY OUTPUT 1 FUSE 1 10A (8W-12-8) FUSE 5 15A (8W-12-8) PARK LAMP RELAY CONTROL BODY CONTROL MODULE (8W-45-3)
L7 12 BK/YL 2
L9 18 BK/WT 27 1 LEFT FRONT TURN SIGNAL 2 FUSE 3 15A (8W-12-8) FUSED B (+) RIGHT FRONT TURN SIGNAL 3 COMBINATION FLASHER/ DRL MODULE
C2
C1
C2 JUNCTION BLOCK
(8W-12-2)
C1
11 L61 18 LG
C2
23
C1
5 L60 18 TN
C2
L77 20 BR/YL
L78 20 DG/YL
Z1 18 BK 6 8
Z1 20 BK
G300
(8W-15-7)
G301
(8W-15-10)
J988W-3
GS005012
NS/GS
8W - 50 - 13
9 L93 22 PK
RUN A22
(8W-10-14)
33
C3 JUNCTION BLOCK
(8W-12-2)
2 BODY CONTROL MODULE (8W-45-3) 12 HIGH/LOW BEAM RELAY CONTROL RED BRAKE WARNING LAMP DRIVER 10 (8W-12-17) COMBINATION FLASHER/ DRL MODULE
C2
C3
C3
Z1 14 BK 9
MESSAGE CENTER
(8W-46-3) G9 20 GY/BK
G9 20 GY/BK
G9 20 GY/BK
G300
(8W-15-7) 1
C1 IGNITION SWITCH
4 1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-14)
0 1 Z1 20 BK
C1
14
GS005013
J988W-3
NS/GS
8W - 51 REAR LIGHTING
8W - 51 - 1
8W - 51 - 2
BATT A0
(8W-10-8)
NS/GS
85 10
87
C3
C1
L97 18 PK/DB 9
L7 12 BK/YL 2
C2
C1 JUNCTION BLOCK
(8W-12-2)
FUSE 1 10A (8W-12-8) 16 1 BODY CONTROL MODULE (8W-45-3) (8W-45-4) PARK FUSED B(+) LAMP RELAY CONTROL
21 Z1 18 BK
C4
2 Z1 14 BK
C2
18
C1
L77 20 BR/LB A TO L78 20 DG/YL
23
C1
L77 20 BR/LB 5 6
L78 20 DG/YL
C2
C2 HEADLAMP SWITCH
1 HEAD 2 PARK 0 OFF (8W-50-9) (8W-50-10) 8
L77 20 BR/LB 2
*1 2 FUSED B(+)
LICENSE LAMP
1 Z1 20 BK 7
G300
(8W-15-6)
NS/GS
BATT A0
8W - 51 - 3
C5
L9 18 BK/WT 27
C2
RUN A22
(8W-10-14)
JUNCTION BLOCK
(8W-12-2) FUSE 12 10A (8W-12-12) 1 FUSED B(+) LEFT REAR TURN SIGNAL 4 RIGHT REAR TURN SIGNAL 5 6 FUSED IGNITION (RUN) COMBINATION FLASHER/ DRL MODULE
28
C2
36
C2
L63 18 DG/RD
L63 18 DG/RD
L62 18 BR/RD
L62 18 BR/RD
14
10
GS005103
J988W-3
8W - 51 - 4
RUN A22
(8W-10-14)
NS/GS
18 F20 20 WT 5 F20 18 WT 1
C2
C3
F32 18 PK/DB
B33 E36
R 6 L1 18 VT/BK
L50 18 WT/TN
JUNCTION BLOCK
(8W-51-3) C
JUNCTION BLOCK
(8W-51-2) B L78 20 DG/YL *3 4
JUNCTION BLOCK
(8W-51-3) D L62 18 BR/RD *5 1
10
BACK-UP LAMP
BACK-UP LAMP
3 *4 L1 20 VT/BK L1 20 VT/BK
6 *1 Z1 20 BK
3 *4 L1 20 VT/BK
6 *1 Z1 20 BK
BS02
9 (8W-70-2) 3
G302
(8W-15-13)
J988W-3
* BUILT-UP-EXPORT
GS005104
NS/GS
RUN A22
(8W-10-14)
8W - 51 - 5
18 F20 20 WT GAS
C2
8
C3
DIESEL 5
F32 18 PK/DB 6
5 F20 18 WT 1
B33 E36
1
F20 20 WT
B33 E120
2 L1 18 VT/BK 10
JUNCTION BLOCK
(8W-51-3) C L63 18 DG/RD *5 1
JUNCTION BLOCK
(8W-51-2) B L78 20 DG/YL *3 4
JUNCTION BLOCK
(8W-51-3) D L62 18 BR/RD *5 1
E36 B33 10
E120 B33
BACK-UP LAMP
BACK-UP LAMP
3 *4 L1 20 VT/BK L1 20 VT/BK
6 *1 Z1 20 BK
3 *4 L1 20 VT/BK
6 *1 Z1 20 BK
BS02
9 (8W-70-2) 3
G302
(8W-15-13)
GS005105
* BUILT-UP-EXPORT
J988W-3
8W - 51 - 6
BATT A0
NS/GS
FROM
FUSE 3 (JB)
(8W-12-8)
C1
L77 20 BR/LB 3
L78 20 DG/YL
L7 12 BK/YL 2
C1 JUNCTION BLOCK
(8W-12-2) FUSE 5 15A (8W-12-8) 2
L36 20 LG
C1
18
C1
B23 P18
B27 27 L36 20 LG 7
B23 P18
L77 18 BR/YL 2
C2
C2
REAR FOG LAMP INDICATOR
C2 HEADLAMP SWITCH
0 OFF 1 PARK 2 HEAD 3 REAR (8W-50-9)
Z1 18 BK
3 2 1
DIMMER SWITCH 6
C1
Z1 20BK 21
C4 JUNCTION BLOCK
(8W-12-2)
3 GROUND
J988W-3
GS005106
NS/GS
8W - 51 - 7
C3
F32 18 PK/DB 6
BS01
(8W-70-2) L50 18 WT/TN 2
B17 J01A
L50 20 WT/TN 2
J02A L15
L50 20 WT/TN 3
1 Z1 20 BK 2
G400
(8W-15-14)
GS005107
J988W-3
NS/GS
8W - 52 TURN SIGNALS
8W - 52 - 1
8W - 52 - 2
BATT A0
(8W-10-8)
NS/GS
C5
L9 18 BK/WT
27
C2
RUN A22
(8W-10-14)
JUNCTION BLOCK
FUSE 12 10A (8W-12-12) 1 LEFT FRONT TURN SIGNAL 2 LEFT TURN SIGNAL SENSE 7 COMBO FLASHER SWITCHED GROUND 9 FUSED B (+) 6 FUSED IGN. (RUN) LEFT REAR TURN SIGNAL 4 COMBINATION FLASHER/ DRL MODULE LEFT REAR TURN SIGNAL 19 BODY CONTROL MODULE (8W-45-5) (8W-12-2)
11 L61 18 LG
C2
4 C3 L305 22 LB/WT
26
C3
L91 20 DB/PK 5
21
C3
28
C2
L91 22 DB/PK
L63 18 DG/RD
P50
NOT USED 4 1
MESSAGE CENTER
L63 18 DG/RD **5 1
**3 1
3 **2
Z1 18 BK
Z1 18 BK
3 *4
6 **1
36 (8W-12-19)
C4 JUNCTION BLOCK
(8W-12-2) 2 Z1 18 BK
G200
(8W-15-4)
2 Z1 14 BK 10 8
C2
14
G300
* RHD ** BUILT-UP-EXPORT J988W-3 (8W-15-5) (8W-15-6) (8W-15-7)
G302
(8W-15-13) GS005202
NS/GS
BATT A0
(8W-10-8)
8W - 52 - 3
C5
L9 18 BK/WT
27
C2
RUN A22
(8W-10-14)
JUNCTION BLOCK
FUSE 12 10A (8W-12-12) 1 RIGHT FRONT TURN SIGNAL 3 RIGHT TURN SIGNAL SENSE 8 COMBO FLASHER SWITCHED GROUND 9 FUSED B (+) 6 FUSED IGN. (RUN) RIGHT REAR TURN SIGNAL 5 COMBINATION FLASHER/ DRL MODULE RIGHT REAR TURN SIGNAL 21 BODY CONTROL MODULE (8W-45-5) (8W-12-2)
5 L60 18 TN
C2
22 C3 L302 22 LB/YL
26
C3
L91 20 DB/PK 5
14
C3
36
C2
L91 22 DB/PK
L62 18 BR/RD
P50
NOT USED 3 1
MESSAGE CENTER
L62 18 BR/RD **5 1
8 **3 1
3 *4
3 **2
Z1 18 BK
36
C4 JUNCTION BLOCK
(8W-12-2)
C2
Z1 14 BK 10
G200 G301
(8W-15-10) * RHD ** BUILT-UP-EXPORT (8W-15-4) 8
G301
(8W-15-10)
G300
(8W-15-6) GS005203
G302
(8W-15-13) J988W-3
NS/GS
8W - 53 WIPERS
8W - 53 - 1
8W-53 WIPERS
Component Page A/C Heater Control . . . . . . . . . . . . . . . . . . . .8W-53-4 Body Control Module . . . . . . . . . . . . .8W-53-2, 3, 4, 5 Front Washer Motor . . . . . . . . . . . . . . .8W-53-3, 4, 5 Front Wiper Switch . . . . . . . . . . . . . . . .8W-53-2, 3, 5 Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-5 Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-4 Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3 Fuse 22 (PDC) . . . . . . . . . . . . . . . . . . . . . . . .8W-53-5 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3, 4 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3, 5 G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-4 Headlamp Washer . . . . . . . . . . . . . . . . . . . . .8W-53-5 HVAC Control . . . . . . . . . . . . . . . . . . . . . . . .8W-53-4 Junction Block . . . . . . . . . . . . . . . . . .8W-53-2, 3, 4, 5 Low Washer Fluid Switch . . . . . . . . . . . . . . .8W-53-3 Component Page Park Lamp Relay . . . . . . . . . . . . . . . . . . . . .8W-53-5 Power Distribution Center. . . . . . . . . . .8W-53-2, 3, 5 PTC 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-5 PTC 7 (JB). . . . . . . . . . . . . . . . . . . . .8W-53-2, 3, 4, 5 Rear Washer Motor . . . . . . . . . . . . . . . . . .8W-53-3, 4 Rear Washer Switch . . . . . . . . . . . . . . . . . . .8W-53-4 Rear Wiper Delay On Indicator . . . . . . . . . . .8W-53-4 Rear Wiper Delay Switch . . . . . . . . . . . . . . .8W-53-4 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . .8W-53-4 Rear Wiper On Indicator . . . . . . . . . . . . . . . .8W-53-4 Rear Wiper On Switch. . . . . . . . . . . . . . . . . .8W-53-4 Washer Module . . . . . . . . . . . . . . . . . . . . .8W-53-3, 5 Wiper High/Low Relay. . . . . . . . . . . . . . . .8W-53-2, 3 Wiper Module . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2 Wiper On Relay . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3
8W - 53 - 2
BATT A0
(8W-10-8)
8W-53 WIPERS
NS/GS
86
30
87 WIPER ON RELAY
86
85 7
87A
85 5 V16 20 WT (8W-10-16)
87
87A
C5
C5
2 Z1 18 BK
C4
C5
C5
V14 18 RD/VT
RUN-ACC A31
V4 12 RD/YL
V3 12 BR/WT
JUNCTION BLOCK
(8W-12-2) PTC 7 9A (8W-12-16)
WIPER MODULE
B1 1 V16 20 WT
B23 P18
5 F1 20 DB 7
C3
0 2
Z1 14 BK 10 12
G300
(8W-15-5) (8W-15-7)
6 V52 20 DG/YL 73
11
8 V7 20 DG/WT 41
C1
C2
NS/GS
BATT A0
(8W-10-8)
8W-53 WIPERS
8W - 53 - 3
86
30
87 WIPER ON RELAY
86
85 7
87A
85
87
87A
C5
2 Z1 18 BK 10
C4
5 V16 20 WT B1 1 V16 20 WT 5
C5
RUN-ACC A31
(8W-10-16)
V14 18 RD/VT
JUNCTION BLOCK
(8W-12-2)
G300
(8W-15-7)
B23 P18
PTC 7 9A (8W-12-16) 3
C2
F1 20 DB A FUSED IGNITION (RUN-ACC) F1 20 DB
0 2
6 A
11 V10 20 BR
Z1 20 BK 14
Z1 18 BK 13
M B V10 20 BR 21
G301
(8W-15-11)
G200
(8W-15-4)
18 20
C3
C2 JUNCTION BLOCK
(8W-12-2)
73
C1
58
C1
GS005303
J988W-3
8W - 53 - 4
RUN-ACC A31
(8W-10-16)
8W-53 WIPERS
ST-RUN A21
(8W-10-16)
NS/GS
JUNCTION BLOCK
PTC 7 9A (8W-12-16) FUSE 6 20A (8W-12-9) 11 12 13 BODY CONTROL MODULE (8W-45-2) (8W-45-4) (8W-45-6) (8W-12-2)
FUSED IGN. (ST-RUN) REAR WASHER PUMP MOTOR CONTROL 50 F1 20 DB A FUSED IGNITION (RUN-ACC) F1 20 DB REAR WIPE/ WASH MUX 38 REAR WIPER MOTOR DRIVER 49
C2
C1
C1
C2
C1
V20 20 BK/WT
V26 22 YL/WT
V13 18 BR/LG 7 2 3
V23 18 BR/PK 8 3 2
M B
C1
HVAC CONTROL (8W-42-3)
C1
Z2 18 BK/LG 5 6
G200
(8W-15-4)
G400
(8W-15-14)
J988W-3
GS005304
NS/GS
8W - 53 - 5
C1
L7 12 BK/YL
RUN-ACC A31
(8W-10-16)
C1
BATT A2
(8W-10-13)
JUNCTION BLOCK
(8W-12-2) PTC 7 9A (8W-12-16) FUSE 5 15A (8W-12-8) PTC 3 9A (8W-12-15)
56
P WASHER MODULE
LOGIC
30
18 V10 20 BR 11
C3
21 V10 20 BR
C2
34
C1
V53 18 RD/YL B Z1 18 BK 11
HEADLAMP WASHER
M
G301
(8W-15-10)
GS005305
J988W-3
NS/GS
8W - 54 TRAILER TOW
8W - 54 - 1
8W - 54 - 2
BATT A0
(8W-10-8)
NS/GS
85 10
87
C3
C1
L97 18 PK/DB 9
L7 12 BK/YL 2
C2
C1 JUNCTION BLOCK
(8W-12-2)
FUSE 1 10A (8W-12-8) 16 PARK LAMP RELAY CONTROL 1 FUSED PARK LAMP RELAY OUTPUT BODY CONTROL MODULE (8W-45-3)
28
C2
L77 20 BR/LB 4 *3 4 FUSED LEFT INBOARD TAIL LAMP
C1
36
C2
L78 20 DG/YL 4 B98 *3 4
23
C1
L77 20 BR/LB 5
B99 T05
L62 18 BR/RD 1 *5 1
B17 J01A
L77 20 BR/LB 6
J02A L15
L77 20 BR/LB
L63 18 DG/RD
L62 18 2 BR/RD 4
LICENSE LAMP
(8W-51-2) * BUILT-UP-EXPORT
J988W-3
NS/GS
8W - 54 - 3
L50 18 WT/TN 1
L50 18 WT/TN 5
B99 T05
L50 18 WT/TN 4 Z1 18 BK 1 5
L50 18 WT/TN
B98 T08
L615 18 OR
L605 18 DG
RIGHT
STOP REAR LAMP LAMP SWITCH OUTPUT GROUND ASSEMBLY (8W-51-4) 5 6 (8W-51-5) *6 *1 Z1 20 BK 6 Z1 20 BK 3 L73 18 YL 4 3 Z1 18 WT 9 Z1 18 BK STOP LAMP SWITCH OUTPUT GROUND 5 6 *6 *1 L50 18 WT/TN Z1 20 BK
T08 B98
6 Z1 20 BK
T05 B99
G302
(8W-15-13) L74 18 LG TRAILER 1
TOW CONNECTOR
* BUILT-UP-EXPORT J988W-3
GS005403
NS/GS
8W - 60 POWER WINDOWS
8W - 60 - 1
8W - 60 - 2
RUN-ACC A31
(8W-10-16)
NS/GS
PTC 9 9A (8W-12-16)
PTC 8 9A (8W-12-16)
JUNCTION BLOCK
(8W-12-2)
(8W-12-23) 34 F21 16 TN 14
C2
17
C2
8 E2 20 OR 4 E2 20 OR
C1
PANEL LAMPS FEED 1
F55 12 TN/DG 7
B02 D01D
F21 16 TN 11
F55 14 TN/DG 9 14
E2 20 OR
Q21 16 WT
Q11 16 LG
DS01
(8W-15-7) 8 *1 3 1 2 13 *3 1 10
D01D B02
Z1 12 BK
LEFT REAR VENT MOTOR (LHD) RIGHT REAR VENT MOTOR (RHD)
RIGHT REAR VENT MOTOR (LHD) LEFT REAR VENT MOTOR (RHD)
G300
(8W-15-7)
* RHD
GS006002
NS/GS
RUN-ACC A31
(8W-10-16)
8W - 60 - 3
PTC 8 9A (8W-12-16)
JUNCTION BLOCK
(8W-12-2)
(8W-12-23) 13
C2
17
C2
8 E2 20 OR 11 E2 20 OR
F55 12 TN/DG 12
F55 12 TN/DG 7
B03 D01P
B02 D01D
B03 D01P
F55 14 TN/DG 9
EXPRESS DOWN MODULE 2 Q26 14 VT/WT 6 F55 12 TN/DG Q26 12 VT/WT 2 2 1 4 Q16 14 BR/WT 9 13
D01D B02
E2 20 OR Z1 20BK
Q16 12 BR/WT 13 3
GROUND 2 Z1 20 BK
B03 D01P
6 7
1 2
D01P B03
10 Z1 18 BK Z1 12 BK 5
DS01
(8W-15-7)
D01D B02
5 2 Q22 14 VT
11
G300
(8W-15-7)
J988W-3
NS/GS
8W - 61 - 1
8W - 61 - 2
NS/GS
JUNCTION BLOCK
(8W-12-2)
C1
C1
E2 20 OR
P97 20 WT/DG 11 4
C1
B02 D01D
11
E2 20 OR
P96 20 WT/LG 4
B03 D01P
E2 20 OR P97 20 WT/DG E2 20 OR
P96 20 WT/LG
3 Z2 20 BK/LG E2 20 OR
3 Z2 20 BK/LG
D01D B02
D01P B03
Z2 20 BK/LG 3
Z2 20 BK/LG 2
G301
(8W-15-10) (8W-15-11) (8W-15-12) J988W-3 GS006102
NS/GS
BATT A2
(8W-10-13)
8W - 61 - 3
JUNCTION BLOCK
(8W-12-2) PTC 3 9A (8W-12-14) (8W-12-15) (8W-10-13)
86
87
86
87
85
30
85
30
15
C1
F136 20 VT/WT TO
19
C1
C1
32
C1
11
C1
C2
F136 20 VT/WT
F136 20 VT/YL
F136 20 VT/YL
F131 20 BK/PK
F133 20 BR
F133 20 BR
F133 20 BR/RD 9 4
5 F131 20 BK/PK
12
B02 D01D
10
B03 D01P
F133 20 BR 2 2
F133 20 BR
F133 20 BR/RD 1
B17 LJ01
F136 20 VT/WT 5
J02A L15
D01P B03
F136 20 VT/WT
G300
(8W-15-6)
GS006103
J988W-3
8W - 61 - 4
BATT A2
(8W-10-13)
NS/GS
JUNCTION BLOCK
(8W-12-2) PTC 3 9A (8W-12-14) (8W-12-15) (8W-10-13) 86 87 87A DOOR UNLOCK RELAY 86 87 87A DOOR LOCK RELAY
85
30
85
30
15
C1
F136 20 VT/WT
19
C1
F136 20 VT/YL F133 20 BR/YL
26
C1
2 Z1 14 BK 8
C2
F136 20 VT/WT
F136 20 VT/YL
F133 20 BR/YL
TO
TO
G300
15
B75 C20
(8W-15-6)
J988W-3
GS006104
NS/GS
BATT A0
(8W-10-8)
8W - 61 - 5
C3
M1 20 PK
13
C1
(8W-12-20)
JUNCTION BLOCK
(8W-12-2) BODY CONTROL MODULE (8W-45-6) 16
9 FUSED B (+)
M1 20 PK
C4
RKE INTERFACE 1
19
C1
C2
C2
G96 20 LG/RD
M1 20 PK
7 M1 22 PK
P50
D9 22 GY/BK
P34 B23
G96 20 LG/RD 3 FUSED B (+) 5 RKE MODULE PROGRAM ENABLE 6 RKE INTERFACE GROUND 4 Z2 20 BK/LG 11
G200
(8W-15-4)
GS006105
J988W-3
8W - 61 - 6
NS/GS
JUNCTION BLOCK
(8W-12-2)
C1
C1
C1
44
C1
P96 20 WT/LG 4
P98 20 WT/RD
11 E2 20 OR
B03 D01P
2
P96 20 WT/LG
P96 20 WT/LG
B17 LJ01
P98 20 WT/RD
J03A L16
P98 20 WT/RD
3 Z2 20 BK/LG
D01D B02
D01P B03
1
Z2 20 BK/LG 3
Z2 20 BK/LG 2
Z2 20 BK/LG 9
G301
(8W-15-10) (8W-15-11) (8W-15-12) J988W-3
G400
(8W-15-14)
GS006106
NS/GS
BATT A2
(8W-10-8)
8W - 61 - 7
JUNCTION BLOCK
(8W-12-2) PTC 3 9A (8W-12-14) (8W-12-15) (8W-10-13)
86
87
87A
87
86
87
85
30
30
85
85
30
(8W-12-19)
15
C1
F136 20 VT/WT TO
19
C1
F136 20 VT/YL
C1
F133 20 BR
32
C1
11
C1
C2
F136 20 VT/WT
F136 20 VT/YL
F131 20 BK/PK
F133 20 BR
F133 20 BR/RD 9 4
16
B75 C20
5 F131 20 BK/PK
12
B02 D01D
10
B03 D01P
F133 20 BR 2 2
F133 20 BR
F133 20 BR/RD 1
TO 10
B17 LJ01
F136 20 VT/WT 5
J02A L15
D01P B03
F136 20 VT/WT
G300
(8W-15-6)
GS006107
J988W-3
8W - 61 - 8
BATT A2
(8W-10-13)
NS/GS
JUNCTION BLOCK
PTC 3 9A (8W-12-14) (8W-12-15) 86 87 87A 87A DOOR UNLOCK RELAY 87 86 DRIVER DOOR UNLOCK RELAY 30 6 DOOR UNLOCK RELAY CONTROL 85 5 LEFT FRONT UNLOCK CONTROL 8 DOOR LOCK RELAY CONTROL BODY CONTROL MODULE (8W-45-7) (8W-12-19) 85 30 86 87 87A DOOR LOCK RELAY (8W-12-2)
(8W-10-13)
85
30
15
C1 B17 LJ01
19
C1
F136 20 VT/YL 9
26
C1
C2
F136 20 VT/WT
10
F136 20 VT/YL
F136 20 VT/WT 5
B03 D01P
F133 20 BR/YL
F133 20 BR/YL
Z1 14 BK
J02A L15
16 TO
B75 C20
15 TO
B75 C20
F136 20 VT/YL
F133 20 BR/YL 8
G300
2 1 1 (8W-15-6)
LEFT REAR SLIDING DOOR CONTACT LEFT REAR SLIDING DOOR LOCK MOTOR
RIGHT REAR SLIDING DOOR CONTACT RIGHT REAR SLIDING DOOR LOCK MOTOR
J988W-3
GS006108
NS/GS
8W - 62 POWER MIRRORS
8W - 62 - 1
8W - 62 - 2
BATT A0
(8W-10-8)
NS/GS
C2
F41 20 PK/VT 15
C2
BODY CONTROL MODULE (8W-45-5)
JUNCTION BLOCK
(8W-12-2)
(8W-12-21)
(8W-12-23)
16
C3
1 E2 20 OR 5
C4
F41 20 PK/VT 9
5 12 7 6
6 1 13 8 11 Z1 20 BK 35
C4 JUNCTION BLOCK
(8W-12-2)
P71 20 YL
P75 20 DB/WT
P73 20 YL/PK
P70 20 WT
P72 20 YL/BK
P74 20 DB
(8W-12-19)
2 Z1 14 BK 8
C2
C1
M
C1
M
C1
C1
C1
C1
M
C1
M
G300
(8W-15-6)
J988W-3
C1
C1
GS006202
NS/GS
BATT A0
(8W-10-8)
8W - 62 - 3
C3
F35 14 RD 3
S02 B09
F35 14 RD
13
C1 JUNCTION BLOCK
(8W-12-2) M1 20 PK 16 F35 14 RD 3
FUSED B (+)
B56 S02
F35 14 RD
C1
5 FUSED B (+)
FUSED B (+) RKE INTERFACE 19 MEMORY SET 8 MEMORY NO. 1 20 MEMORY NO. 2 21
C1
C1
C1
C1
C2
P24 20 PK/WT 7
P24 20 PK/WT 4
GROUND 1 Z1 20 BK
A23 23
B23 P34
3 Z1 20 BK
S02 B09
Z1 12 BK
DS01
(8W-15-7) G96 20 LG/RD 6 RKE INTERFACE G96 20 LG/RD 1 Z1 12 BK 10
RKE INTERFACE
D01D B02
2
G300
(8W-15-5) (8W-15-7) J988W-3
GS006203
8W - 62 - 4
BATT A0
(8W-10-8)
NS/GS
JUNCTION BLOCK
(8W-12-2)
C2
15
C2
16
C3
1 E2 20 OR 5
C4
F41 20 PK/VT
F41 20 PK/VT 9
6 1 13 8 11 Z1 20 BK 35 (8W-12-19)
P18 B23
C4 JUNCTION BLOCK
(8W-12-2)
P73 20 YL/PK 10
C2
P71 20 YL
C1
LEFT MIRROR VERTICAL 11 LEFT MIRROR HORIZONTAL 12 LEFT MIRROR VERTICAL POSITION 2 LEFT MIRROR POSITION GROUND 1 C1 P69 20 WT/RD A28 28 LEFT MIRROR HORIZONTAL POSITION 3
Z1 14 BK
C1
P71 20 YL
C1
C1
C1
P73 20 YL/PK B8 8 3
G300
(8W-15-6)
B23 P18 C1
M
C1
C1
M
C1
C2
C2
J988W-3
C1
GS006204
NS/GS
8W - 62 - 5
JUNCTION BLOCK
(8W-12-2)
(8W-12-23) 1
C4
E2 20 OR 5
BATT F41
(8W-10-20)
5 12 7 6 1
P70 20 WT
C4 JUNCTION BLOCK
(8W-12-2)
P18 B23
2 Z1 14 BK
C2
C1
24
C1
G300
(8W-15-6)
C1
13
C1
C1
P67 20 YL/RD
P66 20 WT/BK
P68 20 DG/RD
P74 20 DB
P72 20 YL/BK
P70 20 WT
A30 30 1
A25 25
A29 29
B23 P34 C2
4
C2
C2
C1
C1
M
C1
M
GS006205
C1
J988W-3
8W - 62 - 6
NS/GS
10
LEFT MIRROR COMMON LEFT MIRROR VERTICAL 11 P73 20 YL/PK P71 20 YL LEFT MIRROR HORIZONTAL 12 LEFT MIRROR POSITION VERTICAL 2 C1 P64 20 YL/OR LEFT MIRROR POSITION GROUND 1 LEFT MIRROR POSITION HORIZONTAL 3
C1
C1
C1
C1
P75 20 DB/WT
P69 20 WT/RD
P65 20 DB/YL
B8 8 P71 20 YL
B15 15
B23 P18
A26 26
B23 P34
P75 20 DB/WT
P65 20 DB/YL
C1
C1
C1
C2
C2
C1
C2
19
20
J988W-3
GS006206
NS/GS
8W - 62 - 7
10
LEFT MIRROR COMMON LEFT MIRROR VERTICAL 11 P73 20 YL/PK P71 20 YL P75 20 DB/WT P64 20 YL/OR P69 20 WT/RD P65 20 DB/YL LEFT MIRROR HORIZONTAL 12 LEFT MIRROR VERTICAL POSITION 2 C1 LEFT MIRROR POSITION GROUND 1 LEFT MIRROR HORIZONTAL POSITION 3 C1
C1
C1
C1
B8 8
B15 15
B23 P18
A27 27
A28 28
A26 26
B23 P34
P71 20 YL
P75 20 DB/WT
P64 20 YL/OR
P69 20 WT/RD
P65 20 DB/YL
C1
C1
C1
C2
C2
GS006207
J988W-3
8W - 62 - 8
BATT A0
(8W-10-8)
NS/GS
C2
F41 20 PK/VT 15
C2 JUNCTION BLOCK
(8W-12-2)
86
87
87A
87
85 30
30
30
85
(8W-12-19)
C2
11
C3
P160 20 LB 6
11
C4
36 P159 20 DG
C1
36
C4
2 Z1 14 BK
C2
P171 20 VT/WT 6
P160 20 LB
P159 20 DG
C2
M
C2
M
Z1 20 BK 2
1 1
P174 20 YL/RD
P136 20 YL
G300
(8W-15-6)
71
C1
74
C1
39
J988W-3
GS006208
NS/GS
8W - 63 POWER SEAT
8W - 63 - 1
8W - 63 - 2
BATT A2
(8W-10-13)
NS/GS
2 OTHER
F35 14 RD
F35 14 RD
FUSED B(+) 2
B09 S02
A TO
F35 14 RD 5
3 P17 14 RD/LB
6 P15 14 YL/LB
8 P11 14 YL/WT A
9 P13 14 RD/WT B
7 P19 14 YL/LG
10 P21 14 RD/LG
2 P43 14 GY/LB A
4 P41 14 GY/WT B
M B A
1 Z1 12 BK 2
S02 B09
G300
(8W-15-5) (8W-15-9) GS006302
NS/GS
BATT A2
(8W-10-13)
8W - 63 - 3
OTHER
F35 14 RD 8
FUSED B (+)
F35 14 RD
3 P16 14 RD/LB
6 P14 14 YL/LB
9 P10 14 YL/WT B
8 P12 14 RD/WT A
10 P18 14 YL/LG
7 P20 14 RD/LG
2 P44 14 GY/LB B
4 P42 14 GY/WT A
M A B
S02 B56
G300
(8W-15-5)
GS006303
J988W-3
8W - 63 - 4
BATT A0
(8W-10-8)
NS/GS
C3
13
C1 JUNCTION BLOCK
(8W-12-2) M1 20 PK 16 F35 14 RD
FUSED B(+)
C1
FUSED B(+) RKE INTERFACE 19 MEMORY SET 8 MEMORY NO. 1 20 MEMORY NO. 2 21
C1
C1
C1
C1
C2
P24 20 PK/WT 7
P24 20 PK/WT 4
GROUND 1 Z1 20 BK
A23 23
B23 P34
3 Z1 20 BK
S02 B09
Z1 12 BK
DS01
(8W-15-7) G96 20 LG/RD 6 RKE INTERFACE G96 20 LG/RD 1 Z1 12 BK 10
RKE INTERFACE
D01D B02
2
G300
(8W-15-5)
J988W-3
GS006304
NS/GS
8W - 63 - 5
5 P9 20 RD 11
3 P17 22 RD/LB
6 P15 22 YL/LB 14
8 P11 22 YL/WT 13
9 P13 22 RD/WT 2
7 P19 22 YL/LG 12
10 P21 22 RD/LG 1
2 P40 22 GY/LB 15
4 P48 22 GY/WT 4
C3
C3
C3
SEAT FWD REAR VERTICAL UP 3
C3
SEAT REAR UP REAR VERTICAL DOWN 6
C3
C3
C3
C3
FUSED B(+)
SEAT RWD
HORIZ. FWD 2
HORIZ. RWD 1
SEAT SEAT SEAT SEAT SEAT RECLINE FRONT FRONT RECLINE REAR RWD UP DOWN FWD DOWN FRONT FRONT RECLINE VERTICAL VERTICAL RECLINE FWD RWD UP DOWN GND 5
C2
C2
C2
C2
C2
10
C2
C2
C2
7 Z1 14 BK
C2
P115 14 YL/LB
P117 14 RD/LB
P111 14 YL/WT
P113 14 RD/WT
P119 14 YL/LG
P121 14 RD/LG
P43 14 GY/LB
P41 14 GY/WT
S02 B09
M A B
M A B
Z1 12 BK
G300
(8W-15-5)
GS006305
J988W-3
8W - 63 - 6
NS/GS
SS02
P29 20 BR/WT P29 20 BR/WT A P29 20 BR/WT P29 20 BR/WT C P29 20 BR/WT
P28 20 BR/RD
P28 20 BR/RD
P28 20 BR/RD
SS01
P26 22 BR
P27 22 LB/RD
P25 22 VT/RD
P47 22 LB
P28 20 BR/RD
20
C3
C3
C3
18
C3
17
C3
10
6V SUPPLY
J988W-3
GS006306
NS/GS
RUN A22
(8W-10-14)
8W - 63 - 7
14 4 F20 20 WT
C2 B09 HS5D
GROUND 1
GROUND 7
C2
Z1 14 BK
HS2
D FUSED IGNITION (RUN) HEATED SEAT TEMPERATURE SENSOR A B FUSED IGNITION (RUN)
Z1 20 BK
S02 HS6D
Z1 14 BK
GROUND E Z1 18 BK
HS1
FROM
FUSIBLE LINK
(8W-63-2) A HEATED SEAT DRIVER A D
Z1 18 BK GROUND HEATED SEAT BACK C P89 20 BK/RD HEATED SEAT DRIVER B P88 18 RD/WT A HEATED SEAT DRIVER B GROUND
Z1 14 BK
1 Z1 12 BK 2
HS5D B09
G300
(8W-15-5)
F35 18 RD
P86 20 VT
P7 20 WT/BK
Z1 18 BK
P87 18 RD/WT
D FUSED B(+)
F GROUND
E FEED BACK
GS006307
8W - 63 - 8
RUN A22
(8W-10-14)
NS/GS
7 4 F20 20 WT
C2 B56 HS5P
HS4
D FUSED IGNITION (RUN) B FUSED IGNITION (RUN)
GROUND E Z1 18 BK
HS3
FROM Z1 18 BK D GROUND HEATED SEAT DRIVER A HEATED SEAT BACK C P89 20 BK/RD HEATED SEAT DRIVER B P88 18 RD/WT A F35 18 RD P86 20 VT P8 20 WT/BK Z1 18 BK P87 18 RD/WT HEATED SEAT DRIVER B GROUND Z1 18 BK 1 Z1 14 BK
FUSIBLE LINK
(8W-63-3) B
HS5P B56
Z1 12 BK 7
G300
(8W-15-9)
D FUSED B(+)
F GROUND
J988W-3
NS/GS
8W - 70 SPLICE INFORMATION
8W - 70 - 1
8W - 70 - 2
LEFT REAR LAMP ASSEMBLY
5 *6 L50 18 WT/TN TRAILER TOW L50 18 WT/TN (8W-51-4) (8W-51-5) 3
NS/GS
CENTER HIGH MOUNTED STOP LAMP
(8W-51-7) L50 20 WT/TN
OTHERS
L50 18 WT/TN
L15 J02A
TRAILER TOW OTHERS
L50 20 WT/TN 2
T05 B99
LJ01 B17
T08 B98
L50 18 WT/TN
L50 18 WT/TN
L50 18 WT/TN
BS01
L50 18 WT/TN 12 L50 18 WT/TN 5 L50 18 WT/TN 44
C1
2 L1 18 VT/BK GAS 10
L1 18 VT/BK
E120 B33
MTX
E36 B33
AW4 B13
10
E36 B33
L1 20 VT/BK
BS02
L1 20 VT/BK *4 3 L1 20 VT/BK *4 3
* BUILT-UP-EXPORT
NS/GS
8W - 70 - 3
C1
3 C70 12 DG
P18 B23
P34 B23
M20 20 BR
BS17
B75 C20
6
M20 20 BR
M20 20 BR
M20 20 BR
M20 20 BR
M20 20 BR
M20 20 BR
CS03
M20 20 BR A A M20 20 BR 2 M20 20 BR 2 M20 20 BR
8W - 70 - 4
VEHICLE SPEED SENSOR
(8W-30-11) 2 K4 18 BK/LB
NS/GS
ENGINE COOLANT TEMPERATURE SENSOR
1 K4 18 BK/LB (8W-30-10)
A K4 18 BK/LB
ES02 (2.0L)
K4 18 BK/LB 2 K4 18 BK/LB 1 K4 18 BK/LB 2
KNOCK SENSOR
(8W-30-10)
C2
K4 18 BK/LB
K4 18 BK/LB
K4 18 BK/LB
K4 18 BK/LB
ES21 (2.0L)
K4 18 BK/LB 1 K4 18 BK/LB
E36 B33
K4 20 BK/LB
NS/GS
8W - 70 - 5
(8W-30-17)
ES02
K4 18 BK/LB 5
K4 18 BK/LB
K4 18 BK/LB 2
E69 F09
K4 18 BK/LB
KNOCK SENSOR
(8W-30-16)
FS01
K4 18 BK/LB K4 18 BK/LB K4 18 BK/LB 1 K4 18 BK/LB K4 18 BK/LB 1
ES21
K4 18 BK/LB 43
E36 B33
K4 20 BK/LB
8W - 70 - 6
NS/GS
K4 20 BK/LB 1
B33 E36
K4 18 BK/LB K4 18 BK/LB K4 18 BK/LB
K4 18 BK/LB
K4 18 BK/LB
ES02
K4 18 BK/LB 14
K4 18 BK/LB
K4 18 BK/LB
K4 18 BK/LB
E78 F02
3 2
K4 18 BK/LB
FS02
ES21
K4 18 BK/LB
K4 18 BK/LB
K4 18 BK/LB 1
K4 18 BK/LB
K4 18 BK/LB
51
NS/GS
A/C PRESSURE TRANSDUCER
2 2.0L (8W-30-10) (8W-30-16) 2.4L B K6 18 VT/WT
8W - 70 - 7
K6 18 VT/WT
FS02 (2.4L)
K6 18 VT/WT K6 18 VT/WT
F09 E69
K6 18 VT/WT
K6 18 VT/WT
ES03 (2.0L/2.4L)
C2
K6 18 VT/WT
K6 18 VT/WT
F02 E78
K6 18 VT/WT
K6 18 VT/WT
ES03 (3.3L/3.8L)
GS007007
J988W-3
8W - 70 - 8
NS/GS
32
C1
(8W-30-14) (8W-30-22)
K24 18 GY/BK
K24 18 GY/BK
K24 18 GY/BK
ES05
C1
(8W-30-17) (8W-30-25)
K22 18 OR/DB
K22 18 OR/DB
K22 18 OR/DB
ES08
T13 18 DB/BK
T13 18 DB/BK
T13 18 DB/BK
T13 18 DB/BK
ES10
J988W-3
GS007008
NS/GS
8W - 70 - 9
C2
(8W-30-8) (8W-30-14)
K7 18 OR
K7 18 OR
K7 18 OR
K7 18 OR
ES17 (2.0L/2.4L)
K7 18 OR
12
C34 22 DB/WT
P30 J01D
C34 20 DB/WT C34 20 DB/WT C34 20 DB/WT
C34 20 DB/WT
JS03
GS007009
J988W-3
8W - 70 - 10
NS/GS
JS01B
C57 20 DB/GY 2
J01D P30
C57 22 DB/GY 20
C1
C26 22 PK/DB 1
P30 J01D
C26 20 PK/DB
JS02B
C26 20 PK/DB 2 C26 20 PK/DB 2 C26 20 PK/DB 4
J988W-3
GS007010
NS/GS
8W - 70 - 11
K4 20 BK/LB
K4 18 BK/LB
K4 20 BK/LB
K4 20 BK/LB
ES05 (DIESEL)
K4 20 BK/LB
E97 B106
K4 18 BK/LB
BS34 (DIESEL)
K4 20 BK/LB K4 20 BK/LB K4 20 BK/LB
33
GS007011
J988W-3
NS/GS
8W - 80 CONNECTOR PIN-OUTS
8W - 80 - 1
. . . . .8W-80-29 . . . . .8W-80-29 . . . . .8W-80-29 . . . . .8W-80-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-30 .8W-80-30 .8W-80-30 .8W-80-30 .8W-80-31 .8W-80-31 .8W-80-31 .8W-80-32 .8W-80-32 .8W-80-32 .8W-80-32 .8W-80-33 .8W-80-33 .8W-80-33 .8W-80-33 .8W-80-33
8W - 80 - 2
8W - 80 CONNECTOR PIN-OUTS
Component Left Headlamp (Built-Up-Export) . . . . . . Left Headlamp (Except Built-Up-Export) Left Headlamp Leveling Motor (Built-Up-Export) . . . . . . . . . . . . . . . . Left High Headlamp (Chrysler) (Except Built-Up-Export). . . . . . . . . . . Left Liftgate Flood Lamp. . . . . . . . . . . . . Left Low Headlamp (Chrysler) (Except Built-Up-Export). . . . . . . . . . . Left Mid Reading Lamp. . . . . . . . . . . . . . Left Rear Door Ajar Switch . . . . . . . . . . . Left Rear Lamp Assembly (Built-Up-Export) . . . . . . . . . . . . . . . . Left Rear Lamp Assembly (Except Built-Up-Export). . . . . . . . . . . Left Rear Pillar Speaker . . . . . . . . . . . . . Left Rear Reading Lamp . . . . . . . . . . . . . Left Rear Sliding Door Contacts . . . . . . . Left Rear Speaker . . . . . . . . . . . . . . . . . . Left Rear Vent Motor (LHD) . . . . . . . . . . Left Rear Vent Motor (RHD) . . . . . . . . . . Left Rear Wheel Speed Sensor . . . . . . . . Left Repeater Lamp. . . . . . . . . . . . . . . . . Left Stop/Turn Signal Relay . . . . . . . . . . Left Visor/Vanity Mirror Lamps . . . . . . . License Lamp . . . . . . . . . . . . . . . . . . . . . Liftgate Ajar Switch . . . . . . . . . . . . . . . . Liftgate Arm/Disarm Switch . . . . . . . . . . Liftgate Lock Motor . . . . . . . . . . . . . . . . . Low Coolant Level Switch . . . . . . . . . . . . Low Note Horn . . . . . . . . . . . . . . . . . . . . Low Washer Fluid Switch . . . . . . . . . . . . Manifold Absolute Pressure Sensor . . . . . Memory Power Seat Switch. . . . . . . . . . . Memory Seat Front Vertical Motor . . . . . Memory Seat Front Vertical Position Sensor . . . . . . . . . . . . . . . . . . Memory Seat Horizontal Motor . . . . . . . . Memory Seat Horizontal Position Sensor Memory Seat Rear Vertical Motor . . . . . . Memory Seat Rear Vertical Position Sensor . . . . . . . . . . . . . . . . . . Memory Seat Recliner Motor . . . . . . . . . . Memory Seat Recliner Position Sensor . . Memory Seat/Mirror Module - C1 . . . . . . Memory Seat/Mirror Module - C2 . . . . . . Memory Seat/Mirror Module - C3 . . . . . . Memory Set Switch . . . . . . . . . . . . . . . . . Message Center (LHD) . . . . . . . . . . . . . . Message Center (RHD) . . . . . . . . . . . . . . Mode Door Actuator. . . . . . . . . . . . . . . . . Multi-Function Switch. . . . . . . . . . . . . . . Needle Movement Sensor . . . . . . . . . . . . Output Shaft Speed Sensor . . . . . . . . . . . Overhead Console . . . . . . . . . . . . . . . . . .
NS/GS
Page . .8W-80-50 . .8W-80-50 . .8W-80-50 . .8W-80-50 . .8W-80-51 . .8W-80-51 . .8W-80-51 . .8W-80-51 . .8W-80-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-51 .8W-80-52 .8W-80-52 .8W-80-52 .8W-80-52 .8W-80-52 .8W-80-53 .8W-80-53 .8W-80-53 .8W-80-53 .8W-80-53 .8W-80-54 .8W-80-54 .8W-80-54 .8W-80-54 .8W-80-54 .8W-80-54 .8W-80-54 .8W-80-55 .8W-80-55 .8W-80-55 .8W-80-55 .8W-80-55 .8W-80-56 .8W-80-56 .8W-80-56 .8W-80-56 .8W-80-56 .8W-80-57 .8W-80-57 .8W-80-58 .8W-80-58 .8W-80-58 .8W-80-59 .8W-80-59 .8W-80-59 .8W-80-60 .8W-80-60 .8W-80-60
Component Page Fuel Injector No. 3 (3.3L/3.8L). . . . . . . . . . .8W-80-34 Fuel Injector No. 4 (2.0L/2.4L). . . . . . . . . . .8W-80-34 Fuel Injector No. 4 (3.3L/3.8L). . . . . . . . . . .8W-80-34 Fuel Injector No. 5 (3.3L/3.8L). . . . . . . . . . .8W-80-34 Fuel Injector No. 6 (3.3L/3.8L). . . . . . . . . . .8W-80-34 Fuel Pump Module . . . . . . . . . . . . . . . . . . .8W-80-35 Fuel Tank Module . . . . . . . . . . . . . . . . . . . .8W-80-35 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-35 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-36 G301 (Diesel) . . . . . . . . . . . . . . . . . . . . . . . .8W-80-37 G301 (Gas) . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-37 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38 G400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38 Generator . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38 Glove Box Lamp . . . . . . . . . . . . . . . . . . . . .8W-80-39 Glow Plug Relay . . . . . . . . . . . . . . . . . . . . .8W-80-39 HS6D S02 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39 HS6P S02 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39 Headlamp Switch - C1. . . . . . . . . . . . . . . . .8W-80-39 Headlamp Switch - C2. . . . . . . . . . . . . . . . .8W-80-40 Headlamp Washer . . . . . . . . . . . . . . . . . . . .8W-80-40 High Note Horn. . . . . . . . . . . . . . . . . . . . . .8W-80-40 Hood Ajar Switch. . . . . . . . . . . . . . . . . . . . .8W-80-41 Horn/Speed Control Switch . . . . . . . . . . . . .8W-80-41 Idle Air Control Motor . . . . . . . . . . . . . . . . .8W-80-41 Ignition Coil Pack (2.0L/2.4L) . . . . . . . . . . .8W-80-41 Ignition Coil Pack (3.3L/3.8L) . . . . . . . . . . .8W-80-41 Ignition Switch - C1 . . . . . . . . . . . . . . . . . .8W-80-42 Ignition Switch - C2 . . . . . . . . . . . . . . . . . .8W-80-42 Ignition Switch - C3 . . . . . . . . . . . . . . . . . .8W-80-42 Instrument Cluster . . . . . . . . . . . . . . . . . . .8W-80-42 Intake Air Temperature Sensor . . . . . . . . . .8W-80-43 Intake Air Temperature/Manifold Absolute Pressure Sensor . . . . . . . . . . . . 8W-80-43 J02A L15 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-43 J03A L16 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-43 Junction Block - C1 . . . . . . . . . . . . . . . . . . .8W-80-44 Junction Block - C2 . . . . . . . . . . . . . . . . . . .8W-80-45 Junction Block - C3 . . . . . . . . . . . . . . . . . . .8W-80-46 Junction Block - C4 . . . . . . . . . . . . . . . . . . .8W-80-47 Key-In Halo Lamp . . . . . . . . . . . . . . . . . . . .8W-80-48 Key-In Switch . . . . . . . . . . . . . . . . . . . . . . .8W-80-48 Knock Sensor. . . . . . . . . . . . . . . . . . . . . . . .8W-80-48 Left Combination Relay. . . . . . . . . . . . . . . .8W-80-48 Left Door Speaker . . . . . . . . . . . . . . . . . . . .8W-80-48 Left Fog Lamp (Built-Up-Export) . . . . . . . .8W-80-49 Left Fog Lamp (Except Built-Up-Export). . .8W-80-49 Left Front Panel Speaker . . . . . . . . . . . . . .8W-80-49 Left Front Park/Turn Signal Lamp (Built-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-49 Left Front Park/Turn Signal Lamp (Except Built-Up-Export) . . . . . . . . . . . . 8W-80-49 Left Front Speaker . . . . . . . . . . . . . . . . . . .8W-80-49 Left Front Wheel Speed Sensor . . . . . . . . . .8W-80-50
NS/GS
8W - 80 CONNECTOR PIN-OUTS
Page .8W-80-60 .8W-80-61 .8W-80-61 .8W-80-61 .8W-80-61 .8W-80-61 .8W-80-62 .8W-80-62 .8W-80-62 .8W-80-62 .8W-80-62 .8W-80-62 .8W-80-63 .8W-80-63 .8W-80-63 .8W-80-64 .8W-80-64 .8W-80-64 .8W-80-64 .8W-80-65 .8W-80-65 .8W-80-65 .8W-80-65 .8W-80-66 .8W-80-66 .8W-80-67 .8W-80-67 .8W-80-67 .8W-80-68 .8W-80-68 .8W-80-68 .8W-80-68 .8W-80-68 .8W-80-69 .8W-80-71 .8W-80-72 .8W-80-72 .8W-80-73 .8W-80-73 .8W-80-73 .8W-80-73 .8W-80-73 .8W-80-74 .8W-80-74 .8W-80-74 .8W-80-74 .8W-80-75
8W - 80 - 3
Component P30 J01D. . . . . . . . . . . . . . . . . . . . . . P50 . . . . . . . . . . . . . . . . . . . . . . . . . . Park/Neutral Position Switch (EATX) Park/Neutral Position Switch (MTX) . Passenger Airbag Squib. . . . . . . . . . . Passenger Door Arm/Disarm Switch . Passenger Door Courtesy Lamp. . . . . Passenger Door Lock Motor. . . . . . . . Passenger Door Lock Switch . . . . . . . Passenger Heated Seat Back . . . . . . . Passenger Heated Seat Cushion . . . . Passenger Heated Seat Module . . . . . Passenger Heated Seat Switch . . . . . Passenger Power Mirror C1. . . . . . . . Passenger Power Mirror C2. . . . . . . . Passenger Power Seat Switch . . . . . . Passenger Power Window Switch . . . Passenger Seat Front Vertical Motor . Passenger Seat Horizontal Motor . . . Passenger Seat Rear Vertical Motor . Passenger Seat Recliner Motor . . . . . Passenger Window Motor . . . . . . . . . Power Distribution Center - C1 . . . . . Power Distribution Center - C2 . . . . . Power Distribution Center - C3 . . . . . Power Distribution Center - C4 . . . . . Power Distribution Center - C5 . . . . . Power Distribution Center - C6 . . . . . Power Distribution Center - C7 . . . . . Power Distribution Center - C8 . . . . . Power Folding Mirror Switch . . . . . . Power Mirror Switch . . . . . . . . . . . . . Power Seat Circuit Breaker. . . . . . . . Powertrain Control Module (Diesel) . Powertrain Control Module - C1 . . . . Powertrain Control Module - C2 . . . . PRNDL Feed . . . . . . . . . . . . . . . . . . . PRNDL Switch . . . . . . . . . . . . . . . . . Radiator Fan Disconnect . . . . . . . . . . Radiator Fan No. 1 . . . . . . . . . . . . . . Radiator Fan No. 2 . . . . . . . . . . . . . . Radiator Fan Relay (Gas) . . . . . . . . . Radiator Fan Relay No. 1 (Diesel) . . . Radiator Fan Relay No. 2 (Diesel) . . . Radiator Fan Relay No. 3 (Diesel) . . . Radio - C1 . . . . . . . . . . . . . . . . . . . . . Radio - C2 . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Page Radio - C3 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-75 Radio Choke . . . . . . . . . . . . . . . . . . . . . . . .8W-80-75 Rear A/C Heater Unit . . . . . . . . . . . . . . . . .8W-80-75 Rear Blower Front Control Switch . . . . . . .8W-80-76 Rear Blower Rear Control Switch . . . . . . . .8W-80-76 Rear Cigar Lighter/Power Outlet. . . . . . . . .8W-80-76 Rear Dome Lamp . . . . . . . . . . . . . . . . . . . .8W-80-77 Rear Washer Motor . . . . . . . . . . . . . . . . . . .8W-80-77 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . .8W-80-77 Recirculation Door Actuator . . . . . . . . . . . .8W-80-77 Remote Keyless Entry Module. . . . . . . . . . .8W-80-77 Right Combination Relay. . . . . . . . . . . . . . .8W-80-78 Right Door Speaker . . . . . . . . . . . . . . . . . . .8W-80-78 Right Fog Lamp (Built-Up-Export) . . . . . . .8W-80-78 Right Fog Lamp (Except Built-Up-Export) .8W-80-78 Right Front Panel Speaker . . . . . . . . . . . . .8W-80-78 Right Front Park/Turn Signal Lamp (Built-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-79 Right Front Park/Turn Signal Lamp (Except Built-Up-Export) . . . . . . . . . . . . 8W-80-79 Right Front Speaker . . . . . . . . . . . . . . . . . .8W-80-79 Right Front Wheel Speed Sensor. . . . . . . . .8W-80-79 Right Headlamp (Built-Up-Export) . . . . . . .8W-80-79 Right Headlamp (Except Built-Up-Export) .8W-80-80 Right Headlamp Leveling Motor (Built-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-80 Right High Headlamp (Chrysler) (Except Built-Up-Export) . . . . . . . . . . . . 8W-80-80 Right Liftgate Flood Lamp . . . . . . . . . . . . .8W-80-80 Right Low Headlamp (Chrysler) (Except Built-Up-Export). . . . . . . . . . . . .8W-80-80 Right Mid Reading Lamp . . . . . . . . . . . . . .8W-80-81 Right Rear Door Ajar Switch . . . . . . . . . . . .8W-80-81 Right Rear Lamp Assembly (Built-Up-Export) . . . . . . . . . . . . . . . . . .8W-80-81 Right Rear Lamp Assembly (Except Built-Up-Export). . . . . . . . . . . . .8W-80-81 Right Rear Pillar Speaker . . . . . . . . . . . . . .8W-80-81 Right Rear Reading Lamp . . . . . . . . . . . . . .8W-80-81 Right Rear Sliding Door Contacts . . . . . . . .8W-80-82 Right Rear Speaker . . . . . . . . . . . . . . . . . . .8W-80-82 Right Rear Vent Motor (LHD) . . . . . . . . . . .8W-80-82 Right Rear Vent Motor (RHD) . . . . . . . . . . .8W-80-82 Right Rear Wheel Speed Sensor . . . . . . . . .8W-80-82 Right Repeater Lamp . . . . . . . . . . . . . . . . .8W-80-82 Right Stop/Turn Signal Relay . . . . . . . . . . .8W-80-83 Right Visor/Vanity Mirror Lamps . . . . . . . .8W-80-83
8W - 80 - 4
Component Seat Belt Switch . . . . . . . . . . . . . . . . . Sentry Key Immobilizer Module . . . . . Speed Control Dimming Module . . . . . Stop Lamp Switch . . . . . . . . . . . . . . . . Throttle Position Sensor (2.0L) . . . . . . Throttle Position Sensor (Except 2.0L) Traction Control Switch. . . . . . . . . . . . Trailer Tow Connector . . . . . . . . . . . . . Transmission Control Module . . . . . . .
8W - 80 CONNECTOR PIN-OUTS
Page .8W-80-83 .8W-80-83 .8W-80-83 .8W-80-83 .8W-80-84 .8W-80-84 .8W-80-84 .8W-80-84 .8W-80-85 Component Transmission Control Solenoids. . . . . . . Transmission Range Sensor. . . . . . . . . . Turbine Speed Sensor . . . . . . . . . . . . . . Turbo Boost Pressure Sensor . . . . . . . . . Upstream Heated Oxygen Sensor . . . . . Vehicle Speed Control Servo . . . . . . . . . Vehicle Speed Sensor . . . . . . . . . . . . . . . Wiper Module (Built-Up-Export) . . . . . . Wiper Module (Except Built-Up-Export)
NS/GS
Page .8W-80-86 .8W-80-86 .8W-80-87 .8W-80-87 .8W-80-87 .8W-80-87 .8W-80-88 .8W-80-88 .8W-80-88
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
NS/GS
8W - 80 - 5
BLUE 10 21 1 11
BLACK
5 10
1 6
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT C6 14LB C104 12RD/WT C5 16LG Z1 12BK C4 16TN C107 12TN/BK C7 12BK/TN
FUNCTION M2 SPEED BLOWER MOTOR M3 SPEED BLOWER MOTOR M1 SPEED BLOWER MOTOR GROUND LOW SPEED BLOWER MOTOR HIGH SPEED BLOWER MOTOR HIGH SPEED BLOWER MOTOR
BLACK 1 2 CAV 1 2 CIRCUIT C3 18DB/BK Z1 18BK FUNCTION A/C COMPRESSOR CLUTCH RELAY OUTPUT GROUND
8W - 80 - 6
GRAY 2 1 CAV 1 2 3 4
NS/GS
2 4
1 3
CAV 1 2 3 4 5
CIRCUIT C61 20DB C57 20DB/GY C102 20LG C26 20PK/DB C62 20DB/PK
FUNCTION DUAL ZONE A/C ACTUATOR (+/-) SENSOR GROUND ZONE DOOR FEEDBACK SIGNAL 5 VOLT SUPPLY DUAL ZONE A/C ACTUATOR (+/-)
BLACK
5 10
1 6
CAV 1 2 3 4 5 6 7 8 9 10
FUNCTION SENSOR GROUND LOW IDLE POSITION SWITCH ACCELERATOR PEDAL SENSOR SIGNAL ACCELERATOR PEDAL SENSOR GROUND 5 VOLT SUPPLY
YELLOW
CAV 1 2 3 4
FUNCTION PASSENGER AIRBAG LINE NO. 1 PASSENGER AIRBAG LINE NO. 2 DRIVER AIRBAG LINE NO. 1 DRIVER AIRBAG LINE NO. 2
NSGS8006
NS/GS
8W - 80 - 7
BLACK
7 1
13 6
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13
CIRCUIT F14 18LG/YL F23 18 DB/YL D1 20VT/BR D2 20WT/BK R41 18BK/TN Z2 18BK/LG -
FUNCTION FUSED IGNITION (ST-RUN) FUSED IGNITION (RUN) CCD BUS(+) CCD BUS(-) AIRBAG WARNING LAMP DRIVER GROUND -
GRAY CAV 1 2 CIRCUIT Z1 18BK L1 18VT/BK FUNCTION GROUND BACK-UP LAMP FEED
GRAY CAV 1 2 CIRCUIT Z1 18BK L1 18VT/BK FUNCTION GROUND BACK-UP LAMP FEED
GRAY CAV 1 2 CIRCUIT G31 20VT/LG G32 20BK/LB FUNCTION AMBIENT TEMPERATURE SENSOR SIGNAL SENSOR GROUND
8W - 80 - 8
RED CAV 1 2
NS/GS
RED CAV 1 2 3 CIRCUIT E2 18OR Z1 18BK FUNCTION PANEL LAMPS FEED GROUND
BLACK 7 1
CAV 1 2 3 4 5 6 7
CIRCUIT V23 18BR/PK Z1 20BK L1 20VT/BK P112 20YL/WT* P114 20YL/BK* L24 20WT/LG*
FUNCTION FUSED IGNITION (ST-RUN) GROUND BACK-UP LAMP FEED POWER MIRROR B(-) POWER MIRROR B(-) AUTOMATIC HEADLAMP SIGNAL
NS/GS
8W - 80 - 9
BLACK CAV 1 2 3 4
B09
HS5D
CIRCUIT Z1 14BK Z1 14BK F35 14RD F35 14RD A2 12PK/BK F20 20WT
BLACK CAV 1 2 3 4
B09
S02
B13
AW4
BLACK
14
B17
CAV 1 2 3 4 5 6 7 8 9 10 11 12
CIRCUIT L50 18WT/TN M11 20PK/LB G78 18TN/BK L77 20BR/LB P98 20WT/RD V13 18BR/LG V23 18BR/PK F133 20BR/RD F136 20VT/WT Z1 12BK C15 12BK/WT
BLACK
14
LJ01
CAV 1 2 3 4 5 6 7 8 9 10 11 12
CIRCUIT L50 20WT/TN M11 20PK/LB G78 18TN/BK L77 20BR/LB P98 20WT/RD V13 18BR/LG V23 18BR/PK F133 20BR/RD F136 20VT/WT Z1 12BK C15 12BK/WT J988W-3
NSGS8009
8W - 80 - 10
CAV B1 B2 B3 B3 B4 B5 B6 B7 B8 BLACK B9 B1 B7 B10 B11 B30 A1 B36 A7 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 B23 B24 B25 B26 B27 B28 B29 B30 B31 B32 B33 B34 B35 B36
NS/GS
A30
A36
P18
B23
NS/GS
CAV A1 BLACK B7 B1 A1 A2 A2 A3 A4 A5 A6 A7 A8 A9 A30 A36 A10 A11 A12 A13 A14 A15 A16 A17 A17 A18 A18 A19 A20 A20 A21 A22 A23 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 * REAR A/C HEATER ** MEMORY SEAT EXCEPT BUILT-UP-EXPORT BUILT-UP-EXPORT RHD DIESEL GAS GAS,BUILT-UP-EXPORT A33 A34 A34 A35 A36
8W - 80 - 11
B30 A1
B36 A7
P34
B23
NSGS8011
J988W-3
8W - 80 - 12
BLACK
NS/GS
5 10
1 6
B33 (DIESEL)
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT G6 20GY G18 20PK/BK G58 20BK/YL A141 16DG/WT F20 20WT K21 20BK/RD K1 20DG/RD K9 20LB K3 20BK/VT L1 20VT/BK
BLACK
1 6
5 10
E120 (DIESEL)
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT G6 16GY G18 20BK/PK G58 20BK/YL A141 18DG/WT F20 20WT K21 18BK/RD K1 18DG/RD K9 18LB K3 20BK/VT L1 18VT/BK
BLACK
5 10
1 6
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT K4 20BK/LB D2 18WT/BK D20 20LG D21 20PK F20 20WT D6 20PK/LB D1 18VT/BR F11 20RD/WT G6 20GY L1 20VT/BK
BLACK
1 6
5 10
B33 (GAS)
E36 (GAS)
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT K4 18BK/LB D2 18WT/BK D20 18LG D21 18PK F20 18WT D6 18PK/LB D1 18VT/BR F11 18RD/WT G6 16GY L1 18VT/BK
BLACK CAV 1 2 3 4 CIRCUIT Z1 14BK F35 14RD F35 14RD F20 20WT
2 4
1 3
B56
HS5P
BLACK CAV 1 2 CIRCUIT Z1 14BK Z1 20BK* A2 12PK/BK F35 14RD F20 20WT * MEMORY
B56
S02
3 4
J988W-3
NSGS8012
NS/GS
8W - 80 - 13
LIGHT GRAY
5 10
1 6
B70
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT C103 20DG/LB A142 18DG/OR V32 20YL/RD G3 20BK/PK V30 20DB/RD K29 20WT/PK V37 20RD/LG Z11 20BK/WT K141 20TN/WT
LIGHT GRAY 1 6 5 10
E43
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT C103 18DG/LB A142 18DG/OR V32 18YL/RD G3 18BK/PK V30 18DB/RD K29 18WT/PK V37 18RD/LG Z11 18BK/WT K141 18TN/WT
BLUE 1 10
11
20
B75
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20
CIRCUIT M20 20BR F41 20PK/VT M13 20BK/YL M113 20LB/PK D2 18WT/BK D1 18VT/BR G10 18LG/RD* G32 20BK/LB Z2 18BK/LG G31 20VT/LG V23 18BR/PK Z1 20BK L1 20VT/BK G74 18TN/RD G75 18TN* F133 20BR/YL F136 20VT/YL E2 20OR L24 20WT/LG** P112 20YL/WT** P114 20YL/BK**
BLUE
10 20
1 11
C20
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
CIRCUIT M20 20BR F41 20PK/VT M13 20BK/YL M113 20LB/PK D2 18WT/BK D1 18VT/BR G10 18LG/RD* G32 20BK/LB Z2 18BK/LG G31 20VT/LG V23 18BR/PK Z1 20BK L1 20VT/BK G74 18TN/RD F133 20BR/YL F136 20VT/YL E2 18OR L24 20WT/LG** P112 20YL/WT** P114 20YL/BK**
8W - 80 - 14
BLACK CAV 3 6 1 4 1 2 3 4 5 6
NS/GS
T08
BLACK CAV 3 6 1 4 1 2 3 4 5 6 CIRCUIT L63 18DG/RD L1 20VT/BK L77 20BR/LB L50 18WT/TN Z1 20BK 1 4
BLACK CAV 3 6 1 2 3 4 5 6 CIRCUIT L63 18DG/RD L63 18DG/RD L1 20VT/BK L77 20BR/LB L50 18WT/TN L50 18WT/TN Z1 20BK Z1 18BK
T05
CAV 1 1 2
FUNCTION FUSED IGNITION SWITCH OUTPUT FUSED IGNITION SWITCH OUTPUT BACK-UP LAMP FEED
BACK-UP SWITCH
NATURAL
CAV 1 2 3 4 5
CIRCUIT C33 20DB/RD C26 20PK/DB C36 20RD/WT C57 20DB/GY C34 20DB/WT
FUNCTION BLEND AIR DOOR DRIVER 5 VOLT SUPPLY BLEND DOOR FEEDBACK SIGNAL SENSOR GROUND BLEND AIR DOOR DRIVER
NS/GS
CAV 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
8W - 80 - 15
NATURAL
50 60 70 80
41 51 61 71
8W - 80 - 16
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
NS/GS
NATURAL 10 20 30 40 1 11 21 31
BLACK CAV A B CIRCUIT G9 20GY/BK Z1 20BK FUNCTION RED BRAKE WARNING LAMP DRIVER GROUND
NS/GS
8W - 80 - 17
6 1
4 3
C19
CAV 1 2 3 4 5 6
CIRCUIT V23 18BRPK Z1 20BK L1 20VT/BK P112 20YL/WT* P114 20YL/BK* L24 20WT/LG*
4 3
6 1
EC1
CAV 1 2 3 4 5 6
CIRCUIT V23 18BRPK Z1 20BK L1 20VT/BK P112 20YL/WT* P114 20YL/BK* L24 20WT/LG*
BLACK CAV 1 2 3 CIRCUIT K7 18OR K4 18BK/LB K44 18TN/YL FUNCTION 8 VOLT SUPPLY SENSOR GROUND CAMSHAFT POSITION SENSOR SIGNAL
BLACK CAV 1 2 3 CIRCUIT M113 20LB/PK M20 20BR FUNCTION CENTER DOME LAMP FEED CENTER DOME LAMP GROUND
RED CAV 1 2 3 CIRCUIT Z1 20BK L50 20WT/TN FUNCTION GROUND STOP LAMP SWITCH OUTPUT * EXCEPT BUILT-UP-EXPORT J988W-3
8W - 80 - 18
YELLOW CAV 1 2
NS/GS
CLOCKSPRING - C1
NATURAL 4 1
CLOCKSPRING - C2
CAV 1 2 3 4
BLACK 1 2 CAV 1 2 CIRCUIT F45 20YL/RD T141 20YL/RD FUNCTION FUSED B(+) ENGINE STARTER MOTOR RELAY IGNITION SWITCH OUTPUT (START)
BLACK 1 2 CAV 1 2 CIRCUIT T141 20YL/RD T141 20YL/RD FUNCTION IGNITION SWITCH OUTPUT (START) IGNITION SWITCH OUTPUT (START)
RED
CAV 1 2
NS/GS
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
8W - 80 - 19
BLACK* NATURAL
10
17
7 8 9 16
23 24 25
CAV 1 2
BLACK
CAV 1 2 3
* DIESEL J988W-3
8W - 80 - 20
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
NS/GS
BLACK
BLACK
14
14
D01D
B02
BLACK
14
CAV 1 2 3 4 5 6 7 7 8 8 9 10 11 12 13 14
CIRCUIT X15 16BK/DG Q26 12VT/RD Z2 20BK/LG P96 20WT/LG Z1 20BK M11 20PK/LB X56 20DB/RD* X55 20BR/RD** X54 20VT* X53 20DG** F136 20VT/YL F133 20BR E2 20OR F55 12TN/DG Q16 12BR/WT X13 16RD/DG
BLACK
14
B03
CAV 1 2 3 4 5 6 7 7 8 8 9 10 11 12 13 14
CIRCUIT X15 16BK/DG Q26 12VT/RD Z2 20BK/LG P96 20WT/LG Z1 18BK M11 20PK/LB X56 20DB/RD* X55 20BR/RD** X54 20VT* X53 20DG** F136 20VT/YL F133 20BR E2 20OR F55 12TN/DG Q16 12BR/WT X13 16RD/DG
D01P
BLACK
10
D02
CAV 1 2 3 4 5 5 6 7 8 8 9 9 10 10
CIRCUIT X15 16BK/DG X13 16RD/DG M11 20PK/LB P22 20PK/BK X153 20WT/BR* X154 20WT/VT** P23 20PK/RD P24 20PK/WT X55 20BR/RD* X56 20DB/RD** X53 20DG* X54 20VT** X155 20BR/WT* X156 20VT/WT**
BLACK
10
B01
CAV 1 2 3 4 5 5 6 7 8 8 9 9 10 10
CIRCUIT X15 16BK/DG X13 16RD/DG M11 20PK/LB P22 20PK/BK X153 20WT/BR* X154 20WT/VT** P23 20PK/RD P24 20PK/WT X55 20BR/RD* X56 20DB/RD** X53 20DG* X54 20VT** X155 20BR/WT* X156 20VT/WT** * LHD ** RHD
J988W-3
NSGS8020
NS/GS
BLACK CAV 1 2 3 4 5 6 7 8 9 10
8W - 80 - 21
BLACK
10
10
D02 (LHD)
B120 (LHD)
BLACK
10
D02 (RHD)
CAV 1 2 3 4 5 6 7 8 9 10
BLACK
10
B120 (RHD)
CAV 1 2 3 4 5 6 7 8 9 10
NSGS8021
J988W-3
8W - 80 - 22
NS/GS
BLACK 1 8
16
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CIRCUIT D1 20VT/BR Z2 20BK/LG Z11 20BK/WT D20 20LG D21 20PK D2 20WT/BK D6 20PK/LB M1 20PK
FUNCTION CCD BUS(+) GROUND GROUND SCI RECEIVE SCI TRANSMIT CCD BUS(-) SCI RECEIVE (EATX) FUSED B(+)
BLACK 1 3 2 4 CAV 1 2 3 4 CIRCUIT Z12 20BK/TN A142 18DG/OR K4 20BK/LB K141 20TN/WT FUNCTION GROUND AUTOMATIC SHUT DOWN RELAY OUTPUT SENSOR GROUND HEATED OXYGEN SENSOR 1/2 SIGNAL
BLACK
CAV 1 2
BLACK 1 2 CAV 1 2 CIRCUIT M11 20PK/LB Z1 20BK FUNCTION COURTESY LAMP RELAY OUTPUT GROUND
J988W-3
NSGS8022
NS/GS
BLACK CAV 1 2
8W - 80 - 23
BLACK
CAV 1
1 2
CAV A B
CAV A
B C D
FUNCTION HEATED SEAT DRIVER HEATED SEAT DRIVER HEATED SEAT BACK GROUND
CAV A
B C D E F
CIRCUIT P87 18RD/WT P86 20VT P7 20WT/BK F35 18RD P89 20BK/RD Z1 18BK
FUNCTION DRIVER HEATED SEAT SWITCH HEATED SEAT TEMPERATURE SENSOR DRIVER HEATED SEAT SWITCH FUSED B(+) HEATED SEAT BACK GROUND * RKE J988W-3
NSGS8023
8W - 80 - 24
NS/GS
CAV A
B C D E F
FUNCTION HEATED SEAT TEMPERATURE SENSOR FUSED IGNITION (RUN) FUSED IGNITION (RUN) GROUND DRIVER HEATED SEAT BACK
4 5 6
RED CAV 1 2 3 4 5 6 CIRCUIT P75 20DB/WT P71 20YL P73 20YL/PK C16 20LB/YL Z1 20BK P112 20YL/WT FUNCTION DRIVER POWER MIRROR UP DRIVER POWER MIRROR LEFT DRIVER POWER MIRROR RIGHT/DOWN REAR DEFOGGER LAMP DRIVER GROUND POWER MIRROR B(-)
3 2 1
4 5 6
BLUE
3 2 1
CAV 1 2 3 4 5 6
CIRCUIT P64 20YL/OR P69 20WT/RD P65 20DB/YL P114 20YL/BK** P159 20DG* P160 20LB*
FUNCTION DRIVER POWER MIRROR UP/DOWN DRIVER POWER MIRROR RETURN DRIVER POWER MIRROR LEFT/RIGHT POWER MIRROR B(-) DRIVER POWER MIRROR UNFOLD DRIVER POWER MIRROR FOLD
NS/GS
8W - 80 - 25
GREEN
1 6
5 10
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT Z1 14BK P43 14GY/LB P17 14RD/LB P41 14GY/WT F35 14RD P15 14YL/LB P19 14YL/LG P11 14YL/WT P13 14RD/WT P21 14RD/LG
FUNCTION GROUND DRIVER SEAT RECLINER SWITCH DOWN DRIVER POWER SEAT HORIZONTAL REARWARD DRIVER SEAT RECLINER SWITCH UP FUSED B(+) DRIVER POWER SEAT HORIZONTAL FORWARD DRIVER POWER SEAT FRONT UP DRIVER POWER SEAT REAR UP DRIVER POWER SEAT REAR DOWN DRIVER POWER SEAT FRONT DOWN
NATURAL
14
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT Q24 18DG Q26 14VT/WT Q13 18DB Q16 14BR/WT Q14 18GY Q21 16WT Q23 18RD/WT Q11 16LG F55 14TN/DG F21 16TN Z1 12BK E2 20OR
FUNCTION POWER WINDOW RIGHT REAR B(+) DOWN MASTER WINDOW SWITCH RIGHT FRONT DOWN POWER WINDOW LEFT REAR B(+) UP MASTER WINDOW SWITCH RIGHT FRONT UP POWER WINDOW RIGHT REAR B(+) UP LEFT FRONT WINDOW DRIVER (DOWN) POWER WINDOW LEFT REAR B(+) DOWN LEFT WINDOW DRIVER (UP) FUSED B(+) FUSED IGNITION SWITCH OUTPUT (RUN/ACC) GROUND PANEL LAMPS FEED
BLACK
CAV A B
FUNCTION DRIVER POWER SEAT FRONT DOWN DRIVER POWER SEAT FRONT UP
BLACK
CAV A B
FUNCTION DRIVER POWER SEAT HORIZONTAL FORWARD DRIVER POWER SEAT HORIZONTAL REARWARD
J988W-3
8W - 80 - 26
BLACK
NS/GS
CAV A B
FUNCTION DRIVER POWER SEAT REAR UP DRIVER POWER SEAT REAR DOWN
BLACK
CAV A B
FUNCTION DRIVER SEAT RECLINER SWITCH DOWN DRIVER SEAT RECLINER SWITCH UP
RED
CAV 1 2
BLACK BLACK 2 1 2 CAV 1 2 CIRCUIT C23 12DG Z1 12BK 1 CAV 1 2 CIRCUIT C23 12DG Z1 12BK
E40
J988W-3
RF3
NSGS8026
NS/GS
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
8W - 80 - 27
CIRCUIT K11 18WT/DB K12 18TN/WT K13 18YL/WT K14 18LB/BR K4 18BK/LB K70 18VT/RD K52 18PK/BK K6 18VT/WT C18 18DB A142 18DG/OR K1 18DG/RD K2 18TN/BK -
BLACK 7 1
BLACK 1 7
14
14
E69 (2.4L)
F09 (2.4L)
BLACK 7 1
14
E78 (3.3L/3.8L)
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT A142 18DG/OR K6 18VT/WT K11 18WT/DB K12 18TN/WT K13 18YL/WT K14 18LB/BR K7 18OR K44 18TN/YL K1 18DG/RD K2 18TN/BK K38 18GY K58 18BR/DB K4 18BK/LB
BLACK 1 7
14
F02 (3.3L/3.8L)
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT A142 18DG/OR K6 18VT/WT K11 18WT/DB K12 18TN/WT K13 18YL/WT K14 18LB/BR K7 18OR K44 18TN/YL K1 18DG/RD K2 18TN/BK K38 18GY K58 18BR/DB K4 18BK/LB
BLACK CAV 1 2 3 4 5 6 CIRCUIT C137 20YL K57 20LG/OR Z1 16BK K153 18OR/DG K152 20WT/DG K90 18TN 6 3 4 1
BLACK CAV 1 2 3 4 5 6 CIRCUIT C137 20YL K57 20LG/OR Z12 14BK/TN K153 18OR/DG K152 20WT/DG K90 20OR/VT
3 6
1 4
E95 (DIESEL)
B107 (DIESEL)
NSGS8027
J988W-3
8W - 80 - 28
LT. GRAY CAV 1 2 3 4 5 6 7 8 9 10
NS/GS
LT. GRAY 1 6 5 10
5 10
1 6
E96 (DIESEL)
B108 (DIESEL)
BLACK
5 10
1 6
CAV 1 2 3 4 5 6 7
CIRCUIT K126 18LG Z122 18BK K67 18BR/BK K68 18LG/YL K24 20GY/BK K4 20BK/LB Z122 18BK K2 20TN/BK C13 20DB/OR C24 20DB/PK
BLACK
1 6
5 10
CAV 1 2 3 4 5 6 7
E97 (DIESEL)
8 9 10
B106 (DIESEL)
8 9 10
CIRCUIT K126 20LG Z1 18BK K67 20BR/BK K68 20LG/YL K24 18GY/BK K4 18BK/LB Z12 18BK Z1 18BK K2 20TN/BK C13 20DB/OR C24 20DB/PK
GRAY CAV 1 2 CIRCUIT K35 18GY/YL F87 18WT/BK FUNCTION EGR SOLENOID CONTROL FUSED IGNITION SWITCH OUTPUT
CAV 1 2
NSGS8028
NS/GS
BLACK 1 2 CAV 1 2
8W - 80 - 29
BLACK 1 2 CAV 1 2 CIRCUIT C66 18BK/WT FUNCTION WIPER DE-ICE SWITCHED GROUND -
BLACK
1 3 CAV 1 2 3 CIRCUIT K2 20TN/BK K4 20BK/LB G58 20BK/YL FUNCTION ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SENSOR GROUND ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
BLACK 1 2 CAV 1 2 CIRCUIT K4 18BK/LB K2 18TN/BK FUNCTION SENSOR GROUND ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
GREEN BLACK (2.0L) 1 2 CAV 1 2 CIRCUIT G6 16GY FUNCTION ENGINE OIL PRESSURE SWITCH SENSE -
8W - 80 - 30
NS/GS
CAV 1 2 3
LIGHT GRAY 4 1
CAV 1 1 2 3 4
FUNCTION LEAK DETECTION PUMP SWITCH SENSE LEAK DETECTION PUMP SWITCH SENSE LEAK DETECTION PUMP SOLENOID CONTROL FUSED IGNITION SWITCH OUTPUT -
BLACK 1 2
EVAP/PURGE SOLENOID
CAV 1 2
BLACK
1 2
CAV 1 2
LT. GRAY 4 1 CAV 1 2 3 4 CIRCUIT K7 18OR K4 18BK/LB K50 18YL/WT FUNCTION 8V SUPPLY SENSOR GROUND FLEXIBLE FUEL SENSOR SIGNAL -
NS/GS
BLACK CAV 1 2
8W - 80 - 31
BLACK 5 10 1 6
CAV 1 2 3 4 5 6 7 8 9 10
FUNCTION M1 SPEED BLOWER MOTOR M2 SPEED BLOWER MOTOR M3 SPEED BLOWER MOTOR HIGH SPEED BLOWER MOTOR LOW SPEED BLOWER MOTOR
RED/BLUE 2 1
CAV 1 2 3
FUNCTION FUSED B(+) FUSED PANEL LAMPS DIMMER SWITCH SIGNAL GROUND
NSGS8031
J988W-3
8W - 80 - 32
BLACK CAV 1 2 3
NS/GS
FUNCTION FRONT READING LAMP FEED COURTESY LAMP GROUND FUSED B(+)
BLUE 4 3 CAV 1 2 3 4 5 6 CIRCUIT M13 20BK/YL E2 18OR Z2 18BK/LG F41 20PK/VT M20 20BR FUNCTION FRONT READING LAMP FEED PANEL LAMPS FEED GROUND FUSED (B+) COURTESY LAMP GROUND
6 1
BLACK CAV A B CIRCUIT F1 20DB V10 20BR FUNCTION FUSED IGNITION (RUN-ACC) WASHER PUMP CONTROL SWITCH OUTPUT
BLACK
2 CAV 1 2 CIRCUIT A141 18DG/WT Z1 18BK FUNCTION FUEL PUMP RELAY OUTPUT GROUND
J988W-3
NSGS8032
NS/GS
BLACK 2 1
8W - 80 - 33
CAV 1 2
BLACK
CAV 1 2
BLACK 2 1
CAV 1 2
BLACK CAV 1 2 CIRCUIT A142 18DG/OR K12 18TN/WT FUNCTION AUTOMATIC SHUTDOWN RELAY OUTPUT INJECTOR NO. 2 DRIVER
CAV 1 2
8W - 80 - 34
BLACK
NS/GS
CAV 1 2
BLACK 2 1
CAV 1 2
BLACK CAV 1 2 CIRCUIT A142 18DG/OR K14 18LB/BR FUNCTION AUTOMATIC SHUTDOWN RELAY OUTPUT INJECTOR NO. 4 DRIVER
BLACK CAV 1 2 CIRCUIT A142 18DG/OR K38 18GY FUNCTION AUTOMATIC SHUTDOWN RELAY OUTPUT INJECTOR NO. 5 DRIVER
BLACK CAV 1 2 CIRCUIT A142 18DG/OR K58 18BR/DB FUNCTION AUTOMATIC SHUTDOWN RELAY OUTPUT INJECTOR NO. 6 DRIVER
NS/GS
BLACK CAV 1 2 3 4 5 6 7 8 9 10
8W - 80 - 35
5 10
1 6
LIGHT GRAY CAV 4 1 1 2 3 4 CIRCUIT Z1 16BK L1 20VT/BK G4 18DB A141 16DG/WT* FUNCTION GROUND BACK-UP LAMP FEED FUEL LEVEL SENSOR SIGNAL FUEL PUMP RELAY OUTPUT
BLACK
7 14
1 8
G200
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT Z2 20BK/LG Z2 20BK/LG Z2 20BK/LG Z2 18BK/LG Z1 20BK Z1 20BK Z1 18BK** Z1 20BK Z1 16BK Z2 20BK/LG Z2 20BK Z1 18BK Z1 20BK
BLACK
1 8
7 14
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT
8W - 80 - 36
CAV BLACK 1 1 2 3 4 5 6
NS/GS
14
14
G300
7 8 9 10 11 12 13 14
NS/GS
BLACK
8W - 80 - 37
CAV 1
BLACK
CAV 1 1 7 2 3 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT
2 3
14
G301 (DIESEL)
4 5 6 7 8 9 10 11 12 13 14
14
Z1 BUS BAR
(DIESEL)
BLACK
14
CAV 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14
G301 (GAS)
CIRCUIT Z1 18BK Z2 20BK/LG Z2 20BK/LG Z2 18BK/LG Z1 20BK* Z1 20BK* Z1 20BK** Z1 20BK Z1 20BK Z1 18BK Z1 18BK Z1 18BK Z1 18BK Z1 20BK
BLACK
14
CAV 1 2 3 4 5 6 7 7 8 9 10 11 12 13 14
CIRCUIT
Z1 BUS BAR
NSGS8037
8W - 80 - 38
NS/GS
BLACK
14
G302
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
BLACK
14
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT
Z1 BUS BAR
BLACK
14
G400
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT Z1 12BK Z1 20BK Z1 20BK Z1 12BK Z1 18BK Z1 20BK Z1 20BK Z2 20BK/LG Z1 20BK -
BLACK
14
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT
Z1 BUS BAR
BLACK CAV 1 2 3 2 CIRCUIT A142 18DG/OR K20 18DG FUNCTION ASD RELAY OUTPUT GENERATOR FIELD DRIVER -
GENERATOR (GAS)
* REAR A/C-HEATER J988W-3 NSGS8038
NS/GS
BLUE 1 2 CAV 1 2
8W - 80 - 39
1 3 4 2
CAV 1 2 3 4
FUNCTION FUSED B(+) GLOW PLUG RELAY CONTROL SENSE AUTO SHUTDOWN RELAY OUTPUT GLOW PLUG RELAY CONTROL
S02
3 4
2 4
1 3
HS6P
S02
NATURAL 6 13 1 7
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13
HEADLAMP SWITCH - C1
CIRCUIT Z1 20BK* L44 20VT/RD* M112 22BR/LG M32 22BK/LB E17 20YL/BK E17 20YL/BK Z1 20BK L13 20BR/YL* M111 22BR/WT M13 20BK/YL M113 20LB/PK E92 22OR/BK -
FUNCTION GROUND FUSED RIGHT LOW BEAM OUTPUT COURTESY LAMP RELAY CONTROL COURTESY LAMP SWITCH SENSE STEP DIMMER SWITCH SENSE STEP DIMMER SWITCH SENSE GROUND HEADLAMP LEVELING SIGNAL COURTESY LAMP RELAY CONTROL COURTESY LAMP RELAY OUTPUT READING LAMP FEED DIMMER SWITCH SIGNAL * BUILT-UP-EXPORT
NSGS8039
J988W-3
8W - 80 - 40
CAV 1 2 3 4 5 5 6 7 7 8
NS/GS
BLACK 4 8 1 5
HEADLAMP SWITCH - C2
CAV A B
BLACK CAV A B CIRCUIT X2 18DG/RD Z1 18BK FUNCTION HORN RELAY OUTPUT GROUND
NS/GS
NATURAL CAV 1 2
8W - 80 - 41
1 2
NATURAL 4 1
CAV 1 2 3 4
BLACK CAV 1 2 3 4 CIRCUIT K59 18VT/BK K40 18BR/WT K60 18YL/BK K39 18GY/RD FUNCTION IDLE AIR CONTROL MOTOR NO.4 DRIVER IDLE AIR CONTROL MOTOR NO.3 DRIVER IDLE AIR CONTROL MOTOR NO.2 DRIVER IDLE AIR CONTROL MOTOR NO.1 DRIVER
BLACK
CAV 1 2 3
FUNCTION IGNITION COIL NO. 2 DRIVER ASD RELAY OUTPUT IGNITION COIL NO. 1 DRIVER
BLACK CAV 1 2 3 4 CIRCUIT K18 18RD/YL K19 18GY/RD A142 18DG/OR K17 18DB/TN FUNCTION IGNITION COIL DRIVER NO. 3, 6 IGNITION COIL DRIVER NO. 1, 4 ASD RELAY OUTPUT IGNITION COIL DRIVER NO. 2, 5
1 3
2 4
8W - 80 - 42
CAV 1 2 3 4 5 6 7 8 9 10
NS/GS
BLACK 5 10 1 6
IGNITION SWITCH - C1
GREEN CAV 1 2 CIRCUIT G26 20LB Z1 20BK FUNCTION KEY-IN IGNITION SWITCH SENSE GROUND
IGNITION SWITCH - C2
BLACK CAV 1 2 CIRCUIT M1 20PK A81 20DG/RD FUNCTION FUSED B(+) IGNITION SWITCH OUTPUT (OFF/RUN/START)
IGNITION SWITCH - C3
RED 6 13 1 7
INSTRUMENT CLUSTER
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13
FUNCTION FUSED B(+) PANEL LAMPS FEED GROUND CCD BUS (-) CCD BUS (+) FUSED IGNITION (ST-RUN-OFF) GROUND NSGS8042
J988W-3
NS/GS
DARK GRAY 1 2 CAV 1 2
8W - 80 - 43
BLACK
CAV A B C D
FUNCTION SENSOR GROUND INTAKE AIR TEMPERATURE SIGNAL 5 VOLT SUPPLY MAP SENSOR SIGNAL
J02A
CAV 1 2 3 4 5 6
CIRCUIT Z1 12BK L50 20WT/TN M11 20PK/LB F133 20BR/RD F136 20VT/WT L77 20BR/LB
BLACK 6 1
L15
CAV 1 2 3 4 5 6
CIRCUIT Z1 12BK L50 20WT/TN M11 20PK/LB F133 20BR/RD F136 20VT/WT L77 20BR/LB
BLACK 1 6 CAV 1 2 3 4 5 6 CIRCUIT C15 12BK/WT V13 18BR/LG V23 18BR/PK G78 18TN/BK P98 20WT/RD 6 1 CAV 1 2 3 4 5 6 CIRCUIT C15 12BK/WT V13 18BR/LG V23 18BR/PK G78 18TN/BK P98 20WT/RD
J03A
L16
NSGS8043
J988W-3
8W - 80 - 44
CAV 1 GRAY 7 14 18 22 29 36 1 8 15 19 23 30 2 3 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
NS/GS
JUNCTION BLOCK - C1
J988W-3
* CHRYSLER ** REAR A/C-HEATER MEMORY SEAT BUILT-UP-EXPORT EXCEPT BUILT-UP-EXPORT EATX DIESEL
NSGS8044
NS/GS
CAV 1 2 GRAY 7 14 18 22 29 36 1 8 15 19 23 30 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
8W - 80 - 45
JUNCTION BLOCK - C2
8W - 80 - 46
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
NS/GS
GRAY 1 14 15 22 23 36 7 8 18 19 29 30
JUNCTION BLOCK - C3
J988W-3
NSGS8046
NS/GS
CAV 1 2 3 4 5 6 7 29 36 23 30 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 * GAS ** RHD REAR A/C GAS, BUILT-UP-EXPORT GAS, EXCEPT BUILT-UP-EXPORT BUILT-UP-EXPORT 24 25 26 27 28 29 30 31 32 33 34 35 36
8W - 80 - 47
GRAY 7 14 18 22 1 8 15 19
JUNCTION BLOCK - C4
NSGS8047
J988W-3
8W - 80 - 48
WHITE
NS/GS
CAV 1 2
GREEN
KEY-IN SWITCH
CAV 1 2
GRAY
CAV 1 2
4 2 1 5 3
BLACK
CAV 1 2 3
4 5
CIRCUIT L63 18DG/RD Z1 18BK Z1 18BK L50 18WT/TN L50 18WT/TN L615 18OR -
FUNCTION LEFT TURN SIGNAL GROUND STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT LEFT COMBINATION RELAY OUTPUT -
BLACK CAV 1 2 3 CIRCUIT X154 20WT/VT* X153 20WT/BR** X15 16BK/DG X53 20DG X156 20VT/WT* X155 20BR/WT** X13 16RD/DG X55 20BR/RD FUNCTION LEFT INSTRUMENT PANEL SPEAKER (+) LEFT INSTRUMENT PANEL SPEAKER (+) AMPLIFIED SPEAKER GROUND LEFT FRONT SPEAKER (+) LEFT INSTRUMENT PANEL SPEAKER (-) LEFT INSTRUMENT PANEL SPEAKER (-) RADIO CHOKE OUTPUT LEFT FRONT SPEAKER (-) * RHD ** LHD
6 3
4 1
4 5 6
J988W-3
NSGS8048
NS/GS
BLACK CAV 1 2
8W - 80 - 49
FUNCTION FUSED PARK LAMP RELAY OUTPUT FOG LAMP SWITCHED GROUND
BLACK
CAV 1
2 3 4
FUNCTION LEFT INSTRUMENT PANEL SPEAKER (-) LEFT INSTRUMENT PANEL SPEAKER (-) LEFT INSTRUMENT PANEL SPEAKER (+) LEFT INSTRUMENT PANEL SPEAKER (+)
CAV 1 2 3
FUNCTION FUSED LEFT INBOARD TAIL LAMP GROUND LEFT TURN SIGNAL
CAV 1 2 3
FUNCTION LEFT TURN SIGNAL FUSED LEFT INBOARD TAIL LAMP GROUND
8W - 80 - 50
BLACK CAV 1 2
NS/GS
FUNCTION LEFT FRONT WHEEL SPEED SENSOR (-) LEFT FRONT WHEEL SPEED SENSOR (+)
BLACK 1 2 CAV 1 2 3 CIRCUIT L33 20RD L43 18VT Z1 20BK FUNCTION FUSED LEFT HIGH BEAM OUTPUT FUSED LEFT LOW BEAM OUTPUT GROUND
BLACK
3 2
CAV 1 2 3
FUNCTION FUSED LEFT LOW BEAM OUTPUT GROUND FUSED LEFT HIGH BEAM OUTPUT
BLACK
CAV 1 2 3
FUNCTION GROUND HEADLAMP ADJUST SIGNAL FUSED RIGHT LOW BEAM OUTPUT
CAV A B
NS/GS
BLACK 2 1 CAV 1 2
8W - 80 - 51
FUNCTION COURTESY LAMP RELAY OUTPUT COURTESY LAMP RELAY OUTPUT GROUND
CAV A B
CAV 1 2 3
3 6
1 4
3 6
1 4
CAV 1 2 3 4 5 6
FUNCTION LEFT TURN SIGNAL BACK-UP SWITCH OUTPUT FUSED LEFT INBOARD TAIL LAMP STOP LAMP SWITCH OUTPUT GROUND * DIESEL J988W-3
8W - 80 - 52
BLACK CAV 1 2
NS/GS
GRAY CAV 1 2 3 CIRCUIT M113 20LB/PK M20 20BR F41 20PK/VT FUNCTION COURTESY LAMP RELAY OUTPUT COURTESY LAMP GROUND FUSED B (+)
BLACK CAV 1 2 3 CIRCUIT F133 20BR/YL F136 20VT/WT FUNCTION FUSED DOOR LOCK RELAY OUTPUT FUSED DOOR UNLOCK RELAY OUTPUT -
BLACK CAV 1 2 3 6 1 4 3 4 5 6 CIRCUIT X151 20BR/YL* X15 16BK/DG* X51 20BR/YL X157 20BR/LB* X13 16RD/DG* X57 20BR/LB FUNCTION LEFT REAR SPEAKER (+) AMPLIFIER SPEAKER GROUND LEFT REAR SPEAKER (+) LEFT REAR SPEAKER (-) RADIO CHOKE OUTPUT LEFT REAR SPEAKER (-)
NATURAL CAV 1 2 3 CIRCUIT Q13 18DB Q23 18RD/WT FUNCTION LEFT REAR VENT MOTOR (CLOSE) LEFT REAR VENT MOTOR (OPEN)
* PREMIUM NSGS8052
NS/GS
NATURAL
8W - 80 - 53
CAV 1 2 3
FUNCTION LEFT REAR VENT MOTOR (CLOSE) LEFT REAR VENT MOTOR (OPEN)
GRAY
CAV 1 2
FUNCTION LEFT REAR WHEEL SPEED SENSOR (-) LEFT REAR WHEEL SPEED SENSOR (+)
CAV 1 2
4 2 1 5 3
BLACK
CAV 1 2 3 4 5
CIRCUIT L50 18WT/TN L50 18WT/TN Z1 18BK Z1 18BK L73 18YL L63 18DG/RD L63 18DG/RD L615 18OR
FUNCTION STOP LAMP SWITCH OUTPUT GROUND LEFT STOP/TURN SIGNAL OUTPUT LEFT REAR TURN SIGNAL LEFT COMBINATION RELAY OUTPUT
BLACK A B
CAV A B
J988W-3
8W - 80 - 54
GRAY 3 1 CAV 1 2 3
NS/GS
LICENSE LAMP
BLACK CAV 1 2 3 CIRCUIT Z1 20BK G78 18TN/BK FUNCTION GROUND LIFTGATE AJAR SWITCH SENSE
CAV 1 2
2 CAV 1 2 CIRCUIT G18 20BK/PK Z1 20BK FUNCTION COOLANT LEVEL SWITCH SENSE GROUND
NS/GS
BLACK CAV A B C
8W - 80 - 55
GREEN
BLACK CAV A B CIRCUIT P121 14RD/LG P119 14YL/LG FUNCTION SEAT FRONT VERTICAL (DOWN) SEAT FRONT VERTICAL (UP)
BLACK CAV A B C CIRCUIT P29 20BR/WT P26 22BR P28 20BR/RD FUNCTION 5 VOLT SUPPLY SEAT FRONT VERTICAL POSITION SENSE SEAT POSITION SENSE COMMON
CAV A B
8W - 80 - 56
BLACK CAV A B C
NS/GS
FUNCTION SEAT POSITION SENSE COMMON SEAT HORIZONTAL POSITION SENSE 5 VOLT SUPPLY
BLACK
CAV A B
BLACK
CAV A B C
FUNCTION SEAT POSITION SENSE COMMON SEAT REAR VERTICAL POSITION SENSE 5 VOLT SUPPLY
BLACK CAV A B CIRCUIT P43 14GY/LB P41 14GY/WT FUNCTION SEAT RECLINER (REARWARD) SEAT RECLINER (FORWARD)
BLACK CAV A B C CIRCUIT P28 20BR/RD P47 22LB P29 20BR/WT FUNCTION SEAT POSITION SENSE COMMON SEAT RECLINER POSITION SENSE 5 VOLT SUPPLY
NS/GS
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
8W - 80 - 57
BLACK 12 25 1 13
BLACK 1 6 5 10
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT P117 14RD/LB P115 14YL/LB P111 14YL/WT P43 14GY/LB P119 14YL/LG P113 14RD/WT Z1 14BK F35 14RD P41 14GY/WT P121 14RD/LG
FUNCTION SEAT HORIZONTAL (REARWARD) SEAT HORIZONTAL (FORWARD) SEAT REAR VERTICAL (UP) SEAT RECLINER (REARWARD) SEAT FRONT VERTICAL (UP) SEAT REAR VERTICAL (DOWN) GROUND FUSED B (+) SEAT RECLINER (FORWARD) SEAT FRONT VERTICAL (DOWN)
NSGS8057
J988W-3
8W - 80 - 58
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
NS/GS
NATURAL 10 21 1 11
4 5 6
BLUE
3 2 1
CAV 1 2 3 4 5 6
BLUE 6 13 1 7
CAV 1 2 3 4 5 6 7 7 8 9 10 11 12 13
CIRCUIT L34 20RD/OR L63 18DG/RD Z1 20BK L62 18BR/RD G19 20LG/OR G2 22VT G3 20BK/PK G85 20OR/BK * G6 22GY G9 20GY/BK V23 18BR/PK R41 18BK/TN M1 20PK G69 22BK/OR
FUNCTION FUSED HIGH BEAM RELAY OUTPUT LEFT TURN SIGNAL GROUND RIGHT TURN SIGNAL ABS WARNING LAMP DRIVER ENGINE TEMPERATURE WARNING LAMP DRIVER SERVICE ENGINE SOON INDICATOR LAMP DRIVER WAIT-TO START WARNING LAMP DRIVER ENGINE OIL PRESSURE SWITCH SENSE RED BRAKE WARNING LAMP DRIVER FUSED IGNITION (ST-RUN) AIRBAG WARNING LAMP DRIVER FUSED B (+) VTSS INDICATOR LAMP DRIVER
NS/GS
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13
8W - 80 - 59
6 13
1 7
BLACK
CAV 1 2 3 4 5
CIRCUIT C34 20DB/WT C26 20PK/DB C37 20YL C57 20DB/GY C35 20DG/YL
FUNCTION DOOR COMMON 5 VOLT SUPPLY MODE DOOR FEEDBACK SIGNAL SENSOR GROUND MODE DOOR DRIVER
BLACK
CAV 1 2 3 4 5 6 7 8 9 10 11 12
7 12 8
MULTI-FUNCTION SWITCH
CIRCUIT L91 22DB/PK L302 22LB/YL L305 22LB/WT V16 20WT V52 20DG//YL F1 20DB Z1 18BK L93 22PK L94 20OR/WT V10 20BR L324 22WT/LG
FUNCTION COMBO FLASHER SWITCHED GROUND LEFT TURN SIGNAL SENSE RIGHT TURN SIGNAL SENSE HIGH SPEED RELAY DRIVER WIPER MUX SIGNAL FUSED B(+) GROUND HIGH/LOW BEAM RELAY CONTROL LOW BEAM RELAY CONTROL FRONT WASHER MOTOR CONTROL HIGH BEAM RELAY CONTROL
NSGS8059
J988W-3
8W - 80 - 60
NS/GS
BLACK
CAV 1 2
4 5 6
RED
3 2 1
OVERHEAD CONSOLE
CAV 1 2 3 4 5 6
CIRCUIT D2 18WT/BK G32 20BK/LB Z2 18BK/LG V23 18BR/PK G31 20VT/LG D1 18VT/BR
FUNCTION CCD BUS(-) SENSOR GROUND GROUND FUSED IGN. (ST-RUN) AMBIENT TEMPERATURE SENSOR SIGNAL CCD BUS(+)
BLACK
7 14
1 8
P30
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT C26 22PK/DB C57 22DB/GY C32 22GY/DB C33 22DB/RD C34 22DB/WT C35 22DG/YL C36 22RD/WT C37 22YL C61 22DB C62 22DB/PK C102 22LG C21 22DB/OR -
BLACK
1 8
7 14
J01D
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CIRCUIT C26 20PK/DB C57 20DB/GY C32 20GY/DB C33 20DB/RD C34 20DB/WT C35 20DG/YL C36 20RD/WT C37 20YL C61 20DB* C62 20DB/PK* C102 20LG* C21 20DB/OR -
* REAR A/C
J988W-3
NSGS8060
NS/GS
NATURAL CAV 1 2 3 4 5 6 7 8
8W - 80 - 61
3 8
1 4
P50 (RHD)
CIRCUIT D1 20VT/BR G96 22LG/RD D2 20WT/BK F11 20RD/WT L91 20DB/PK X12 20RD/WT M1 22PK Z1 18BK
CAV 1 2 3 4 5 6 7 8
CIRCUIT -
BLACK
CAV 1 2 3
FUNCTION BACK-UP LAMP RELAY OUTPUT PARK/NEUTRAL POSITION SWITCH SENSE FUSED IGNITION (RUN)
BLACK
1 CAV 1 2 3 CIRCUIT T3 18VT T41 18BK/WT F11 18RD/WT FUNCTION PARK/NEUTRAL POSITION SWITCH OUTPUT PARK/NEUTRAL POSITION SWITCH SENSE FUSED IGNITION (ST-RUN-OFF)
YELLOW 4 1 CAV 1 2 3 4 CIRCUIT R44 18DG/YL R42 18BK/YL FUNCTION PASSENGER AIRBAG LINE NO. 2 PASSENGER AIRBAG LINE NO. 1 -
1 CAV 1 2 CIRCUIT Z2 20BK/LG P96 20WT/LG FUNCTION GROUND PASSENGER DOOR SWITCH MUX
NSGS8061
J988W-3
8W - 80 - 62
BLACK 1 2 CAV 1 2
NS/GS
CAV 1 2
FUNCTION FUSED DOOR UNLOCK RELAY OUTPUT FUSED DOOR LOCK RELAY OUTPUT
BLACK
CAV 1
1 2
CAV A B
CAV A
B C D
FUNCTION HEATED SEAT DRIVER HEATED SEAT DRIVER HEATED SEAT BACK GROUND
CAV A
B C D E F
CIRCUIT P87 18RD/WT P86 20VT P8 20WT/BK F35 18RD P89 20BK/RD Z1 18BK
FUNCTION HEATED SEAT DRIVER HEATED SEAT TEMPERATURE SENSOR PASSENGER HEATED SEAT SWITCH FUSED B(+) HEATED SEAT BACK GROUND * RKE NSGS8062
J988W-3
NS/GS
CAV A
8W - 80 - 63
B C D E F
4 5 6
RED
3 2 1
CAV 1 2 3 4 5 6
CIRCUIT P74 20DB P72 20YL/BK P70 20WT C16 20LB/YL Z1 20BK -
FUNCTION MIRROR SWITCH OUTPUT (HORIZONTAL) MIRROR SWITCH OUTPUT (VERTICAL) MIRROR SWITCH COMMON FUSED B(+) GROUND -
4 5 6
BLUE
3 2 1
CAV 1 2 3 4 5 6
CIRCUIT P67 20YL/RD P66 20WT/BK P68 20DG/RD P159 20DG* P160 20LB*
FUNCTION PASSENGER MIRROR POSITION (VERTICAL) PASSENGER MIRROR POSITION COMMON PASSENGER MIRROR POSITION (HORIZONTAL) PASSENGER MIRROR UNFOLD SIGNAL PASSENGER MIRROR FOLD SIGNAL
NSGS8063
* BUILT-UP-EXPORT ** RKE
J988W-3
8W - 80 - 64
GREEN 1 6 5 10 CAV 1 2 3 4 5 6 7 8 9 10
NS/GS
BLACK CAV 1 2 3 4 5 6 7 8 CIRCUIT F55 12TN/DG Q26 12VT/WT Q16 12BR/WT Q22 14VT E2 20OR Z1 20BK Q12 14BR FUNCTION FUSED IGNITION SWITCH OUTPUT (RUN/ACC) RIGHT FRONT WINDOW (DOWN) RIGHT FRONT WINDOW (UP) RIGHT FRONT WINDOW (DOWN) PANEL LAMPS FEED GROUND RIGHT FRONT WINDOW (UP)
4 8
1 5
BLACK CAV A B CIRCUIT P18 14YL/LG P20 14RD/LG FUNCTION SEAT FRONT VERTICAL (UP) SEAT FRONT VERTICAL (DOWN)
BLACK
CAV A B
NS/GS
BLACK
8W - 80 - 65
CAV A B
BLACK
CAV A B
RED
CAV 1 2
NATURAL 4 6
CAV 1 2 3 4 5 6
FUNCTION BLOWER MOTOR FEED FROM ATC/RELAY TAIL, LICENSE, SIDE MARKER LAMP, PARK LAMP FEED FUSED B (+)
J988W-3
8W - 80 - 66
ORANGE CAV 1 2 3 3 4 5 6 7 8 9 10
NS/GS
5 10
1 6
DK. GREEN CAV 1 2 3 4 5 6 7 8 9 10 CIRCUIT L44 20VT/RD L324 20WT/LG M1 20PK A20 12RD/DB L94 20OR/WT* L193 20OR/WT** F32 18PK/DB L97 18PK/DB FUNCTION FUSED LOW BEAM RELAY OUTPUT HIGH BEAM RELAY DRIVER FUSED B (+) FUSED B (+) LOW BEAM RELAY DRIVER LOW BEAM RELAY DRIVER FUSED B (+) PARK LAMP RELAY CONTROL
5 10
1 6
NS/GS
BLACK 4 1 6 3 CAV 1 2 3 4 5 6
8W - 80 - 67
LT. GRAY
CAV 1 2
5 10
1 6
3 4 5 6 7 8 9 10
CIRCUIT L33 20RD F14 20LG/YL* F14 18LG/YL** V3 12BR/WT V4 12RD/YL V16 20WT L34 20RD/OR L34 20RD/OR V14 18RD/VT L43 18VT L9 18BK/WT F23 20DB/YL* F23 18DB/YL**
FUNCTION HIGH BEAM RELAY OUTPUT FUSED IGNITION SWITCH OUTPUT (ST-RUN) FUSED IGNITION SWITCH OUTPUT (ST-RUN) WIPER HIGH/LOW RELAY OUTPUT (LOW) WIPER HIGH/LOW RELAY OUTPUT (HIGH) WIPER HIGH/LOW RELAY DRIVER HIGH BEAM RELAY OUTPUT HIGH BEAM RELAY OUTPUT WIPER ON RELAY DRIVER LOW BEAM RELAY OUTPUT FUSED HAZARD FLASHER FEED (DEDICATED) FUSED IGNITION SWITCH OUTPUT (RUN) FUSED IGNITION SWITCH OUTPUT (RUN)
LT. GREEN
5 10
1 6
CAV 1 1 2 3 3 4 5 6 7 7 8 8 9 10
CIRCUIT F87 18BK/WT A142 18DG/OR C3 18DB/BK K31 18BR Z1 20BK K90 18TN A142 18DG/OR F87 18WT/BK C13 18DB/OR C13 20DB/OR K51 18DB/YL K51 20DB/YL A14 18RD/WT -
FUNCTION FUSED IGNITION "C" (7.5A) FUSED IGNITION "C" (7.5A) A/C COMPRESSOR CLUTCH RELAY OUTPUT FUEL PUMP RELAY CONTROL GROUND ENGINE STARTER MOTOR RELAY CONTROL ASD RELAY OUTPUT FUSED IGNITION SWITCH OUTPUT (RUN/START) A/C COMPRESSOR CLUTCH RELAY CONTROL A/C COMPRESSOR CLUTCH RELAY CONTROL ASD RELAY CONTROL ASD RELAY CONTROL FUSED B(+) * EXCEPT BUILT-UP-EXPORT ** BUILT-UP-EXPORT DIESEL GAS
NSGS8067
J988W-3
8W - 80 - 68
GRAY 4 1 6 3 CAV 1 2 3 4 5 6
NS/GS
AQUA
5 10
1 6
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT T16 18RD T15 18LG Z16 18BK F45 18YL/RD A5 18RD/DB
FUNCTION TRANSMISSION CONTROL RELAY OUTPUT TRANSMISSION CONTROL RELAY CONTROL GROUND FUSED B(+) FUSED B(+)
BLACK 1 2 CAV 1 2 CIRCUIT P136 20YL Z1 20BK FUNCTION POWER FOLDING MIRROR INPUT GROUND
BLACK 6 13 1 7
NS/GS
GRAY CAV 1 2
8W - 80 - 69
23
68
46
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
CIRCUIT Z12 16BK/TN K159 20VT/RD K90 20TN K140 18TN/WT K140 18TN/WT C24 20DB/PK K57 20LG/OR K24 18GY/BK K68 20LG/YL K67 20BR/BK C18 20DB K2 20TN/BK K22 20OR/DB K119 20LG/BK K7 20OR K29 20WT/PK K3 20BK/VT A142 16DG/OR Z12 16BK/TN K35 20GY/YL G85 20OR/BK V38 20LB/RD C13 20DB/OR K134 20LB/BK K4 20BK/LB V37 20RD/LG C103 20DG/LB F87 18WT/BK K1 20DG/RD
FUNCTION GROUND ENGINE SPEED SENSOR SIGNAL ENGINE STARTER MOTOR RELAY CONTROL FUEL QUANTITY ACTUATOR SIGNAL FUEL QUANTITY ACTUATOR SIGNAL LOW SPEED RADIATOR FAN RELAY NO. 2 CONTROL CONTROL SLEEVE POSITION SENSOR ENGINE SPEED SENSOR FEED NEEDLE MOVEMENT SENSOR RETURN NEEDLE MOVEMENT SENSOR SIGNAL A/C PRESSURE SWITCH SIGNAL ENGINE COOLANT TEMPERATURE SENSOR SIGNAL ACCELERATOR PEDAL SENSOR SIGNAL CLUTCH SWITCH SIGNAL 5 VOLT SUPPLY BRAKE SWITCH SENSE ENGINE SPEED SENSOR RETURN DIESEL POWER RELAY OUTPUT GROUND EGR SOLENOID CONTROL GLOW PLUG LAMP DRIVER SPEED CONTROL LAMP DRIVER A/C COMPRESSOR CLUTCH RELAY CONTROL SLEEVE POSITION SENSOR SENSOR GROUND SPEED CONTROL SWITCH SIGNAL A/C SWITCH SIGNAL FUSED IGNITION (ST-RUN) BOOST PRESSURE SENSOR SIGNAL CONTINUED ON NEXT PAGE * MEMORY SEAT J988W-3
NSGS8069
8W - 80 - 70
NS/GS
J988W-3
NSGS8070
NS/GS
CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
8W - 80 - 71
BLACK
31 21 11 1
40 30 20 10
8W - 80 - 72
CAV 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
NS/GS
GRAY
50 60 70 80
41 51 61 71
BLACK CAV 1 2 CIRCUIT M1 20PK A81 20DG/RD FUNCTION FUSED B(+) IGNITION SWITCH OUTPUT (OFF/RUN/START)
PRNDL FEED
J988W-3
NS/GS
NATURAL CAV 1 2 3
8W - 80 - 73
PRNDL SWITCH
BLACK CAV 1 2 3 4 CIRCUIT Z1 12BK C27 12DB/PK C116 12LG/WT C25 12YL FUNCTION GROUND RADIATOR FAN RELAY CONTROL HIGH SPEED RELAY OUTPUT RADIATOR FAN RELAY OUTPUT
BLACK CAV 1 2 CIRCUIT C23 12DG Z1 12BK FUNCTION LOW SPEED RADIATOR FAN RELAY OUTPUT GROUND
BLACK CAV 1 2 CIRCUIT C23 12DG Z1 12BK FUNCTION LOW SPEED RADIATOR FAN RELAY OUTPUT GROUND
BLACK CAV 1 2 3 4 CIRCUIT Z1 14BK K173 14LG/DB C23 12DG A16 12GY FUNCTION GROUND RADIATOR FAN RELAY CONTROL LOW SPEED RADIATOR FAN RELAY OUTPUT FUSED B(+)
8W - 80 - 74
NATURAL
NS/GS
3 6 9
2 5 8
1 4 7 CAV 2 4 5 6 8 CIRCUIT Z1 12BK A142 18DG/OR C27 12DB/PK C137 20YL C116 12LG/WT FUNCTION GROUND AUTO SHUTDOWN RELAY OUTPUT HIGH SPEED RADIATOR FAN RELAY CONTROL HIGH SPEED RADIATOR FAN RELAY CONTROL HIGH SPEED RELAY OUTPUT
3 6 9
2 5 8
1 4 7 CAV 2 4 6 8 CIRCUIT C25 12YL A142 18DG/OR C24 20DB/PK A16 12GY FUNCTION RADIATOR FAN RELAY OUTPUT AUTO SHUTDOWN RELAY OUTPUT LOW SPEED RADIATOR FAN RELAY CONTROL FUSED B(+)
3 6 9
2 5 8
1 4 7 CAV 2 4 6 8 CIRCUIT C27 12DB/PK A142 18DG/OR C137 20YL A17 12RD/BK FUNCTION RADIATOR FAN RELAY CONTROL AUTO SHUTDOWN RELAY OUTPUT HIGH SPEED RADIATOR FAN RELAY CONTROL FUSED B(+)
RADIO - C1
NS/GS
CAV BLACK 1 2 3 7 1 4
8W - 80 - 75
RADIO - C2
5 6 7
BLACK CAV 1 2 CIRCUIT D1 20VT/BR D2 20WT/BK FUNCTION CCD BUS(+) CCD BUS(-)
LT.GRAY 1 2 CAV 1 2 CIRCUIT X1 16DG/RD X13 16RD/DG FUNCTION NAME BRAND SPEAKER RELAY OUTPUT RADIO CHOKE OUTPUT
RADIO CHOKE
LT. GREEN CAV 1 2 3 4 5 6 7 8 9 10 CIRCUIT C34 20DB/WT C61 20DB C40 12BR/WT C65 14BK/OR C60 16BK/LB C70 12DG FUNCTION A/C MODE DOOR DRIVER (A) DUAL ZONE A/C ACTUATOR REAR BLOWER RELAY OUTPUT REAR BLOWER MEDIUM SPEED REAR BLOWER MEDIUM SPEED REAR BLOWER HIGH SPEED -
5 10
1 6
8W - 80 - 76
NS/GS
BLACK CAV 1 2 3 4 5 6 7 8 CIRCUIT C70 12DG C60 16BK/LB C50 12BK/LG Z1 12BK E2 20OR FUNCTION REAR BLOWER HIGH SPEED REAR BLOWER MEDIUM SPEED REAR BLOWER LOW SPEED GROUND PANEL LAMPS FEED
BLACK CAV 1 2 3 4 5 6 7 8 CIRCUIT C60 16BK/LB C65 14BK/OR C70 12DG Z1 18BK C50 12BK/LG E2 20OR FUNCTION REAR BLOWER MEDIUM SPEED REAR BLOWER MEDIUM SPEED REAR BLOWER HIGH SPEED GROUND REAR BLOWER LOW SPEED PANEL LAMPS FEED
4 8
1 5
RED CAV 1 2 3 3 CIRCUIT F30 16RD Z1 16BK GROUND FUNCTION FUSED B(+) -
J988W-3
NSGS8076
NS/GS
BLACK CAV 1 2 3
8W - 80 - 77
CIRCUIT M113 20LB/PK M20 20BR READING LAMP FEED COURTESY LAMP GROUND
BLACK CAV A B CIRCUIT F1 20DB V20 20BK/WT FUNCTION FUSED IGNITION (RUN-ACC) REAR WASHER MOTOR CONTROL
BLACK CAV 1 2 3 CIRCUIT Z1 18BK V23 18BR/PK V13 18BR/LG FUNCTION GROUND FUSED IGNITION SWITCH OUTPUT REAR WIPER MOTOR CONTROL
NATURAL
CAV 1 2 3 4 5
4 5 6
RED
3 2 1
CAV 1 2 3 4 5 6
FUNCTION FUSED B(+) GROUND RKE MODULE PROGRAM ENABLE RKE INTERFACE
NSGS8077
J988W-3
8W - 80 - 78
BLACK 4 CAV 2 5 3 1 2 3 4 5
NS/GS
CIRCUIT L62 18BR/RD L62 18BR/RD Z1 18BK L50 18WT/TN L605 18DG -
FUNCTION RIGHT TURN SIGNAL GROUND STOP LAMP SWITCH OUTPUT RIGHT TURN SIGNAL -
6 3
4 1
CAV 1 2 3 4 5 6
CIRCUIT X153 20WT/BR X154 20WT/VT X15 16BK/DG X54 20VT X155 20BR/WT X156 20VT/WT X13 16RD/DG X56 20DB/RD
FUNCTION RIGHT I/P SPEAKER (+) RIGHT I/P SPEAKER (+) AMPLIFIED SPEAKER GROUND RIGHT FRONT SPEAKER (+) RIGHT FRONT I/P SPEAKER (-) RIGHT FRONT I/P SPEAKER (-) RADIO CHOKE OUTPUT RIGHT FRONT SPEAKER (-)
BLACK GRAY CAV 1 2 CIRCUIT F39 18PK/LG Z39 20BK FUNCTION FUSED PARK LAMP RELAY OUTPUT FOG LAMP SWITCHED GROUND
BLACK CAV 1 4 1 2 3 4 CIRCUIT X155 20BR/WT X156 20VT/WT X153 20WT/BR X154 20WT/VT FUNCTION RIGHT FRONT I/P SPEAKER (-) RIGHT FRONT I/P SPEAKER (-) RIGHT FRONT I/P SPEAKER (+) RIGHT FRONT I/P SPEAKER (+)
J988W-3
NS/GS
BLACK 3 1 CAV 1 2 3
8W - 80 - 79
CAV 1 2 3
BLACK CAV 1 2 3 4 CIRCUIT X56 20DB/RD X54 20VT FUNCTION RIGHT FRONT SPEAKER (-) RIGHT FRONT SPEAKER (+) -
BLACK CAV 1 2 CIRCUIT B6 18WT/DB B7 18WT FUNCTION RIGHT FRONT WHEEL SPEED SENSOR (-) RIGHT FRONT WHEEL SPEED SENSOR (+)
BLACK 1 2 CAV 1 2 3 CIRCUIT L34 20RD/OR L44 20VT/RD Z1 20BK FUNCTION FUSED RIGHT HIGH BEAM RELAY OUTPUT FUSED RIGHT LOW BEAM OUTPUT GROUND
8W - 80 - 80
BLACK
NS/GS
CAV 1 2 3
FUNCTION FUSED RIGHT LOW BEAM OUTPUT GROUND FUSED RIGHT HIGH BEAM OUTPUT
BLACK CAV 1 2 3 CIRCUIT Z1 20BK L13 18BR/YL L44 20VT/RD FUNCTION GROUND HEADLAMP ADJUST SIGNAL FUSED RIGHT LOW BEAM OUTPUT
CAV A B
BLACK 1 2 CAV 1 2 CIRCUIT M11 20PK/LB Z1 20BK FUNCTION COURTESY LAMP RELAY OUTPUT GROUND
CAV A B
J988W-3
NSGS8080
NS/GS
GRAY CAV 1 2 3
8W - 80 - 81
3 6
1 4
CAV 1 2 3 4 5 6
CIRCUIT Z1 20BK L36 20LG L78 20DG/YL L1 20VT/BK L62 18BR/RD L50 18WT/TN
FUNCTION GROUND REAR FOG LAMP FUSED B(+) BACK-UP LAMP FEED RIGHT TURN SIGNAL STOP LAMP SWITCH OUTPUT
BLACK
3 6
1 4
CAV 1 2 3 4 5 6
FUNCTION RIGHT TURN SIGNAL BACK-UP LAMP FEED FUSED B(+) STOP LAMP SWITCH OUTPUT GROUND
BLACK 1 2 CAV 1 2 CIRCUIT X158 20DB/OR X152 20DB/WT FUNCTION RIGHT REAR PILLAR SPEAKER (+) RIGHT REAR PILLAR SPEAKER (-)
8W - 80 - 82
BLACK CAV 1 2 3
NS/GS
3 6
1 4
CAV 1 2 3 4 5 6
CIRCUIT X152 20DB/WT* X15 16BK/DG* X52 20DB/WT X158 20DB/OR* X13 16RD/DG* X58 20DB/OR
FUNCTION RIGHT REAR SPEAKER (-) AMPLIFIED SPEAKER GROUND RIGHT REAR SPEAKER (+) RIGHT REAR SPEAKER (+) RADIO CHOKE OUTPUT RIGHT REAR SPEAKER (-)
CAV 1 2 3
FUNCTION RIGHT REAR VENT MOTOR (OPEN) RIGHT REAR VENT MOTOR (CLOSE) -
CAV 1 2 3
FUNCTION RIGHT REAR VENT MOTOR (OPEN) RIGHT REAR VENT MOTOR (CLOSE) -
CAV 1 2
FUNCTION RIGHT REAR WHEEL SPEED SENSOR (-) RIGHT REAR WHEEL SPEED SENSOR (+)
NS/GS
4 2 5 3 1 2 BLACK CAV
8W - 80 - 83
3 4 5
CIRCUIT L50 18WT/TN L50 18WT/TN Z1 18BK Z1 18BK L74 18LG L62 18BR/RD L605 18DG
GROUND STOP LAMP SWITCH OUTPUT RIGHT TURN SIGNAL RIGHT COMBINATION RELAY OUTPUT
CAV A B
BLACK
CAV 1 2 3 4 5 6
FUNCTION FUSED B(+) GROUND FUSED IGNITION (ST-RUN) CCD BUS (-) CCD BUS (+)
CAV 1 2 3 4
FUNCTION PARK LAMP RELAY CONTROL SPEED CONTROL RELAY CONTROL SPEED CONTROL ON/OFF SWITCH SENSE
GRAY CAV 1 2 3 4 5 6 CIRCUIT K29 20WT/PK Z1 20BK V32 20YL/RD* V30 20DB/RD* L50 18WT/TN F32 18PK/DB FUNCTION STOP LAMP SWITCH SENSE GROUND SPEED CONTROL ON/OFF SWITCH SENSE SPEED CONTROL BRAKE SWITCH OUTPUT STOP LAMP SWITCH OUTPUT FUSED B(+)
8W - 80 - 84
WHITE
NS/GS
CAV 1 2 3
WHITE 1 3 CAV 1 2 CIRCUIT K4 18BK/LB K22 18OR/DB K6 18VT/WT FUNCTION SENSOR GROUND THROTTLE POSITION SENSOR SIGNAL 5 VOLT SUPPLY
BLACK 1 3 CAV 1 2 3 CIRCUIT Z1 20BK B27 20RD/YL E2 20OR FUNCTION GROUND TRACTION CONTROL SWITCH SENSE PANEL LAMP FEED
CAP
CAV 1 2 3 4
FUNCTION STOP LAMP SWITCH OUTPUT FUSED B(+) GROUND STOP LAMP SWITCH OUTPUT
NSGS8084
NS/GS
8W - 80 - 85
21 41
+++++++++
50
10
51
11
60 40
20
CAV 1 2 BLACK 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
CIRCUIT T1 18LG/BK T3 18VT D2 18WT/BK K24 18GY/BK D21 18PK F45 18YL/RD T9 18OR/BK T10 18YL/DG F11 18RD/WT K22 18OR/DB T13 18DB/BK T14 18LG/WT T15 18LG T16 18RD T16 18RD T19 18WT T20 18LB -
FUNCTION TRANSMISSION RANGE SWITCH T1 SENSE TRANSMISSION RANGE SWITCH T3 SENSE CCD BUS(-) CRANKSHAFT POSITION SENSOR SIGNAL SCI TRANSMIT FUSED IGNITION (ST) OVERDRIVE PRESSURE SWITCH SENSE TORQUE MANAGEMENT REQUEST SENSE FUSED IGNITION (ST-RUN-OFF) THROTTLE POSITION SENSOR SIGNAL SPEED SENSOR GROUND OUTPUT SHAFT SPEED SENSOR SIGNAL 12 VOLT SUPPLY TRANSMISSION CONTROL RELAY OUTPUT TRANSMISSION CONTROL RELAY OUTPUT 2-4 SOLENOID CONTROL LOW/REVERSE SOLENOID CONTROL (CONTINUED ON NEXT PAGE)
NSGS8085
J988W-3
8W - 80 - 86
NS/GS
BLACK 1 2
CAV 1 2 3 4 5 6 7 8
CIRCUIT T47 18YL/BK T50 18DG T9 18OR/BK T16 18RD T59 18PK T60 18BR T20 18LB T19 18WT
FUNCTION 2/4 PRESSURE SWITCH SENSE LOW/REVERSE PRESSURE SWITCH SENSE OVERDRIVE PRESSURE SWITCH SENSE TRANSMISSION CONTROL RELAY OUTPUT UNDERDRIVE PRESSURE SWITCH SENSE OVERDRIVE SOLENOID CONTROL LOW/REVERSE SOLENOID CONTROL 2/4 SOLENOID CONTROL
BLACK 5 1
10
CAV 1 2 3 4 5 6 7 8 9 10
CIRCUIT F20 18WT T13 18DB/BK T54 18VT/LG T41 18BK/WT L1 18VT/BK T1 18LG/BK T3 18VT T42 18VT/WT T41 18BR/YL
FUNCTION FUSED IGNITION SWITCH OUTPUT SPEED SENSOR GROUND TRANSMISSION TEMPERATURE SENSOR SIGNAL TRANSMISSION RANGE SENSOR T41 SENSE BACK-UP LAMP FEED TRANSMISSION RANGE SENSOR T1 SENSE TRANSMISSION RANGE SENSOR T3 SENSE TRANSMISSION RANGE SENSOR T42 SENSE TRANSMISSION RANGE SENSOR T41 SENSE NSGS8086
J988W-3
NS/GS
GRAY
8W - 80 - 87
CAV 1 2
CAV 1 2 3 4
FUNCTION SENSOR GROUND INTAKE AIR TEMPERATURE SIGNAL 5 VOLT SUPPLY BOOST PRESSURE SIGNAL
GRAY 1 3 2 4
CAV 1 2 3 4
FUNCTION GROUND ASD RELAY OUTPUT SENSOR GROUND UPSTREAM HEATED OXYGEN SENSOR SIGNAL
BLACK
CAV 1 2 3 4
FUNCTION SPEED CONTROL VACUM SOLENOID CONTROL SPEED CONTROL VENT SOLENOID CONTROL STOP LAMP SWITCH OUTPUT GROUND
J988W-3
8W - 80 - 88
BLACK CAV 3 1 1 1 2 2 3
NS/GS
FUNCTION 8 VOLT SUPPLY FUSED IGNITION (ST-RUN) SENSOR GROUND SENSOR GROUND VEHICLE SPEED SENSOR SIGNAL
BLACK 1 4 CAV 1 2 3 4 CIRCUIT V3 12BR/WT V7 20DG/WT V4 12RD/YL Z1 14BK FUNCTION WIPER HIGH/LOW RELAY LOW SPEED OUTPUT WIPER PARK SWITCH SENSE WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT GROUND
BLACK CAV 1 2 3 4 5 6 7 8 9 10 CIRCUIT V3 12BR/WT V7 20DG/WT V4 12RD/YL Z1 14BK FUNCTION WIPER HIGH/LOW RELAY LOW SPEED OUTPUT WIPER PARK SWITCH SENSE WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT GROUND * DIESEL J988W-3 NSGS8088
5 10
1 6
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 1
CONNECTOR/GROUND LOCATIONS
For items not shown in this section a N/S is placed in the Fig. column.
Component/ Ground A/C Compressor Clutch A/C-Heater Control Module C1 A/C-Heater Control Module C2 A/C Pressure Transducer A/C Zone Door Actuator Airbag Control Module C1 Airbag Contol Module C2 All Wheel Drive Solenoid Ambient Temperature Sensor Ash Receiver Lamp Automatic Day/Night Mirror B01 B02 B03
Color BK
Fig. 5, 6, 7, 8, 9 11
Component/ Ground B09 B17 B23 B33 B56 B70 B75 B98 B99
Location Under Seat LT Quarter Panel RT of Steering Column LT Frame Rail Under Seat LT Frame Rail Bottom of RT B-Pillar Rear of RT Tail Rear of LT Tail Lamp LT Kick Panel On Transmission LT Side of HVAC On Junction Block On Master Cylinder Above RT Vanity Mirror
NAT
BK
Rear of Control
11
GY NAT YL BK BK BK
RT Side Cowl LT Side of HVAC Rear of I.P. Center Stack Rear of I.P. Center Stack Near Fuel Tank On Radiator Closure Panel At Lamp At Mirror LT Kick Panel LT Kick Panel RT Kick Panel
3 15 12
B120 12 20 4 Backup Lamp Switch (M/T) Blend Door Actuator Body Control Module C1 Brake Pressure Switch C19
RD BK BK BK BK
10 15 18 18 18
BK
8W - 90 - 2
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
BK RD BK YL NAT BK BK
N/S 21 9 11 11 13 N/S
BK
BK
N/S
GN
5, 6, 7, 8, 9 5, 6, 7, 8, 9 3 N/S
N/S 5, 6, 7, 9 18 18 12 16
BK BK BK BK
9 6, 7 10 4
BK RD BK BK BK BK BK BK BK BK BK BK LT/GY
Rear of Lighter At Lamp Bottom of Reservior Near Pump At Injector At Injector At Injector At Injector At injector At Injector At Injectors At Heater Side of Fuel Tank
YL BK BK LT/GY BK BK
11 2 N/S 2 6, 7 9
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 3
NAT BK
11 11
8W - 90 - 4
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
BK BK BK BK BK BK
19 19 4 19 11 4
BK NAT BK GY
At Speaker At Motor Center Rear of Floor Pan At Lamp Left Side of Steering Wheel Pad LT Quarter Panel At Lamp At Lamps At Latch At Key Cylinder
21 21 16 N/S 11
N/S 15 21 21 21
BK BK BK BK BK
At Motor LT Quarter Panel At Reservior LT Frame Rail Bottom of Reservior On Intake On Intake Near Throttle Body Under Seat
21 21 8 4 N/S
BK BK BK BK
5 N/S 9 16
BL
At Switch
19
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 5
Mode Door Actuator Multi Function Switch Name Brand Speaker Relay Needle Movement Sensor Output Shaft Speed Sensor Overhead Console P18 P25 P30 P34 P50
BK BK LT/GY BK
15 11 11 8
BK
BK
BK BK BK
N/S N/S 3
GY RD GY BK BK GY NAT
7, 9 15 12 10
GY BK BK LT/GY LT/GN BK
11 11 11 N/S 22 11
Park Brake Switch Park/Neutral Positon Switch Passenger Airbag PDC C1 PDC C2 PDC C3 PDC C4 PDC C5 PDC C6 PDC C7 PDC C8 Power Folding Mirror Switch
13 N/S 11 2 2 2 2 2 3 3 3 N/S
BK
At Switch
N/S
BK
LT Quarter Panel At Lamp Bottom of Reservior On Liftgate At Motor RT Side of HVAC Top Left of I.P. At Radiator Fan
21
BK BK BK BK NAT RD BK
N/S 4 21 21 15 11 N/S
8W - 90 - 6
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
BK BK BK BK BK
17 17 N/S 4 12
BK
At Motor
N/S
BK NAT BK
At Speaker At Motor Center Rear of Floor Pan At Lamp Right Side of Steering Wheel Pad LT Quarter Panel At Lamp Under Seat LT B-Pillar Near Steering at Module Top of Brake Pedal LT Quarter Panel LT Quarter Panel On Throttle Body LT Quarter Panel RT Fender Side Shield Top of Transmission
22 22 16
BK BK
At Speaker At Lamp
11 4
GY
N/S 11
BK
RD
19
GY BK
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 7
GY BK
7, 9 11
BK BK
GY
5, 6, 7, 8, 9
BK
8W - 90 - 8
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 9
8W - 90 - 10
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 11
8W - 90 - 12
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 13
8W - 90 - 14
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 15
8W - 90 - 16
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 17
8W - 90 - 18
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 19
8W - 90 - 20
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 21
8W - 90 - 22
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 23
8W - 90 - 24
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 25
8W - 90 - 26
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 27
8W - 90 - 28
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 29
8W - 90 - 30
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 31
CONNECTOR/GROUND LOCATIONS
For items not shown in this section a N/S is placed in the Fig. column.
Component/ Ground A/C Compressor Clutch A/C-Heater Control Module C1 A/C-Heater Control Module C2 A/C Pressure Transducer A/C Zone Door Actuator Airbag Control Module C1 Airbag Contol Module C2 All Wheel Drive Solenoid Ambient Temperature Sensor Ash Receiver Lamp Automatic Day/Night Mirror B01 B02 B03 B09 B17 B23 B33 B56 B70 B75 B98
Color BK
Fig. 5, 6, 7, 8, 9 11
Location Rear of LT Tail Lamp LT Kick Panel On Transmission LT Side of HVAC On Junction Block On Junction Block On Master Cylinder At Top Center of Windshield Bottom of RT B-Pillar
NAT
Backup Lamp Switch (M/T) Blend Door Actuator Body Control Module C1 Body Control Module C2 Brake Pressure Switch C19 C20 Camshaft Position Sensor 2.4L Camshaft Position Sensor 3.3L, 3.8L Center Dome Lamp CHMSL Clockspring C1 Clockspring C2 Clutch Switch Controller Anti-Lock Brake Crankshaft Position Sensor D01 D02 Data Link Connector
BK
Rear of Control
11
GY NAT YL BK BK GY
RT Side Cowl LT Side of HVAC Rear of I.P. Center Stack Rear of I.P. Center Stack Near Fuel Tank On Radiator Closure Panel At Lamp At Mirror RT Kick Panel RT Kick Panel LT Kick Panel Under Seat LT Quarter Panel RT of Steering Column LT Frame Rail Under Seat LT Frame Rail Bottom of RT B-Pillar Rear of RT Tail Lamp
3 15 12 12 20 4
BK
Rear of Cylinder Head RT Side of Engine At Lamp Rear of CHMSL Rear of Clockspring Rear of Clockspring Top of Clutch Pedal LT Side of Engine Compartment Rear of Engine On Kick Panel On Kick Panel LT of Steering Column
BK
RD BK BK BK BK BK BK BK BK BK LT/GY BL BK
10 17 18 18 18 16 21 13 2 16 2 14 N/S
BK RD YL NAT BK BK
N/S 23 11 11 13 N/S
BK BK BK BK
5, 6, 7, 9 19 19 12
8W - 90 - 32
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
YL BK BK LT/GY BK BK
11 2 N/S
BK
BK
11
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 33
BK BK
12 19
BK BK GY BK BK BK
19 19 4 19 11 4
BK
LT Fender Side Shield At Motor At Lamp At Motor At Lamp At Lamp At Switch At Mirror At Mirror At Switch At Lamp LT C-Pillar At Speaker
RD BK BK BK GY BK RD BL OR BK BK BK
19 2 N/S 23 17 19 11 11 19 21 21 21
8W - 90 - 34
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
15 11 N/S 7, 9 17 12 10 12 10
BK NAT GY GY
21 21 16
BL
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 35
BK BK BK GY BK BK LT/GY LT/GN BK
BK
At Motor
19
BK BK
At Speaker At Lamp
11 4
BK
Right Fender Side Shield At Motor At Lamp At Motor At Lamp At Lamp At Switch
RD BK BK BK GY BK
19 4 N/S 23 17 19
BK
At Switch
N/S
BK
LT Quarter Panel At Lamp Bottom of Reservior On Liftgate At Motor RT Side of HVAC Top RT of I.P. LT Quarter Panel At Switch
21
BK BK BK BK NAT RD BK
N/S 4 23 23 15 11 N/S
RD BL BK BK BK BK GY
11 11 19 22 N/S 22 17
BK
19
8W - 90 - 36
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
BK
At Motor
N/S
GY BK
7, 9 11
GY
5, 6, 7, 8, 9 5, 6, 7, 8, 9 5, 6, 8 11
BK
LT Rear of Engine Compartment Rear of Transmission Part of Multifunction Switch LT Side of Engine
BK BK
GY BK BK
12 N/S N/S
BK
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 37
8W - 90 - 38
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 39
8W - 90 - 40
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 41
8W - 90 - 42
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 43
8W - 90 - 44
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 45
8W - 90 - 46
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 47
8W - 90 - 48
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 49
8W - 90 - 50
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 51
8W - 90 - 52
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
8W - 90 - 53
8W - 90 - 54
8W - 90 CONNECTOR/GROUND LOCATIONS
NS/GS
NS/GS
8W - 90 CONNECTOR/GROUND LOCATIONS
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ENGINE
9-1
ENGINE
CONTENTS
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MOPAR SILICONE RUBBER ADHESIVE SEALANT Mopar Silicone Rubber Adhesive Sealant or equivalent, normally black in color, is available in three ounce tubes. Moisture in the air causes the Mopar Silicone Rubber Adhesive Sealant material to cure. This material is normally used on flexible metal flanges. It has a shelf life of one year and will not properly cure if over age. Always inspect the package for the expiration date before use. MOPAR GASKET MAKER Mopar Gasket Maker is an anaerobic type gasket material normally red in color. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. It is normally red in color. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges. MOPAR TORQUE CURE GASKET MAKER Mopar Torque Cure Gasket Maker is a unique anaerobic type gasket material to be used ONLY between the bedplate and engine block. The material cures in the absence of air when torqued between two metallic surfaces. It will not cure if left in the uncovered tube. This anaerobic material is specially
9-2
ENGINE
NS
GASKET DISASSEMBLY Parts assembled with form-in-place gaskets may be disassembled without unusual effort. In some instances, it may be necessary to lightly tap the part with a mallet or other suitable tool to break the seal between the mating surfaces. A flat gasket scraper may also be lightly tapped into the joint but care must be taken not to damage the mating surfaces. SURFACE PREPARATION Scrape clean or wire brush all gasket surfaces to remove all loose material. Inspect stamped parts to ensure gasket rails are flat. Gasket surfaces must be free of oil and dirt. Make sure old gasket material is removed from blind attaching holes. FORM-IN-PLACE GASKET APPLICATION Assembling parts using a form-in-place gasket requires care but its easier then using precut gaskets. Mopar Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing the material off location. The Mopar Silicone Rubber Adhesive Sealant gasket material or equivalent should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towels. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing of material off location.
ENGINE PERFORMANCE
If a loss of performance is noticed, timing belt or chain may have skipped one or two teeth. Camshaft and crankshaft timing should be checked. Refer to Group 9, Engine Timing belt or chain installation. It is important that the vehicle is operating to its optimum performance level to maintain fuel economy and lowest vehicle emissions. If vehicle is not operating to these standards, refer to Engine Diagnosis outlined is this section. The following procedures can assist in achieving the proper engine diagnosis. (1) Test cranking amperage draw. Refer to Group 8B, Starting. (2) Check intake manifold for vacuum leaks. (3) Perform cylinder compression pressure test. Refer to Engine Diagnosis, outlined in this section. (4) Clean or replace spark plugs as necessary and adjust gap as specified in Group 8D, Ignition System. Tighten to specifications.
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GENERAL INFORMATION (Continued)
(5) Test resistance of spark plug cables. Refer to Group 8D, Ignition System. (6) Test ignition coils primary and secondary resistance. Replace parts as necessary. Refer to Group 8D, Ignition System. (7) Check fuel pump pressure at idle and different RPM ranges. Refer to Group 14, Fuel System for Specifications. (8) The air filter elements should be replaced as specified in Group 0, Lubrication and Maintenance. (9) Inspect crankcase ventilation system as outlined in Group 25, Emission Control Systems. (10) Road test vehicle as a final test.
ENGINE
9-3
(4) A controlled hone motor speed between 200-300 RPM is necessary to obtain the proper crosshatch angle. The number of up and down strokes per minute can be regulated to get the desired 50-60 degree angle. Faster up and down strokes increase the cross-hatch angle. (5) After honing, it is necessary that the block be cleaned again to remove all traces of abrasive. CAUTION: Ensure all abrasives are removed from engine parts after honing. It is recommended that a solution of soap and hot water be used with a brush and the parts then thoroughly dried. The bore can be considered clean when it can be wiped clean with a white cloth and cloth remains clean. Oil the bores after cleaning to prevent rusting.
PREFERRED METHOD Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254 mm (0.010 in.) shim (e. g. cardboard, matchbook cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14-20 Nm (10-15 ft. lbs.). The number of main bearing will vary from engine to engine.
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CONNECTING ROD BEARING CLEARANCE Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: (1) Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. (2) Remove oil film from surface to be checked. Plastigage is soluble in oil. (3) Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 in.) off center and away from the oil hole (Fig. 3). In addition, suspect areas can be checked by placing plastigage in the suspect area. (4) Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. (5) Remove the bearing cap and compare the width of the flattened Plastigage (Fig. 4) with the scale provided on the package. Locate the band closest to the same width. This band indicates the amount of oil clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Engine Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds 0.076 mm (0.003 in.) replace bearing.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking.
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GENERAL INFORMATION (Continued)
CAUTION: Be sure that the tapped holes maintain the original centerline. Heli-Coil tools and inserts are readily available from automotive parts jobbers.
ENGINE
9-5
ing is at the MIN mark will result in a MAX reading on these engines. For the 3.0L engine, add one full quart when the level on the dipstick is at or below the ADD mark.
ENGINE OIL
Checking Oil Level To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has sat overnight. Checking the oil while the vehicle is on level ground, will improve the accuracy of the oil level readings. For 2.4L, 3.3L and 3.8L engines, maintain the oil level between the MIN and MAX markings on the dipstick. Adding one quart of oil when the read-
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ENGINE
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ENGINE
9-7
ENGINE DIAGNOSIS
INDEX
page DIAGNOSIS AND TESTING CYLINDER COMBUSTION PRESSURE LEAKAGE TEST . . . . . . . . . . . . . . 8 CYLINDER COMPRESSION PRESSURE TEST . . 7 ENGINE DIAGNOSISMECHANICAL . . . . . . . . . 12 ENGINE DIAGNOSISPERFORMANCE . . . . . . 10 GENERAL INFORMATION . . . . . . . . . . . . . INSPECTION (ENGINE OIL LEAKS IN GENERAL) . . . . INTAKE MANIFOLD LEAKAGE DIAGNOSIS LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS . . . . . . . . . . . . . . . . . page ..... 7 ..... 8 ..... 7 ..... 8
9-8
ENGINE
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DIAGNOSIS AND TESTING (Continued)
(2) Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light. (3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions. (4) If dye is not observed, drive the vehicle at various speeds for approximately 24km (15 miles), and repeat inspection. (5) If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows: (6) Disconnect the fresh air hose (makeup air) at the cylinder head cover and plug or cap the nipple on the cover. (7) Remove the PCV valve hose from the cylinder head cover. Cap or plug the PCV valve nipple on the cover. (8) Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure. (9) Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures. (10) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak. (11) If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose. Proceed to next step. (12) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
ENGINE
9-9
INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: (1) Disconnect the battery. (2) Raise the vehicle. (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area remove transmission for further inspection. (a) Circular spray pattern generally indicates seal leakage or crankshaft damage. (b) Where leakage tends to run straight down, possible causes are a porous block, oil galley cup plug, bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items. (4) If no leaks are detected, pressurized the crankcase as outlined in the, Inspection (Engine oil Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi). (5) If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. (6) For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. (7) After the oil leak root cause and appropriate corrective action have been identified. Refer to Rear Crankshaft Seals, for proper replacement procedures.
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ENGINE DIAGNOSISPERFORMANCE
CONDITION ENGINE WILL NOT START POSSIBLE CAUSE 1. Weak battery. CORRECTION 1. Test battery. Charge or replace as necessary.Refer to Group 8A, Battery. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to terminals. Test starting system. Refer to Group 8B, Starting. 4. Remove moisture from wires. 5. Replace any cracked or shorted cables. 6. Test and replace as needed. Refer to Group 8D, Ignition System 7. Set gap. Refer to Group 8D, Ignition System. 8. Clean system and replace fuel filter. 9. Test fuel pump and replace as needed. Refer to Group 14, Fuel System. 1. Test minimum air flow. Refer to Group 14, Fuel System. 2. Refer to Group 14, Fuel System. 3. Inspect intake manifold, manifold gasket, and vacuum hoses. Refer to Group 11, Exhaust System and Intake Manifold. 4. Install correct wiring. 5. Test and replace as necessary. Refer to Group 8D, Ignition System. 1. Clean plugs and set gap. Refer to Group 8D, Ignition System. 2. Clean system and replace fuel filter. 3. Test and replace as necessary. Refer to Group 14, Fuel System. 4. Correct valve timing. 5. Replace cylinder head gasket. 6. Test compression of each cylinder. 7. Replace valves. 8. Install new parts, as necessary. 9. Replace any cracked or shorted cables. 10. Test and replace as necessary. Refer to Group 8D, Ignition System.
2. Corroded or loose battery connections. 3. Faulty starter. 4. Moisture on ignition wires. 5. Faulty ignition cables. 6. Faulty coil or control unit. 7. Incorrect spark plug gap. 8. Contamination in fuel system. 9. Faulty fuel pump.
1. Idle speed too low. 2. Incorrect fuel mixture. 3. Intake manifold leakage.
4. Incorrect ignition wiring. 5. Faulty coil(s) ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 2. Contamination in fuel system. 3. Faulty fuel pump. 4. Incorrect valve timing. 5. Leaking cylinder head gasket. 6. Low compression. 7. Burned, warped, or pitted valves. 8. Plugged or restricted exhaust system. 9. Faulty ignition cables. 10. Faulty coil(s).
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DIAGNOSIS AND TESTING (Continued)
CONDITION ENGINE MISSES ON ACCELERATION POSSIBLE CAUSE 1. Dirty or incorrectly gapped spark plugs. 2. Contamination in Fuel System. 3. Burned, warped, or pitted valves. 4. Faulty coil(s). ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 2. Faulty coil(s). 3. Dirty fuel injector(s). 4. Contamination in fuel system.
ENGINE
9 - 11
CORRECTION 1. Clean spark plugs and set gap. Refer to Group 8D, Ignition System. 2. Clean fuel system and replace fuel filter. 3. Replace valves. 4. Test and replace as necessary. Refer to Group 8D, Ignition System. 1. Clean spark plugs and set gap. Refer to Group 8D, Ignition System. 2. Test and replace as necessary. Refer to Group 8D, Ignition System. Test and replace as necessary. Refer to Group 14, Fuel System. 4. Clean system and replace fuel filter.
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ENGINE
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ENGINE DIAGNOSISMECHANICAL
CONDITION NOISY VALVES POSSIBLE CAUSES 1. High or low oil level in crankcase. 2. Thin or diluted oil. 3. Low oil pressure. 4. Dirt in tappets/lash adjusters. 5. Worn rocker arms. 6. Worn tappets/lash adjusters. 7. Worn valve guides. 8. Excessive runout of valve seats on valve faces. 9. Missing adjuster pivot. CONNECTING ROD NOISE 1. Insuffient oil supply. 2. Low oil pressure. 3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Connecting rod journal out-of-round. 6. Misaligned connecting rods. MAIN BEARING NOISE 1. Insufficient oil supply. 2. Low oil pressure. 3. Thin or diluted oil. 4. Excessive bearing clearance. 5. Excessive end play. 6. Crankshaft journal out-of-round or worn. 7. Loose flywheel or torque converter. OIL PRESSURE DROP 1. Low oil level. 2. Faulty oil pressure sending unit. 3. Low oil pressure. 4. 5. 6. 7. Clogged oil filter. Worn parts in oil pump. Thin or diluted oil. Excessive bearing clearance. CORRECTION 1. Check for correct oil level. 2. Change oil to correct viscosity. 3. Check engine oil level. 4. Replace rocker arm/hydraulic lash adjuster assembly. 5. Inspect oil supply to rocker arms. 6. Install new rocker arm/hydraulic lash adjuster assembly. 7. Ream and install new valves with oversize stems. 8. Grind valve seats and valves. 9. Replace rocker arm/hydraulic lash adjuster assembly. 1. Check engine oil level. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Change oil to correct viscosity. 4. Measure bearings for correct clearance. Repair as necessary. 5. Replace crankshaft or grind surface. 6. Replace bent connecting rods. 1. Check engine oil level. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Change oil to correct viscosity. 4. Measure bearings for correct clearance. Repair as necessary. 5. Check thrust bearing for wear on flanges. 6. Replace crankshaft or grind journals. 7. Tighten to correct torque. 1. Check engine oil level. 2. Install new sending unit. 3. Check sending unit and main bearing oil clearance. 4. Install new oil filter. 5. Replace worn parts or pump. 6. Change oil to correct viscosity. 7. Measure bearings for correct clearance. 8. Remove valve and inspect, clean, or replace. 9. Remove oil pan and install new tube or clean, if necessary. 10. Install new oil pump.
8. Oil pump relief valve stuck. 9. Oil pump suction tube loose. 10. Oil pump cover warped or cracked.
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DIAGNOSIS AND TESTING (Continued)
CONDITION OIL LEAKS POSSIBLE CAUSES 1. Misaligned or deteriorated gaskets. 2. Loose fastener, broken or porous metal part. 3. Misaligned or deteriorated cup or threaded plug. 1. PCV system malfunction.
ENGINE
9 - 13
CORRECTION 1. Replace gasket(s). 2. Tighten, repair or replace the part. 3. Replace as necessary. 1. Check system and repair as necessary. Refer to Group 25, Emission Control Systems. 2. Hone cyinder bores. Install new rings. 3. Install new rings. 4. Remove rings and check grooves. If groove is not proper width, replace piston. 5. Ream guides and replace valves with oversize valves and seals. 6. Repair or replace seal.
2. Worn, scuffed or broken rings. 3. Carbon in oil ring slots. 4. Rings fitted too tightly in grooves.
9 - 14
2.4L ENGINE
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2.4L ENGINE
INDEX
page DESCRIPTION AND OPERATION ENGINE COMPONENTS . . . . . . . . . . . . . ENGINE IDENTIFICATION . . . . . . . . . . . . ENGINE LUBRICATION SYSTEM . . . . . . . DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE . . . . SERVICE PROCEDURES CRANKSHAFT END PLAY . . . . . . . . . . . . FITTING CONNECTING ROD BEARINGS FITTING MAIN BEARINGS . . . . . . . . . . . . FITTING PISTON RINGS . . . . . . . . . . . . . FITTING PISTONS . . . . . . . . . . . . . . . . . . VALVE SERVICE RECONDITION . . . . . . . REMOVAL AND INSTALLATION BALANCE SHAFTS CARRIER ASSEMBLY CAMSHAFT FOLLOWER . . . . . . . . . . . . . CAMSHAFT OIL SEALFRONT . . . . . . . . CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT OIL SEALFRONT . . . . . . CRANKSHAFT OIL SEALREAR . . . . . . . CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . ENGINE MOUNTFRONT . . . . . . . . . . . . ENGINE MOUNTLEFT . . . . . . . . . . . . . ENGINE MOUNTREAR . . . . . . . . . . . . . ENGINE MOUNTRIGHT . . . . . . . . . . . . HYDRAULIC LASH ADJUSTER . . . . . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD . . . . STRUCTURAL COLLAR . . . . . . . . . . . . TIMING BELT COVER . . . . . . . . . . . . . TIMING BELT TENSIONER ASSEMBLY TIMING BELT . . . . . . . . . . . . . . . . . . . . VALVE SPRINGS AND VALVE SEALS IN VEHICLE . . . . . . . . VALVES AND VALVE SPRINGS . . . . . . VIBRATION DAMPER . . . . . . . . . . . . . DISASSEMBLY AND ASSEMBLY OIL PUMP . . . . . . . . . . . . . . . . . . . . . . CLEANING AND INSPECTION OIL PUMP . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT . . . . . . . . . . . . . . . . . . . CYLINDER BLOCK . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . VALVE AND VALVE SPRING . . . . . . . . . ADJUSTMENTS ENGINE MOUNTS . . . . . . . . . . . . . . . . SPECIFICATIONS 2.4L ENGINE . . . . . . . . . . . . . . . . . . . . TORQUE CHART 2.4L . . . . . . . . . . . . . SPECIAL TOOLS 2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . . . . . 33 47 45 47 49 25 37 40 37
. . . . . 15 . . . . . 14 . . . . . 14 . . . . . 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 18 19 16 16 21 30 30 41 28 42 43 46 28 34 26 23 24 25 24
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cylinder block. Oil pickup, pump and check valve provide oil flow to the main oil gallery.
MAIN/ROD BEARINGS A diagonal hole in each bulkhead feeds oil to each main bearing. Drilled passages within the crankshaft route oil from main bearing journals to connecting rod journals. CAMSHAFT/HYDRAULIC LASH ADJUSTERS A vertical hole at the number five bulkhead routes pressurized oil through a restrictor up past a cylinder head bolt to an oil gallery running the length of the cylinder head. The camshaft journals are partially slotted to allow a predetermined amount of pressurized oil to pass into the bearing cap cavities with small holes directed to spray lubricate the camshaft lobes.
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DESCRIPTION AND OPERATION (Continued)
2.4L ENGINE
9 - 15
Engine2.4L
These gears are driven by a short chain from the crankshaft, to rotate at two times crankshaft speed. This counterbalances certain engine reciprocating masses. CYLINDER BLOCK AND BEDPLATE ASSEMBLY: A closed deck design is used for cooling and weight reduction with water pump molded into the block. Nominal wall thickness is 4.5 mm. The bedplate incorporates main bearing caps. Rear seal retainer is integral with the block. CRANKSHAFT: A nodular cast iron crankshaft is used. The engine has 5 main bearings, with number 3 flanged to control thrust. The 60 mm diameter main and 50 mm diameter crank pin journals (all) have undercut fillets that are deep rolled for added strength. To evenly distribute bearing loads and minimize internal stress, 8 counterweights are used. Hydrodynamic seals provide end sealing, where the crankshaft exits the block. Anaerobic gasket material is used for parting line sealing in the block. A sintered powder metal timing belt sprocket is mounted on the crankshaft nose. This sprocket provides motive power; via timing belt to the camshaft sprockets (providing timed valve actuation) and to the water pump. PISTONS: There is provisions for free wheeling valve train. Piston has a unique height. All engines use pressed in piston pins to attach forged powder metal connecting rods. Incorporate hex head cap screw threaded into the connecting rod. Piston and Rods are serviced as a assembly. PISTONS RINGS: The piston rings include a molybdenum faced top ring for reliable compression
ENGINE COMPONENTS
BALANCE SHAFTS: 2.4L engines are equipped with two balance shafts installed in a carrier attached to the lower crankcase. The shafts interconnect through gears to rotate in opposite directions.
9 - 16
2.4L ENGINE
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SERVICE PROCEDURES (Continued)
2.4L ENGINE
9 - 17
Upper Ring Intermediate Ring Oil Control Ring Ring Position Upper Ring Intermediate Ring
Standard Piston Size 87.450 - 87.468 mm (3.4434 - 3.4441 in.) Piston To Bore Clearance 0.024 - 0.057 mm (0.0009 - 0.0022 in.) Note: Measurements taken at Piston Size Location.
Oil Control Ring - Three Piece. Oil Ring Side Rails Must Be Free To Rotate After Assembly.
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2.4L ENGINE
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SERVICE PROCEDURES (Continued)
scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Engine Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. (6) Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (.001-.003 in.) is usually the most appropriate for checking engine bearing proper specifications.
2.4L ENGINE
9 - 19
CRANKSHAFT MAIN BEARINGS The crankshaft is supported in five main bearings. All upper and lower bearing shells in the crankcase have oil grooves. The number three lower main thrust bearing is plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal (Fig. 10). Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 10). All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersized: 0.025 mm (0.001 in.) and 0.250 mm (0.010 in.). Never install an undersize bearing that will reduce clearance below specifications.
9 - 20
2.4L ENGINE
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SERVICE PROCEDURES (Continued)
OPTIONAL CRANKSHAFT END PLAY CHECK (1) Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek, using care not to damage any bearing surface. DO NOT loosen main bearing cap. (2) Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play.
2.4L ENGINE
9 - 21
REFACING VALVES AND VALVE SEATS (1) The intake and exhaust valve seats and valve face have a 45 and a 45 1/2 degree angles.
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Head Diameter 34.67 - 34.93 mm (1.364 - 1.375 in.) 30.37 - 30.63 mm (1.195 - 1.205 in.) Length (Overall) 112.76 - 113.32 mm (4.439 - 4.461 in.) 109.59 - 110.09 mm (4.314 - 4.334 in.) Stem Diameter 5.934 - 5.952 mm (0.2337 - 0.2344 in.) 5.906 - 5.924 mm (0.2326 - 0.2333 in.) Valve Margin 1.285 - 1.615 mm (0.050 - 0.063 in.) 0.985 - 1.315 mm (0.038 - 0.051 in.)
Intake: Exhaust:
Intake: Exhaust:
Intake: Exhaust:
Intake valve seat diameter is 34.37 34.63 mm (1.158 1.363 inch.) Exhaust valve seat diameter is 29.37 29.63 mm (1.156 1.166 inch.) (6) Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.
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SERVICE PROCEDURES (Continued)
need to be reground to prevent seal damage when the valve is installed.
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CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves. (3) Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool. (4) Check the valve spring installed height B after refacing the valve and seat (Fig. 20). Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a .762 mm (0.030 inch.) spacer under the valve spring seat to bring spring height back within specification. (5) Install rocker arm shafts as previously described in this section. (6) Checking dry lash. Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed. Specified dry lash is 1.17 mm (0.046 in.) for intake and 1.28 mm (0.050 in.) for exhaust. After performing dry lash check, refill adjuster with oil and allow 10 minutes for adjuster/s to bleed down before rotating cam.
Fig. 20 Checking Spring Installed Height and Valve Tip Height Dimensions
VALVE INSTALLATION (1) Coat valve stems with clean engine oil and insert in cylinder head. (2) Install new valve stem seals on all valves using a valve stem seal tool (Fig. 21). The valve stem seals should be pushed firmly and squarely over valve guide.
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ENGINE MOUNTRIGHT
REMOVAL
NOTE: Right mount should only be serviced as an assembly to prevent noise, vibration and harshness concerns. (1) Remove the purge duty solenoid and wiring harness from engine mount bracket. (2) Remove the two right engine mount insulator vertical fasteners from frame rail and loosen the one horizontal fastener. Do not remove the large nut located at the end of the core (Fig. 24). (3) Remove the load on the engine mounts by carefully supporting the engine and transaxle assembly with a floor jack. (4) Remove the vertical and horizontal fasteners from the engine side bracket. Remove the mount assembly.
ENGINE MOUNTLEFT
REMOVAL (1) Raise vehicle on hoist and remove left front wheel. (2) Support the transaxle with a jack. (3) Remove the insulator through bolt from the mount. (4) Remove the transaxle mount fasteners and remove mount (Fig. 23). INSTALLATION (1) Reverse removal procedure for installation. (2) Tighten mount to transaxle bolts to 55 Nm (40 ft. lbs.) (3) Tighten through bolt to 75 Nm (55 ft. lbs.) (Fig. 23). (4) Engine mount adjustment, Refer to Engine Mount Adjustment in this section.
INSTALLATION (1) Reverse removal procedure for installation. Tighten assembly in the following order: a. Engine mount to rail fasteners to 68 Nm (50 ft. lbs.). b. The vertical engine fastener to 102 Nm (75 ft. lbs.). c. The horizontal fastener to 150 Nm (111 ft. lbs.).
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REMOVAL AND INSTALLATION (Continued)
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STRUCTURAL COLLAR
REMOVAL (1) Raise vehicle on hoist. (2) Remove front engine mounting bracket from bending strut and front insulator mount. (3) Remove bolts attaching bending strut to engine and transaxle. (4) Remove bolts attaching collar and strut to engine, oil pan, and transaxle. Remove strut and collar.
ENGINE MOUNTREAR
REMOVAL (1) Raise vehicle on hoist and remove the left front wheel. (2) Support the transaxle with a jack so it will not rotate. (3) Remove the insulator thru bolt from the mount and rear suspension crossmember. (4) Remove the four mount fasteners and remove the mount. INSTALLATION (1) Reverse the removal procedure for installation. Refer to (Fig. 25).
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ENGINE ASSEMBLY
REMOVAL (1) Perform fuel pressure release procedure. Refer to Group 14, Fuel System for procedure. Remove fuel line to fuel rail. (2) Disconnect battery. (3) Remove Air cleaner and hoses. (4) Drain cooling system. Refer to Group 7, Cooling System for procedure. (5) Remove upper radiator hose and remove radiator fans. Refer to Group 7, Cooling System for procedure. (6) Remove lower radiator hose. (7) Disconnect automatic transmission cooler lines and plug, if equipped. (8) Disconnect transmission shift linkage. (9) Disconnect throttle body linkage. (10) Disconnect engine wiring harness. (11) Disconnect heater hoses. (12) Discharge Air Conditioning System. Refer to Group 24, Air Conditioning for procedure. (13) Hoist vehicle and remove right inner splash shield. Remove wheels and tires. (14) Loosen power steering belt for pump removal. Refer to Group 7, Cooling System for procedure. (15) Remove axle shafts. Refer to Group 2, Suspension and Driveshafts for procedure. (16) Disconnect exhaust pipe from manifold. (17) Remove front and rear engine mount brackets from the body. (18) Remove bending braces and front engine mount bracket. Remove transmission inspection cover. (19) Mark flexplate to torque converter and remove torque converter bolts. (20) Install front engine mount bracket. (21) Lower vehicle. (22) Remove power steering pump. Set pump aside. (23) Remove A/C lines at compressor and cap. (24) Remove ground straps to body. (25) Raise vehicle enough to allow engine dolly Special Tool 6135, cradle Special Tool 6710 with Posts Special Tool 6848 and Adaptor Special Tool 8130 to be installed under vehicle (Fig. 27). (26) Loosen cradle posts to allow movement for proper positioning. Locate two rear posts (right side of engine) into the holes on the engine bedplate. Locate the two front posts (left side of engine) on the front engine bracket and A/C compressor bracket (Fig. 27). Lower vehicle and position cradle mounts until the engine is resting on mounts. Tighten mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission.
(27) Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION are on the cradle. (28) Remove engine and transmission mount bolts. (29) Raise vehicle slowly. It may be necessary to move the engine/transmission assembly on the cradle to allow for removal around the body.
INSTALLATION (1) Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission. (2) Align engine and transmission mounts to attaching points. Install mounting bolts at the right engine and left transmission mounts. Refer to procedures outlined in this section. (3) Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135 and 6710. (4) Install axle shafts. Refer to Group 2, Suspension and Driveshafts for procedure. (5) Install transmission and engine braces and splash shields. (6) Connect exhaust system to manifold. Refer to Group 11, Exhaust System and Intake Manifold for procedure and torque specifications. (7) Install power steering pump. Refer to Cooling System Group 7, Accessory Drive Section for belt tension adjustment. (8) Install A/C compressor hoses. Refer to Group 24, Heater and Air Conditioning for procedure. (9) Install accessory drive belts. Refer to Group 7, Cooling System Accessory Drive Section for belt tension adjustment. (10) Install front and rear engine mounts. Refer to this section for procedure. (11) Install inner splash shield. Install wheels and tires. (12) Connect automatic transmission cooler lines, and shift linkage. Refer to Group 21, Transmission for procedures. (13) Connect fuel line and heater hoses. (14) Install ground straps. Connect engine and throttle body connections and harnesses. Refer to Group 8, Electrical for procedure. (15) Connect throttle body linkage. Refer to Group 14, Fuel System for procedure. (16) Install radiator fans. Install radiator hoses. Fill cooling system. Refer to Group 7, Cooling System for filling procedure. (17) Connect battery. (18) Install air cleaner and hoses. (19) Install oil filter. Fill engine crankcase with proper oil to correct level. (20) Start engine and run until operating temperature is reached. (21) Adjust transmission linkage, if necessary.
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REMOVAL AND INSTALLATION (Continued)
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CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. (3) Apply Mopar Silicone Rubber Adhesive Sealant at the camshaft cap corners and at the top edge of the 1/2 round seal. (4) Install cylinder head cover assembly to head and tighten fasteners in sequence shown in (Fig. 30). Using the 3 step torque method: (a) Tighten all fasteners to 4.5 Nm (40 in. lbs.) (b) Tighten all fasteners to 9.0 Nm (80 in. lbs.) (c) Tighten all fasteners to 12 Nm (105 in. lbs.)
CAMSHAFT
REMOVAL (1) Remove cylinder head cover using procedure outlined in this section. (2) Remove timing belt, sprockets and covers. Refer to Timing Belt Service outlined in this section. (3) Bearing caps are identified for location. Remove the outside bearing caps first (Fig. 31). (4) Loosen the camshaft bearing cap attaching fasteners in sequence shown (Fig. 32) one camshaft at a time.
CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is wider.
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REMOVAL AND INSTALLATION (Continued)
(5) Identify the camshafts before removing from the head. The camshafts are not interchangeable.
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CAMSHAFT FOLLOWER
REMOVAL (1) Remove cylinder head cover using procedure outlined in this section. (2) Remove timing belt, sprockets and covers using procedure outlined in this section. (3) Remove camshaft. Refer to procedure previously outline this section. (4) Remove cam follower assemblies from cylinder head. Keep the cam followers in the order they have been removed from the head for reassembly. INSPECTION Inspect the cam follower assembly for wear or damage (Fig. 36). Replace as necessary.
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REMOVAL AND INSTALLATION (Continued)
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BALANCE SHAFT INSTALLATION Balance shaft and carrier assembly installation is the reverse of the removal procedure. During installation crankshaft to balance shaft timing must be established. Refer to Timing procedure outlined in this section.
BALANCE SHAFT TIMING (1) With balance shafts installed in carrier (Fig. 42) position carrier on crankcase and install four attaching bolts and tighten to 54 Nm (40 ft. lbs.). (2) Turn balance shafts until both shaft key ways are up Parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After installation gear and balance shaft keyways must be up with gear timing marks meshed as shown in (Fig. 43).
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REMOVAL AND INSTALLATION (Continued)
NOTE: THE TIMING MARK ON THE SPROCKET, THE (LOWER) NICKEL PLATED LINK, AND THE ARROW ON THE SIDE OF THE GEAR COVER SHOULD LINE UP WHEN THE BALANCE SHAFTS ARE TIMED CORRECTLY. (9) If the sprockets are timed correctly install the balance shaft bolts and tighten to 28 Nm (250 in. lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation. CHAIN TENSIONING (1) Install chain tensioner loosely assembled. (2) Position guide on double ended stud making sure tab on the guide fits into slot on the gear cover. Install and tighten nut/washer assembly to 12 Nm (105 in. lbs.). (3) Place a shim 1 mm (0.039 in.) thick x 70 mm (2.75 in.) long or between tensioner and chain. Push tensioner and shim up against the chain. Apply firm pressure (5.5 to 6.6 lbs.) directly behind the adjustment slot to take up all slack. Chain must have shoe radius contact as shown in (Fig. 46). (4) With the load applied, tighten top tensioner bolt first, then bottom pivot bolt. Tighten bolts to 12 Nm (105 in. lbs.). Remove shim. (5) Install carrier covers and tighten screws to 12 Nm (105 in. lbs.).
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INSTALLATION
NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced (Fig. 49). Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.
CYLINDER HEAD
REMOVAL (1) Perform fuel system pressure release procedure before attempting any repairs. Refer to Group 14, Fuel System for procedure. (2) Disconnect negative battery cable. Drain cooling system. Refer to Group 7, Cooling System for procedure. (3) Remove air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from throttle body. (4) Remove throttle linkage. Refer to Group 14, Fuel System for procedures (5) Remove accessory drive belts. Refer to Group 7, Cooling System for procedure. (6) Remove power brake vacuum hose from intake manifold. (7) Raise vehicle and remove exhaust pipe from manifold.
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REMOVAL AND INSTALLATION (Continued)
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(3) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. (4) Inspect and clean the valves. Refer to Cleaning and Inspection outlined in this section for procedure.
INSTALLATION (1) Coat valve stems with clean engine oil and insert in cylinder head. (2) Install new valve stem seals on all valves using a valve stem seal tool (Fig. 51). The valve stem seals should be pushed firmly and squarely over valve guide.
CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves.
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Fig. 52 Checking Spring Installed Height and Valve Tip Height Dimensions
VIBRATION DAMPER
REMOVAL Remove crankshaft vibration damper bolt. Remove damper by using Special Tool 1026 and Insert 6827A (Fig. 53).
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REMOVAL AND INSTALLATION (Continued)
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TIMING BELT
REMOVAL (1) Raise vehicle on hoist. Remove right front wheel. (2) Remove right inner splash shield. (3) Remove accessory drive belts. Refer to Group 7, Cooling System. (4) Remove crankshaft damper bolt, and remove damper. Refer to Removal and Installation procedure in this section. (5) Remove lower timing belt cover fasteners and remove cover (Fig. 57).
REAR COVER
REMOVAL (1) Remove front covers. (2) Remove engine mount bracket (Fig. 55). (3) Remove Timing Belt, Idler Pulley, and Camshaft Sprockets. Refer to procedure outlined in this section. (4) Remove rear cover fasteners and remove cover from engine (Fig. 56).
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REMOVAL AND INSTALLATION (Continued)
CAUTION: If timing belt was damaged due to incorrect tracking (alignment), the belt tensioner assembly must be replace. Refer to Timing Belt Tensioner Assembly Removal and Installation procedure outlined in this section.
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INSTALLATION (1) Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. (2) Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket (Fig. 61).
CAUTION: Ensure that the arrows on both camshaft sprockets are facing up. (3) Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner (Fig. 62). (4) Move the exhaust camshaft sprocket counterclockwise (Fig. 62) to align marks and take up belt slack. NOTE: A new tensioner is held in the wound position by a pull pin. (5) Remove the pull pin or Allen wrench from the belt tensioner. (6) Once timing belt has been installed and tensioner released, rotate crankshaft two (2) complete revolutions. Verify that the TDC marks on crankshaft and timing marks on the camshafts are aligned as shown in (Fig. 60). (7) Install right engine mount and support bracket. Refer to Removal and Installation procedure in this section. (8) Install upper timing belt cover bolts 4.5 Nm (40 in. lbs.). (9) Install the lower timing belt cover bolts 4.5 Nm (40 in. lbs.). (10) Install crankshaft damper. Refer to procedure outlined in this section. (11) Install accessory drive belts. Refer to Group 7, Cooling System. (12) Install right inner splash shield. (13) Install right front wheel.
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INSTALLATION (1) Align timing belt tensioner assembly to engine and install lower mounting bolt but do not tighten (Fig. 65). To properly align tensioner assemblyinstall one of the engine bracket mounting bolts (M10) 5 to 7 turns into the tensioners upper mounting location (Fig. 65). (2) Torque the tensioners lower mounting bolt to 61 Nm (45 ft. lbs.). Remove the upper bolt used for tensioner alignment. (3) Install rear timing belt cover and fasteners. (4) Install timing belt idler pulley and tighten mounting bolt to 61 Nm (45 ft. lbs.). (5) Install camshaft sprockets. Use Special Tools C-4687 and C-4687-1 Adapter to hold camshaft sprockets (Fig. 63) and tighten attaching bolts to 101 Nm (75 ft. lbs.). (6) Install timing belt. Refer to procedure outlined in this section.
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REMOVAL AND INSTALLATION (Continued)
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(4) Using Tool 6771 to remove front crankshaft oil seal (Fig. 71). Be careful not to damage the seal surface of cover.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
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OIL PAN
REMOVAL (1) Raise vehicle on hoist and drain engine oil. (2) Remove front engine mount bracket from engine and insulator mount. (3) Remove bolts attaching bending strut to engine and transaxle. (4) Remove bolts attaching collar and bending strut to engine, oil pan, and transaxle (Fig. 79). Remove strut and collar. (5) Remove oil pan. (6) Clean oil pan and all gasket surfaces.
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CRANKSHAFT
REMOVAL
NOTE: Crankshaft can engine is in vehicle. not be removed when
CAUTION: Do not get oil on the bedplate mating surface. It will may effect the sealer ability to seal the bedplate to cylinder block. (3) Oil the bearings and journals. Install crankshaft. CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. (4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of Mopar Torque Cure Gasket Maker to cylinder block as shown in (Fig. 83).
(1) Remove oil filter and oil pan. Refer to procedure outlined in this section. (2) Remove Timing Belt Cover, Timing Belt and Oil Pump. Refer to procedure outlined in this section. (3) Remove Balance Shafts Assembly. Refer to procedure outlined in this section. (4) Remove all main bearing cap bedplate bolts from the engine block. Refer to procedure outlined in this section. (5) Using a mallet gently tap the bedplate loose from the engine block dowel pins. CAUTION: Do not pry up on one side of the bedplate. Damage may occur to cylinder block to bedplate alignment and thrust bearing. (6) Bedplate should be removed evenly from the cylinder block dowel pins to prevent damage to the dowel pins and thrust bearing. (7) Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.
INSTALLATION
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REMOVAL AND INSTALLATION (Continued)
(7) Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block. (8) To ensure correct thrust bearing alignment perform the following steps: Step 1: Rotate crankshaft until number 4 piston is at TDC. Step 2: Move crankshaft rearward to limits of travel. Step 3: Then, move crankshaft forward to limits of travel. Step 4: Wedge an appropraite tool between the rear of the cylinder block (NOT BED PLATE) and the rear crankshaft counterweight. This will hold the crankshaft in its furthest forward position. Step 5: Install and tighten bolts (1-10) in sequence shown in (Fig. 84) to 41 N m (30 ft. lbs.). Step 6: Remove wedge tool used to hold crankshaft. (9) Tighten bolts (1-10) again to 41 N m (30 ft. lbs) + 1/4 turn in sequence shown in (Fig. 84). (10) Install main bearing bedplate to engine block bolts (11-20), and torque each bolt to 28 N m (20 ft. lbs.) in sequence shown in (Fig. 84). (11) After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 N m (50 in. lbs.).
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(1) Turn counterclockwise to remove. (2) To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until the gasket contacts base. Tighten to 21 Nm (15 ft. lbs.).
OIL PUMP
REMOVAL (1) Disconnect negative cable from battery. (2) Remove Timing Belt. Refer to procedure outlined in this section. (3) Remove Oil Pan. Refer to procedure outlined in this section. (4) Remove Crankshaft Sprocket using Special Tool 6793 and insert C-4685-C2 (Fig. 85).
OIL FILTER
CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate.
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REMOVAL AND INSTALLATION (Continued)
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Fig. 93 PistonInstallation
(3) Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Fig. 93). Be sure position of rings does not change during this operation. (4) The directional stamp on the piston should face toward the front of the engine (Fig. 90). (5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. (6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
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DISASSEMBLY AND ASSEMBLY (Continued)
(4) Wash all parts in a suitable solvent and inspect carefully for damage or wear.
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Chart. Replace guides if they are not within specification. (3) Check valve guide height (Fig. 98).
ASSEMBLY (1) Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover. (2) Prime oil pump before installation by filling rotor cavity with engine oil. (3) Install cover and tighten screws to 12 Nm (105 in. lbs.).
CAUTION: Oil pump pressure relief valve must be installed as shown in (Fig. 95) or serious damage may occur.
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VALVE SPRINGS (1) Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct tension. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: Valve Closed Nominal Tension 76 lbs. @ 38.0 mm (1.50 in.) Valve Open Nominal Tension 136 lbs. @ 29.75 mm (1.17 in.) (2) Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring.
CRANKSHAFT
The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 99). Limits of taper or out-of-round on any crankshaft journals should be held to .025 mm (.001 inch). Journal grinding should not exceed .305 mm (.012 inch) under the standard journal diameter. DO NOT grind thrust faces of Number 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine.
OIL PUMP
(1) Clean all parts thoroughly. Mating surface of the oil pump should be smooth (Fig. 100). Replace pump cover if scratched or grooved.
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CLEANING AND INSPECTION (Continued)
between rotors and the straightedge, replace pump assembly (Fig. 106), ONLY if rotors are in specs. (8) Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400 grit wet or dry sandpaper. (9) The relief valve spring has a free length of approximately 60.7 mm (2.39 inches) it should test between 18 and 19 pounds when compressed to 40.5 mm (1.60 inches). Replace spring that fails to meet specifications.
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CYLINDER BLOCK
(1) Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. (2) If new core plugs are installed, refer to Engine Core Plugs outlined in this section. (3) Examine block and cylinder bores for cracks or fractures.
Standard Piston Size 87.450 - 87.468 mm (3.4434 - 3.4441 in.) Piston To Bore Clearance 0.024 - 0.057 mm (0.0009 - 0.0022 in.) Measurements taken at Piston Size Location.
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Oil Ring (Pack) . . . . . . . . . . . . . .0.012 - 0.178 mm (0.0004 - 0.0070 in.) Piston Ring Width Compression Rings . . . . . . . . . . . . .1.47 - 1.50 mm (0.057 - 0.059 in.) Oil Ring (Pack) . . . . . . . . . . . . . . . .2.72 - 2.88 mm (0.107 - 0.1133 in.) Connecting Rod Bearing Clearance . . . . . . . . . . . .0.025 - 0.071 mm (0.0009 - 0.0027 in.) Piston Pin Bore Diameter . . . . . .20.96 - 20.98 mm (0.8252 - 0.8260 in.) Large End Bore Diameter . . . .53.007 - 52.993 mm (2.0868 - 2.0863) Side Clearance . . . . . . . . . . . . . .0.013 - 0.0150 mm (0.0051 - 0.0150 in.) Total Weight (Less Bearing). . . . . . . . .565.8 grams (19.96 oz.) Crankshaft Connecting Rod Journal Diameter . . . . . . . . . .49.984 - 50.000 mm (1.967 - 1.9685 in.) Out-of-Round (Max.) . . . . . .0.0035 mm (0.0001 in.) Taper (Max.) . . . . . . . . . . . .0.0038 mm (0.0001 in.) Main Bearing Diametrical Clearance No. 1 - 5 . . . . . . . . . . .0.018 - 0.058 mm (0.0007 - 0.0023 in.) End Play . . . . . . . . . . . . . . . . . . . . .0.09 - 0.24 mm (0.0035 - 0.0094 in.) Main Bearing Journals Diameter . . . . . . . . . . . . . . . . .59.992 - 60.008 mm (2.361 - 2.3625 in.) Out-of-Round (Max.) . . . . . .0.0035 mm (0.0001 in.) Taper (Max.) . . . . . . . . . . . . . . .0.0038 (0.0001 in.) Hydraulic Lash Adjusters Body Diameter . . . . . . . . . . . . .15.901 - 15.913 mm (0.626 - 0.6264 in.) Plunger Travel Minimum (Dry). . . . . . . . . .3.0 mm (0.118 in.) Camshaft Bearing Bore Diameters No. 16. . . . . . . . . .26.020 - 26.041 mm (1.024 - 1.025 in.) Diametrical Bearing Clearance . .0.069 - 0.071 mm (0.0027 - 0.003 in.) End Play . . . . . . . . . . . . . . . . . . .0.050 - 0.170 mm (0.0019 - 0.0066 in.) Bearing Journal Diameter No. 16 . . . . . . . . . .25.951 - 25.970 mm (1.021 - 1.022 in.) Lift (Zero Lash) Intake . . . . . . .8.25 mm (0.324 in.) Lift (Zero Lash) Exhaust . . . . .6.52 mm (0.256 in.) Valve Timing Intake Valve Closes (ABDC) . . . . . . . . . . . . . . . . . . . . . . . . . .51 Opens (BTDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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SPECIFICATIONS (Continued)
Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 Valve Timing Exhaust Valve Closes (ATDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Opens (BBDC) . . . . . . . . . . . . . . . . . . . . . . . . . .52 Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 Valve Timing Valve Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Cylinder Head Material . . . . . . . . . . . . . . . . . . . . .Cast Aluminum Gasket Thickness (Compressed) . . . . . . . .1.15 mm (0.045 in.) Cylinder Head Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Runout (Max.). . . . . . . . . . . . .0.050 mm (0.002 in.) Width (Finish) Intake and Exhaust. . .0.9 - 1.3 mm (0.035 - 0.051 in.) Guide Bore Diameter (Std). . . . . . .11.0 - 11.02 mm (0.4330 - 0.4338 in.) Finish Guide Bore ID. . . . . . . . . .5.975 - 6.000 mm (0.235 - 0.236 in.) Valves Face Angle . . . . . . . . . . . . . . . . . . . . . .44-1/2 - 45 Head Diameter Intake . . . . . . . . .34.67 - 34.93 mm (1.364 - 1.375 in.) Head Diameter Exhaust . . . . . . .30.37 - 30.63 mm (1.195 - 1.205 in.) LengthIntake (Overall) . . . . . .112.76 - 113.32 mm (4.439 - 4.461 in.) LengthExhaust (Overall) . . . .109.59 - 110.09 mm (4.314 - 4.334 in.) Valve MarginIntake . . . . . . . . . .1.285 - 1.615 mm (0.050 - 0.063 in.) Valve MarginExhaust . . . . . . . .0.985 - 1.315 mm (0.038 - 0.051 in.) Valve Stem Tip HeightIntake . . . . . . . .48.04 mm (1.891 in.) Valves Valve Stem Tip HeightExhaust . . . . . . .47.99 mm (1.889 in.) Stem DiameterIntake . . . . . . . .5.934 - 5.952 mm (0.234 - 0.234 in.) Stem DiameterExhaust . . . . . . .5.906 - 5.924 mm (0.233 - 0.233 in.) Stem-to-Guide ClearanceIntake . . . . . . . . . . . .0.048 - 0.066 mm (0.0018 - 0.0025 in.) Stem-to-Guide ClearanceExhaust . . . . . . . . . .0.0736 - 0.094 mm (0.0029 - 0.0037 in.) Max. Allowable Stem-to-Guide ClearanceIntake and Exhaust . . . . . . .0.025 mm (0.010 in.) Valve Springs Free Length (Approx.) . . . . . . .48.4 mm (1.905 in.) Spring Tension (Valve Closed) . . . . . . . . .338 N 20 N @ 38.0 mm (75.98 lbs. 4.5 lbs. @ 1.496 in.) Spring Tension (Valve Open) . . . . . . . . .607 N 30 N @ 29.75 mm (136 lbs. 7 @ 1.172 in.) Number of Coils . . . . . . . . . . . . . . . . . . . . . . . .7.82 Wire Diameter . . . . . . . . . . . . .3.86 mm (0.151 in.) Installed Spring Height . . . . .38.00 mm (1.496 in.) Oil Pump Clearance Over Rotors (Max.). .0.10 mm (0.004 in.) Cover Out-of-Flat (Max.). . . . .0.025 mm (0.001 in.) Inner Rotor Thickness (Min.) . .9.40 mm (0.370 in.) Outer Rotor (Oil Pump) Clearance (Max.) . . . . . . . . . . .0.39 mm (0.015 in.) Diameter (Min.) . . . . . . . . . . .79.95 mm (3.148 in.) Thickness (Min.) . . . . . . . . . . . .9.40 mm (0.370 in.) Tip Clearance Between Rotors (Max.) . . . .0.20 mm (0.008 in.) Oil Pressure At Curb Idle Speed* . . . . . . . . . . . . .25 kPa (4 psi) At 3000 rpm . . . . . . . . .170 - 550 kPa (25 - 80 psi) CAUTION: * If pressure is ZERO at curb Idle, DO NOT run engine at 3,000 rpm.
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SPECIFICATIONS (Continued)
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DESCRIPTION TORQUE Engine Mount Bracket Bolts . . . . . . . . . . . . . . . . . . . . .61 Nm (45 ft. lbs.) Engine MountFront and Rear Through Bolt . . . . . . . . . . . . . . .61 Nm (45 ft. lbs.) Exhaust Manifold to Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . .23 Nm (200 in. lbs.) Exhaust Manifold Heat Shield Bolts . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Front Torque Bracket2.0/2.4L Engine Bolts . . . . . . . . . . . . . . . . . . . . .33 Nm (24 ft. lbs.) Front Torque Bracket Strut2.0/2.4L Engine Long Bolts . . . . . . . . . . . . . . . .110 Nm (80 ft. lbs.) Short Bolt . . . . . . . . . . . . . . . . .61 Nm (45 ft. lbs.) Intake Manifold Bolts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Oil Filter Filter . . . . . . . . . . . . . . . . . . . . .20 Nm (15 ft. lbs.) Oil Pan Oil Pan Bolts . . . . . . . . . . . . .12 Nm (105 in. lbs.) Drain Plug. . . . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Oil Pump Attaching Bolts . . . . . . . . . . . . . . . . . . . .28 Nm (250 in. lbs.) Oil Pump Cover Fastener . . . .12 Nm (105 in. lbs.) Oil Pump Pick-up Tube Bolt . .28 Nm (250 in. lbs.) Oil Pump Relief Valve Cap . . . .41 Nm (30 ft. lbs.) Rear Torque Bracket Bolts . . . . . . . . . . . . . . . . . . . .110 Nm (80 ft. lbs.) Spark Plugs Plugs . . . . . . . . . . . . . . . . . . . . .28 Nm (20 ft. lbs.) Thermostat Housing Bolts . . . . . . . . . . . . . . . . . . . .23 Nm (200 in lbs.) Timing Belt Tensioner Assembly Bolts . . . . . . . . . . . . . . . . . . . . .61 Nm (45 ft. lbs.) Water Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.)
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Cradle 6710
Puller 1026
Dolly 6135
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SPECIAL TOOLS (Continued)
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Front Crankshaft Oil Seal Installer 6780 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2
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3.0L ENGINE
INDEX
page DESCRIPTION AND OPERATION ENGINE COMPONENTS . . . . . . . . . . . . ENGINE IDENTIFICATION NUMBER . . . ENGINE LUBRICATION . . . . . . . . . . . . . DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE . . . SERVICE PROCEDURES AUTO LASH ADJUSTER . . . . . . . . . . . . . CHECKING CRANKSHAFT END PLAY . . FITTING CONNECTING ROD BEARINGS FITTING MAIN BEARING . . . . . . . . . . . . VALVE SERVICE RECONDITION . . . . . . REMOVAL AND INSTALLATION CAMSHAFT SEAL . . . . . . . . . . . . . . . . . CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . ENGINE ASSEMBLY . . . . . . . . . . . . . . . . ENGINE MOUNTS . . . . . . . . . . . . . . . . . FRONT CRANKSHAFT OIL SEAL . . . . . . OIL FILTER AND ADAPTOR . . . . . OIL PAN . . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD REAR CRANKSHAFT SEAL . . . . . ROCKER ARMS . . . . . . . . . . . . . . TIMING BELT . . . . . . . . . . . . . . . . DISASSEMBLY AND ASSEMBLY ROCKER ARMS AND SHAFTS . . . CLEANING AND INSPECTION CYLINDER BORE . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . TIMING BELT . . . . . . . . . . . . . . . . ADJUSTMENTS ENGINE MOUNTS . . . . . . . . . . . . SPECIFICATIONS 3.0L ENGINE . . . . . . . . . . . . . . . . TORQUE CHART 3.0L . . . . . . . . . SPECIAL TOOLS 3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . . . 84 77 84 78 83 72 75
. . . . . . 61 . . . . . . 61 . . . . . . 61 . . . . . . 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 65 63 63 66 72 71 81 70 73 69 68 83
. . . . . . . . . . . 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 86 87 86
. . . . . . . . . . . 88 . . . . . . . . . . . 89 . . . . . . . . . . . 90 . . . . . . . . . . . 91
ENGINE LUBRICATION
System is a full flow filtration, pressure feed type. The oil pump is mounted behind the timing belt cover. The pump inner rotor is driven by the crankshaft. The engine oil pan contains a baffle plate to control oil level fluctuation during engine operation.
ENGINE COMPONENTS
BLOCK: The cylinder block is a light weight design created by reducing thickness in many parts and a short 10 mm (3/8 in.) block skirt. High rigidity is provided with ribs cast in the outer wall, a full length water jacket, and a mono-block or beam type, main bearing cap. This single unit four bearing cap is designed to control vibration of the cylinder block partition walls. CRANKSHAFT: A six throw, five weight crankshaft is supported by four main bearings with number three being the thrust bearing. The six separate connecting rod throws pins reduce torque fluctua-
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FUNCTION CHECK Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker arm and very lightly pushing the auto adjuster ball check down (Fig. 3). While lightly holding the check ball down move the rocker up and down to check for free play. If there is no play replace the adjuster.
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SERVICE PROCEDURES (Continued)
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CONNECTING ROD SIDE CLEARANCE Using a feeler gauge, check connecting rod side clearance (Fig. 5). Refer to Connecting Rod Specification Chart.
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Main Bearing Oil Clearance 0.018 - 0.036 mm (0.0007 - 0.0014 in.) 0.10 mm (0.0039 in.) 59.980 mm (2.361 in.) 50.00 mm (1.968 in.)
CAUTION: Do not rotate crankshaft or the plastigage will be smeared. (4) Install the main bearing cap carefully and tighten the bolts to specified torque.
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SERVICE PROCEDURES (Continued)
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Crankshaft Main Bearing Journal Crankshaft Connecting Rod Journal Standard Diameter:
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VALVES
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SERVICE PROCEDURES (Continued)
VALVE SPECIFICATION CHART
Valve Dimensions INTAKE VALVE (MINIMUM) Stem Diameter: 7.960 mm (0.313 in.) Face Angle: 45 Valve Margin: 0.700 mm (0.028 in.) Length: 103.0 mm (4.055 in.) EXHAUST VALVE (MINIMUM) Stem Diameter: 7.930 mm (0.312) Face Angle: 45 Valve Margin: 1.50 mm (0.059 in.) Length: 102.70 mm (4.043 in.) Valve Guide Clearance New Service Limit 0.10 mm (0.004 in.) 0.15 mm (0.006 in.) Service Limit 48.8 mm (1.921 in.) 4 Maximum
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Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of the valve face, lower valve seat with a 15 degrees stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degree stone (Fig. 17).
INSTALLATION (1) Install valve spring seat. (2) Using suitable tool install seal by tapping lightly until seal is in place (Fig. 18). (3) Install valve spring with the enamelled ends facing the rocker arms (Fig. 19).
CAUTION: During reassembly, compressing the valve spring more than necessary to install valve spring retainer locks can cause the retainer to be forced against the stem seal and damaging it.
Intake: 0.03 - 0.06 mm (0.001 - 0.002 in.) Exhaust: 0.05 - 0.09 mm (0.002 - 0.0035 in.) Valve Springs New
Free Length: 49.8 mm (1.960 in.) Squarness: 2 Maximum Spring Tension: 33 Kg @ 40.4 mm (73 lbs. @ 1.59 in.)
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FRONT MOUNT
REMOVAL (1) Support the engine and transmission assembly with a floor jack so it will not rotate. (2) Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket (Fig. 21). (3) Remove six screws from air dam to allow access to the front mount screws. (4) Remove the front engine mount screws and remove the insulator assembly. (5) Remove the front mounting bracket, if necessary (Fig. 21). INSTALLATION (1) Reverse removal procedure for installation and tighten fasteners in this order: (a) Tighten bolts 2, 3, and 4 to 108 Nm (80 ft. lbs.). (b) Tighten bolts 1 and 5 to 54 Nm (40 ft. lbs.). (2) Engine mount adjustment. Refer to Engine Mount Insulator Adjustment of this section. (3) Install six screws to air dam and tighten to 12 Nm (105 in. lbs.).
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REMOVAL AND INSTALLATION (Continued)
(2) Tighten mount to transmission bolts to 55 Nm (40 ft. lbs.) (Fig. 22). Tighten through bolt to 75 Nm (55 ft. lbs.) (3) Engine mount adjustment, Refer to Engine Mount Insulator Adjustment of this section.
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ENGINE MOUNT RUBBER INSULATORS Insulator location on (right side) is adjustable to allow right/left drive train adjustment in relation to driveshaft assembly length. See Engine Mount Adjustments in this section. Check and reposition right engine mount insulator. Adjust drive train position, if required, for the following conditions: Driveshaft distress: See Group 2, Suspension and Driveshafts. Any front end structural damage (after repair). Insulator replacement.
ENGINE ASSEMBLY
REMOVAL (1) Perform fuel pressure release procedure. Refer to Group 14, Fuel System for procedure. Remove fuel line to fuel rail. (2) Disconnect battery. (3) Remove Air cleaner and hoses. (4) Remove battery cover, battery and battery tray, with integral vacuum reservoir, from vehicle. (5) Block off heater hoses to rear heater assembly, if equipped. (6) Drain cooling system. Refer to Group 7, Cooling System for procedure. (7) Disconnect heater hoses. (8) Remove fan module and radiator. Refer to Group 7, Cooling System for procedure. (9) Disconnect transmission shift linkage. (10) Disconnect throttle body linkage and vacuum hoses from throttle body. (11) Remove accessory drive belts. Refer to Accessory Drive System located in Group 7, Cooling System for procedure. (12) Remove air conditioning compressor from engine and set it aside. (13) Disconnect generator wiring harness and remove generator. (14) Hoist vehicle and remove axle shafts. Refer to Group 2, Driveshaft for procedure. (15) Remove right and left inner splash shields. (16) Disconnect exhaust pipe from manifold. (17) Remove front engine mount and bracket as an assembly. (18) Remove rear transmission mount and bracket. (19) Remove power steering pump and bracket assembly. (20) Remove wiring harness and connectors from front of engine. (21) Remove bending braces and install tool number 6910 on engine. (22) Remove trans inspection cover and mark flexplate to torque converter. (23) Remove driveplate to torque converter bolts. (24) Lower the vehicle.
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REMOVAL AND INSTALLATION (Continued)
(6) When removing right cylinder head cover, disconnect generator wiring and remove generator. (7) Relocate spark plug wires. (8) Remove vacuum connections. (9) Remove rocker cover screws and remove cover (Fig. 25).
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INSTALLATION (1) Clean cylinder head and cover mating surfaces. Install new gasket. (2) See (Fig. 25) and apply sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends. (3) Install cover and tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.). (4) Reverse removal procedures for installation.
CAMSHAFT
REMOVAL
NOTE: SEE AUTO LASH ADJUSTER FUNCTION CHECK BEFORE DISASSEMBLY (1) Install auto lash adjuster retainers (Fig. 26). (2) Remove distributor adaptor (Fig. 27). (3) When removing camshaft bearing caps do not remove the bolts from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an assembly.
CAMSHAFT INSTALL Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head.
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ROCKER ARMS
INSTALL ROCKER ARM SHAFT ASSEMBLY (1) Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in (Fig. 29). (2) Install the rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark on the cylinder head are in the same direction (Fig. 29).
NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other. (3) Tighten bearing cap bolts in the following order to 10 Nm (85 in. lbs.). First #3, then #2, #1 and #4. (4) Repeat step 3 increasing the torque to 20 Nm (180 in.lbs.). (5) Install distributor drive adaptor assembly (Fig. 30).
CAMSHAFT SEAL
Fig. 28 Checking Camshafts
CAMSHAFT END SEAL (PLUG) IN VEHICLE SERVICE (1) Remove air cleaner assembly from engine. (2) Use a small punch and a hammer, carefully remove cam plug from cylinder head.
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REMOVAL AND INSTALLATION (Continued)
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CAMSHAFT OIL SEAL PLUG OUT OF VEHICLE SERVICE (1) Apply light coat of engine oil to the camshaft oil seal lip. (2) Install the oil seal using camshaft oil seal installer tool MD-998713 (Fig. 31).
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CYLINDER HEAD
REMOVAL (1) Remove timing belt and camshaft sprockets. See Timing Belt in this section for procedures. (2) Remove cylinder head covers and rocker arms and shafts. Refer to procedure outlined in this section. (3) Remove intake manifolds. Refer to Intake and Exhaust Manifolds, Group 11. (4) Remove distributor. (5) Remove exhaust manifolds and cross over Refer to Intake and Exhaust Manifolds, Group 11.
CAUTION: Attach the cylinder head bolt washer in the direction shown in (Fig. 34).
INSTALLATION (1) Clean surfaces of head and block, install head gasket over locating dowels. (2) Install head on locating dowels. (3) Install 10 mm Allen hex head bolts with washers.
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REMOVAL AND INSTALLATION (Continued)
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TIMING BELT
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REMOVAL AND INSTALLATION (Continued)
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OIL PAN
Oil pan to crankcase sealing is provided with Mopar Silicone Rubber Adhesive Sealant or equivalent gasket material. See Form-In-Place Gaskets in Standard Service Procedures. (1) Apply sealant as shown in (Fig. 42). (2) Install pan and tighten screws to 6 Nm (50 in. lbs.) in sequence shown in (Fig. 43).
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
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CRANKSHAFT
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REMOVAL AND INSTALLATION (Continued)
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(3) Apply light coating of engine oil to the entire circumference of oil seal lip. (4) Install seal assembly on cylinder block and tighten bolts to 12 Nm (104 in. lbs.)
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OIL PUMP
CAUTION: When servicing the oil filter avoid deforming the filter. Install the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can-to-base is reinforced by the base plate. (3) Using Tool C-4065, turn filter counterclockwise to remove from base. Properly discard filter. (4) Wipe base clean, then inspect gasket contact surface. (5) Lubricate gasket of new filter with clean engine oil.
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REMOVAL AND INSTALLATION (Continued)
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ASSEMBLE ROCKER ASSEMBLY Install the rocker arms, bearing caps and springs. Springs are the same and can be used at all locations on the rocker arm shafts (Fig. 71) and (Fig. 73). Insert bolts in number four bearing cap to retain assembly.
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CYLINDER HEAD
Fig. 72 Number One Camshaft Bearing Cap
CLEANING AND INSPECTION (1) Before cleaning, check for leaks, damage and cracks. (2) Clean cylinder head and oil passages. (3) Check cylinder head for flatness (Fig. 76). (4) Cylinder head must be flat within: Standard dimension = less than 0.05 mm (.002 in.) Service Limit = 0.2 mm (.008 in.) Grinding Limit = Maximum of 0.2 mm (.008 in.) is permitted.
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CLEANING AND INSPECTION (Continued)
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OIL PUMP
(1) Check oil pump case for damage. Remove rear oil pump cover. (2) Remove pump rotors and inspect case for excessive wear. (3) Measure clearance between case and inner rotor (Fig. 78). (4) Insert the rotor into the oil pump case and measure clearance between outer rotor and case with a feeler gauge (Fig. 79). Replace if out of specifications.
CYLINDER BORE
INSPECTION (1) Measure the cylinder bore at three levels in directions A and B (Fig. 77). Top measurement
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OIL RELIEF PLUNGER (1) Check that the oil relief plunger smoothly. (2) Check for broken relief spring.
slides
ENGINE MOUNT INSULATOR ADJUSTMENT (1) Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. (2) Loosen the right engine mount insulator vertical fastener and the fore and aft fasteners, and the front engine mount bracket to front crossmember screws. (3) Pry the engine right or left as required to achieve the proper drive shaft assembly length. Refer to Group 2, Suspension and Driveshafts for driveshaft identification and related assembly length measuring. (4) Tighten engine mounts and fasteners in the following order: (a) Right engine mount insulator vertical bolts to 102 Nm (75 ft. lbs.) and the fore and aft bolts to 150 Nm (110 ft. lbs.). (b) Front engine mount screws to 54 Nm (40 ft. lbs.) the clearance between the snubbers and the engine should be 2 mm (0.078 inch.) each side. (c) Left engine mount through bolt to 75 Nm (55 ft. lbs.). (5) Recheck driveshaft length.
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Wear Limit . . . . . . . . . . . . . . . . .0.4 mm (0.015 in.) LengthCenter to Center . . . . . . .140.9 - 141.0 mm (5.547 - 5.551 in.) ParallelismTwist . . . . . . . . . .0.05 mm (0.0019 in.) Torsion . . . . . . . . . . . . . . . . . . .0.1 mm (0.0039 in.) Crankshaft Main Journal Diameter . . . . . . .59.980 - 60.0 mm (2.361 - 2.362 in.) Connecting Rod Journal Diameter . . . . . . . . . .49.980 - 50.000 mm (1.968 - 1.969 in.) Out-of-Round (Max.) . . . . . . . . .0.03 mm (0.001 in.) Taper (Max.) . . . . . . . . . . . . .0.005 mm (0.0002 in.) Main and Rod Bearing Clearance . . . . . . . . . . .0.018 - 0.036 mm (0.0007 - 0.0014 in.) Undersize Service Bearings . . . . . . . . . . . . . . . .0.25 - 0.50 - 0.75 mm (0.010 - 0.020 - 0.030 in.) End Play . . . . . . .0.05 - 0.25 mm (0.002 - 0.010 in.) Service Limit. . . . . . . . . . . . . .0.3 mm (0.012 in.) Cylinder Head Flatness of Gasket Surface . . . .0.05 mm (0.002 in.) Grinding Limit of Gasket Surface . . . . . . . . . . . . .0.2 mm (0.008 in.) Cylinder Head Valve Seat AngleIntake and Exhaust . . . . . . . . . .44 - 44.3 Contact Width . . . . . . . . . . . . . . . . . . .0.9 - 1.3 mm (0.035 - 0.051 in.) SinkageService Limit . . . . . . . .0.2 mm (0.078 in.) Guide Bore Diameter (Std) . . . . . . .7.95 - 7.98 mm (0.313 - 0.314 in.) Valves Face Angle . . . . . . . . . . . . . . . . . . . . . .45 - 45 30 Head Diameter Intake . . . . . . . . .48.64 - 48.90 mm (1.915 - 1.925 in.) Head Diameter Exhaust . . . . . . .40.01 - 40.26 mm (1.575 - 1.585 in.) Length Intake (Overall) . . . . .103.0 mm (4.055 in.) Length Exhaust (Overall) . . . .102.7 mm (4.043 in.) Valve MarginIntake . . . . . . . . .1.2 mm (0.047 in.) Service Limit. . . . . . . . . . . . . .0.7 mm (0.027 in.) Valve MarginExhaust . . . . . . . .2.0 mm (0.079 in.) Service Limit. . . . . . . . . . . . . .1.5 mm (0.059 in.) Valve Stem Tip Height . . . . . .49.02 mm (1.929 in.) Stem DiameterIntake . . . . . . . .7.960 - 7.975 mm (0.313 - 0.314 in.) Stem DiameterExhaust . . . . . . .7.930 - 7.950 mm (0.312 - 0.3125 in.) Stem-to-Guide ClearanceIntake. . .0.03 - 0.06 mm (0.001 - 0.002 in.) Service Limit. . . . . . . . . . . . .0.10 mm (0.004 in.) Stem-to-Guide Clearance Exhaust . . . . . . . . . . . . . . . . . . . . .0.05 - 0.09 mm (0.0019 - 0.003 in.)
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SPECIFICATIONS (Continued)
Service Limit. . . . . . . . . . . . .0.15 mm (0.006 in.) Valve Guide Overall LengthIntake . . . . . . . .44 mm (1.732 in.) Overall LengthExhaust . . . . . . .48 mm (1.889 in.) Outside Diameter. . . . . . . . . . .13.055 - 13.065 mm (0.514 - 0.5143 in.) Inside Diameter . . . . . . . . . . . . . .8.000 - 8.018 mm (0.314 - 315 in.) Valve Springs Free Length (Approx.) . . . . . . .49.8 mm (1.960 in.) Service Limit. . . . . . . . . . . .48.8 mm (1.9213 in.) Loaded Height . . . . . . . . . . . . . . .40.4 mm @ 33 kg (1.59 in. @73 lbs.) PerpendicularityIntake and Exhaust . . .2 (Max.) Service Limit. . . . . . . . . . . . . . . . . . . . .4 (Max.) Oil Pump Clearance Over Rotors (Max.).0.077 mm (0.003 in.) Cover Out-of-Flat (Max.). . . . .0.076 mm (0.003 in.) Inner Rotor Thickness (Min.) .18.92 mm (0.744 in.) Outer Rotor (Oil Pump) Clearance (Max.) . . . . . . . . . . .0.19 mm (0.007 in.) Diameter (Min.) . . . . . . . . . . .82.45 mm (3.246 in.) Thickness (Min.) . . . . . . . . . . .18.92 mm (0.744 in.) Tip Clearance Between Rotors (Max.) . . .0.150 mm (0.0068 in.) Oil Pressure At Curb Idle Speed* . . . . . . . . . . .68.9 kPa (10 psi) At 3000 rpm . . . . . . . . .310 - 517 kPa (45 - 75 psi) CAUTION: * If pressure is ZERO at curb Idle, DO NOT run engine at 3,000 rpm. DESCRIPTION TORQUE Cylinder Head Bolts . . . . . . . .Refer To Cylinder Head Installation Cylinder Head Cover Bolts . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Engine Mount Bracket Bolts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. lbs.) Engine MountFront and Rear Through Bolt . . . . . . . . . . . . . . .61 Nm (45 ft. lbs.) Exhaust Manifold to Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . .23 Nm (200 in. lbs.) Exhaust Manifold Heat Shield Bolts . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Intake Manifold Bolts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Oil Filter to Engine Block Adapter Bolts . . . . . . . . . . . . . . . . . . . . .55 Nm (40 ft. lbs.) Oil Filter Filter . . . . . . . . . . . . . . . . . . . . .20 Nm (15 ft. lbs.) Oil Pan Oil Pan Bolts . . . . . . . . . . . . .12 Nm (105 in. lbs.) Drain Plug. . . . . . . . . . . . . . . . .39 Nm (29 ft. lbs.) Oil Pump Attaching Bolts . . . . . . . . . . . . . . . . . . . .15 Nm (130 in. lbs.) Oil Pump Cover Fastener . . . . .9 Nm (104 in. lbs.) Oil Pump Pick-up Tube Bolt . .28 Nm (250 in. lbs.) Oil Pump Relief Valve Cap . . . .49 Nm (36 ft. lbs.) Spark Plugs Plugs . . . . . . . . . . . . . . . . . . . . .28 Nm (20 ft. lbs.) Thermostat Housing Bolts . . . . . . . . . . . . . . . . . . . .23 Nm (200 in lbs.) Timing Belt Tensioner Bolt . . . . . . . . . . . . . . . . . . . . . .28 Nm (20 ft. lbs.) Timing Belt Tensioner Pulley Assembly Bolt . . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. lbs.) Water Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.)
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Adaptor 6910
Dolly 6135
Cradle 6710
Adaptor 6909
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3.3/3.8L ENGINE
INDEX
page DESCRIPTION AND OPERATION ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . 93 ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . 93 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . 93 DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE . . . . . . . . . 96 HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 94 SERVICE PROCEDURES CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . 99 FITTING CONNECTING ROD BEARINGS . . . . . . 97 FITTING MAIN BEARINGS . . . . . . . . . . . . . . . . . 98 FITTING PISTONS AND RINGS . . . . . . . . . . . . . 97 MEASURING TIMING CHAIN FOR STRETCH . . . 96 VALVE SERVICE RECONDITION . . . . . . . . . . . 100 VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 96 REMOVAL AND INSTALLATION CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . 114 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 CRANKSHAFT DAMPER . . . . . . . . . . . . . . . . . 106 CRANKSHAFT OIL SEALFRONT . . . . . . . . . . 117 CRANKSHAFT OIL SEALREAR . . . . . . . . . . . 118 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 116 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . 107 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 108 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 104 ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . 102 ENGINE OIL GALLERY PLUGS . . . . . . . . . . . . . 119 page OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD . . . . . . . . . . ROCKER ARMS AND SHAFT ASSEMBLY . . . . . TAPPET REMOVAL . . . . . . . . . . . . . . . . . . . . . . TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . . TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . VALVE STEM SEALS OR SPRINGS, CYLINDER HEAD NOT REMOVED . . . . . . . . VALVES AND VALVE SPRINGS . . . . . . . . . . . . WIPER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND ASSEMBLY HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING AND INSPECTION CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . ENGINE BLOCK AND BORE . . . . . . . . . . . . . . . OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . 119 114 115 106 110 111 112 106 109 102 120 119 120 121 121 121 123 123 125 127
ENGINE COMPONENTS
ENGINE: The 3.3L (201 Cubic Inches) and 3.8L (231 Cubic Inches) displacement engines are 60 V type six cylinder power plants with cast iron cylinder blocks and aluminum cylinder heads (Fig. 3). Firing order for these engines is 1-2-3-4-5-6. High turbulence cylinder heads allow a 8.9-1 compression ratio. CRANKSHAFT: The nodular iron crankshaft is supported by four main bearings, with number two being the thrust bearing. Crankshaft end sealing is provided by front and rear rubber seals. PISTONS: The pistons are cast aluminum alloy. Three rings are used. Piston pins, press fitted into place, join the pistons to forged steel connecting rods. CAMSHAFT: The nodular iron camshaft is mounted in four steel backed babbitt bearings. A thrust plate located in front of the first bearing, and bolted to the block, controls end play. Silent timing chain drives the camshaft. This chain is enclosed by a cast aluminum cover which also carries a front
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DIAGNOSIS AND TESTING (Continued)
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OIL LEVEL TOO HIGH If oil level is above the MAX mark on dip stick, it is possible for the connecting rods to dip into the oil while engine is running and create foam. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to become soft and allow valves to seat noisily. OIL LEVEL TOO LOW Low oil level may allow pump to take in air which when fed to the tappets, causes them to become soft and allows valves to seat noisily. Any leaks on intake side of pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, engine should be operated at fast idle to allow all of the air inside of the tappets to be bled out. VALVE TRAIN NOISE DIAGNOSIS To determine source of valve train noise, operate engine at idle with cylinder head covers removed and listen for source of the noise.
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SERVICE PROCEDURES (Continued)
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Engine 3.3L
3.8L
Standard Piston Size 3.3L 92.950 - 92.968 mm (3.6594 - 3.6602 in.) 3.8L 95.950 - 95.968 mm (3.7776 - 3.7783 in.) Piston to Bore Clearance: 0.025 - 0.057 mm (0.0009 - 0.0022 in.) Measurements taken at Piston Size Location.
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SERVICE PROCEDURES (Continued)
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Main Bearing Clearance New Part: Wear Limit: 0.011 - 0.059 mm (0.0005 - 0.0024 in.) 0.076 mm (0.003 in.)
Standard Size:
Crankshaft Connecting Rod Journal Standard Size: 57.989 - 58.005 mm (2.2831 - 2.2837 in.)
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SERVICE PROCEDURES (Continued)
VALVE GUIDES
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NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 in.) oversize reamer, or if guide is loose in cylinder head.
REFACING VALVES AND VALVE SEATS The intake and exhaust valves have a 44-1/2 to 45 degree face angle. The valve seats have a 45 to 45-1/2 degree face angle. The valve face and valve seat angles are shown in (Fig. 19).
VALVES (1) Inspect the remaining margin after the valves are refaced Refer to Valve Dimension Chart.
Dial Indicator Reading (Maximum): Valve Guide Reamer Oversize 0.15 mm (0.005 in.) 0.40 mm (0.015 in.) 0.80 mm (0.030 in.)
8.125 - 8.150 mm (0.3198 - 0.3208 in.) 8.375 - 8.400 mm (0.3297 - 0.3307 in.) 8.775 - 8.800 mm (0.3454 - 0.3464 in.)
dure of 0.15 mm (0.005 in.), 0.40 mm (0.015 in.) and 0.80 mm (0.030 in.) so the valve guides may be reamed true in relation to the valve seat. After reaming guides, the seat runout should be measured and resurfaced if necessary. See Refacing Valves and Valve Seats.
7.935 mm (0.3124 in.) 44.5 0.794 mm (0.031 in.) 45.5 mm (1.79 in.) 127.2 mm (5.008 in.) 7.906 mm (0.3112 in.) 44.5 1.191 mm (0.0469 in.) 37.5 mm (1.476 in.) 127.82 (5.032 in.)
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TESTING VALVE SPRINGS Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 21). As an example; the compression length of the spring to be tested is 33.34 mm (1-5/16 inches). Turn table of Tool C-647 until surface is in line with the 33.34 mm (1-5/16 inch) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications.
ENGINE MOUNTS
RIGHT SIDE MOUNT
REMOVAL NOTE: Right mount should only be serviced as an assembly to prevent noise, vibration and harshness concerns. (1) Remove the purge duty solenoid and wiring harness from engine mount. (2) Remove the two right engine mount insulator vertical fasteners and loosen the horizontal fastener, Do Not remove the large nut on the end of the core from frame rail (Fig. 23). (3) Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack.
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REMOVAL AND INSTALLATION (Continued)
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(3) Install six screws to air dam and tighten to 12 Nm (105 in. lbs.).
FRONT MOUNT
REMOVAL (1) Support the engine and transmission assembly with a floor jack so it will not rotate. (2) Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket (Fig. 24). (3) Remove six screws from air dam to allow access to the front mount screws. (4) Remove the front engine mount screws and remove the insulator assembly. (5) Remove the front mounting bracket, if necessary (Fig. 24). INSTALLATION (1) Reverse removal procedure for installation and tighten fasteners in this order: a. Tighten bolts 2,3, and 4 to 108 Nm (80 ft. lbs.). b. Tighten bolts 1 and 5 to 54 Nm (40 ft. lbs.). (2) Engine mount adjustment, Refer to Engine Mount Insulator Adjustment of this section.
REAR MOUNT
REMOVAL (1) Raise vehicle on hoist. (2) Support the transmission with a transmission jack so it will not rotate. (3) Remove the insulator through bolt from the mount and rear suspension crossmember. (4) Remove the four transmission mount fasteners and remove the mount. INSTALLATION (1) Reverse the removal procedure for installation. Refer to (Fig. 26). Tighten through bolt to 75 Nm (55 ft. lbs.)
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ENGINE ASSEMBLY
REMOVAL (1) Perform fuel pressure release procedure. Refer to group 14 fuel system for procedure. Remove fuel line to fuel rail. (2) Disconnect battery. (3) Remove air cleaner and hoses. (4) Remove battery cover, battery and battery tray, with integral vacuum reservoir, from vehicle. (5) Block off heater hoses to rear heater assembly, if equipped. (6) Drain cooling system. Refer to Group 7, Cooling System for procedure. (7) Disconnect heater hoses. (8) Remove fan module and radiator. Refer to Group 7 Cooling System for procedure. (9) Disconnect transmission shift linkage. (10) Disconnect throttle body linkage and vacuum hoses from throttle body. (11) Remove accessory drive belts. Refer to Group 7, Accessory Drive Belts located in Cooling System for procedure. (12) Remove air conditioning compressor from engine and set it aside. (13) Disconnect generator wiring harness and remove generator. (14) Hoist vehicle and remove right and left inner splash shields. (15) Remove crossmember cradle plate (Fig. 27).
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REMOVAL AND INSTALLATION (Continued)
(20) Remove rear transmission mount and bracket. (21) Remove power steering pump and bracket assembly. (22) Remove wiring harness and connectors from front of engine. (23) Remove bending braces and install tool number 6912 on engine. (24) Remove transmission inspection cover and mark flexplate to torque converter. (25) Remove driveplate to torque converter bolts. (26) Lower the vehicle. (27) Remove ground straps to body. (28) Raise vehicle enough to allow engine dolly Special Tool 6135 and cradle Special Tool 6710 with post Special Tool 6848 and adaptor Special Tool 6909 to be installed under vehicle (Fig. 28). (29) Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on the engine. Lower vehicle and position cradle mounts until the engine is resting on mounts. Tighten mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission. (30) Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION is on the cradle. (31) Remove right engine mount assembly and left transmission mount through bolt. Refer to Engine Mounts Section of this Group. (32) Raise vehicle slowly. It may be necessary to move the engine/transmission assembly on the cradle to allow for removal around body flanges.
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INSTALLATION (1) Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission. It may be necessary to move the engine/transmission assembly with the cradle for clearance around body flanges. (2) Align engine and transmission mounts to attaching points. Install mounting bolts at the right engine and left transmission mounts. Refer to procedures outlined in this section. (3) Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135, 6710, 6848 and 6909. (4) Remove Special tools 6912 and install bending braces. (5) Lower vehicle. Install generator and wiring harness. (6) Connect wiring harness on the front of the engine. (7) Install Air Conditioning Compressor. (8) Install power steering pump and bracket and accessory drive belt. Refer to Accessory drive Section Located in group 7 for installation procedure. (9) Raise vehicle and install axle shafts. Refer to Group 3, Differential and Driveline for procedure. (10) Install transmission and engine mount and bracket assemblies. Refer to Engine Mounts section of this Group. (11) (AWD equipped) Install propeller shaft to power transfer unit. Refer to Group 3, Differential and Driveline for procedure. (12) Connect exhaust system to manifold. Refer to Group 11, Exhaust System and Intake Manifold for procedure and torque specifications. (13) Install crossmember cradle plate (Fig. 27). (14) Install left and right inner splash shields. (15) Connect automatic transmission shifter linkage. Refer to Group 21, Transmission for procedures. (16) Lower vehicle and connect fuel line and heater hoses. Remove plugs from rear heater hoses and install, if equipped. (17) Install ground straps. Connect engine and throttle body connections and harnesses. (18) Connect throttle body linkage. Refer to Group 14, Fuel System for procedure. (19) Install radiator and fan module assembly. Install radiator hoses. Fill cooling system. See Group 7 for filling procedure. (20) Install battery tray, battery and cover. (21) Install air cleaner and hoses. (22) Install oil filter. Fill engine crankcase with proper oil to correct level. (23) Start engine and run until operating temperature is reached. (24) Adjust transmission linkage, if necessary.
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CRANKSHAFT DAMPER
REMOVAL (1) Disconnect negative cable from battery. (2) Raise vehicle on hoist. (3) Remove right wheel and inner splash shield. (4) Remove drive belt. Refer to Group 7, Cooling System for procedure. (5) Remove crankshaft pulley (Fig. 29).
(2) Disconnect spark plug wires by pulling on the boot straight out in line with plug. (3) Disconnect closed ventilation system. (4) Remove cylinder head cover and gasket. (5) Remove four rocker shaft bolts and retainers. (6) Remove rocker arms and shaft assembly. (7) If rocker arm assemblies are disassembled for cleaning or replacement. Assemble rocker arms in their original position. Refer to (Fig. 31) for rocker arm for positioning on the shaft.
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REMOVAL AND INSTALLATION (Continued)
(4) Remove upper intake manifold. Refer to Group 11, Exhaust System and Intake Manifolds for procedure. (5) Remove cylinder head covers and spark plugs. (6) Remove electrical connector from ignition coils. (7) Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the number 1 piston is at Top Dead Center on the compression stroke. (8) Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be disturbed and left on shaft. (9) With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to hold valves in place while servicing components. (10) Using Tool C-4682 or equivalent, compress valve spring and remove retainer valve locks and valve spring. (11) The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not pinch seal between retainer and top of valve guide. (12) Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at TDC on the valve spring that is being covered. (13) Remove spark plug adapter tool. (14) Remove dummy shaft and install rocker shaft assembly and tighten screws to 28 Nm (250 in. lbs.). (15) Install cylinder head covers tighten screws to 14 Nm (120 in. lbs.) and electrical connector to ignition coils. (16) Install Intake Manifold. Refer to Group 11, Exhaust System and Intake Manifold for procedure. (17) Connect negative cable to battery.
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REAR CYLINDER HEAD COVER (1) Disconnect negative cable from battery. (2) Remove Wiper Unit. Refer to Group 8K, Windshield Wipers and Washers for procedure. (3) Remove intake manifold upper plenum. Refer to Group 11, Exhaust System and Intake Manifold for procedure. (4) Disconnect PCV hose from cylinder head cover. (5) Remove rear cylinder head cover bolts (6) Remove cylinder head cover and gasket.
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INSTALLATION (1) Clean all sealing surfaces of cylinder block and cylinder heads. (2) Install new gaskets on cylinder block (Fig. 34).
CYLINDER HEAD
REMOVAL (1) Drain cooling system. Refer to Group 7, Cooling System for procedure and disconnect negative cable from battery. (2) Remove upper and lower intake manifolds. Refer to Group 11, Exhaust System and Intake Manifold.
WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE. (3) Disconnect coil wires, sending unit wire, heater hoses and bypass hose. (4) Remove PCV system hoses, evaporation control system hose and cylinder head covers. (5) Remove exhaust manifolds. (6) Remove rocker arm and shaft assemblies. Remove push rods and mark positions to ensure installation in original locations. (7) Remove the 9 head bolts from each cylinder head and remove cylinder heads (Fig. 33).
NOTE: Bolt torque after 1/4 turn should be over 122 Nm (90 ft. lbs.). If not, replace the bolt. (6) Tighten head bolt number 9 (Fig. 33) to 33 Nm (25 ft. lbs.) after head bolts 1 8 have been tighten to specifications.
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REMOVAL AND INSTALLATION (Continued)
(7) Inspect push rods and replace worn or bent rods. (8) Install push rods, rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 in. lbs.) (Fig. 36). (9) Place new cylinder head cover gaskets in position and install cylinder head covers. Tighten to 12 Nm (105 in. lbs.).
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(4) Install intake manifold and (8) bolts and torque to 1 Nm (10 in. lbs.). Then tighten bolts to 22 Nm (200 in. lbs.) in sequence shown in (Fig. 39). Then tighten again to 22 Nm (200 in. lbs.). After intake manifold is in place, inspect to make sure seals are in place. Refer to Group 11, Exhaust System and Intake Manifold to complete intake manifold installation. (5) Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lbs.) and nuts to 20 Nm (15 ft. lbs.). (6) Adjust spark plugs to specification in Group 8, Electrical Section and install the plugs.
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Fig. 40 Compress Valve Springs with Special Tool C-3422-B with Adapter 6412
VALVE INSTALLATION (1) Coat valve stems with clean engine oil and insert them in cylinder head. (2) Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to give 49.541 to 51.271 mm (1.950 to 2.018 in.) over spring seat when installed in the head (Fig. 41). Check valve tip for scoring, if necessary, the tip chamfer should be reground to prevent seal damage when the valve is installed. (3) Install valve spring seat spacer on head (Fig. 42). (4) Install new cup seals on all valve stems and over valve guides (Fig. 41). Install valve springs and valve retainers (Fig. 42).
TAPPET REMOVAL
(1) Refer to Cylinder Head Removal in this section. Cylinder Head must be removed to gain access to tappets for service. (2) Remove yoke retainer and aligning yokes. (3) Use Tool C-4129 to remove tappets from their bores. If all tappets are to be removed, identify tappets to insure installation in original location. NOTE: If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize and replace with oversize tappet. CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. Do not disassemble a tappet on a dirty work bench.
INSTALLATION (1) Lubricate tappets. (2) Install tappets in their original positions. (3) With roller tappets, install aligning yokes (Fig. 43). (4) Install yoke retainer and torque screws to 12 Nm (105 in. lbs.) (Fig. 43). (5) Install cylinder heads. Refer to cylinder head installation of this section for procedure.
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REMOVAL AND INSTALLATION (Continued)
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TIMING CHAIN
Fig. 47 Timing Chain Case Cover Gaskets and O-Rings
REMOVAL (1) Disconnect negative cable from battery. (2) Remove timing chain cover. Refer to procedure outlined in this section. (3) Remove camshaft sprocket attaching bolt, and timing chain with camshaft sprocket. (4) Using a suitable puller remove the crankshaft sprocket. Be careful not to damage the crankshaft surface. INSTALLATION (1) Position a new crankshaft sprocket on the shaft, install sprocket with suitable tool and mallet. Be sure sprocket is seated into position. (2) Rotate crankshaft so the timing arrow is to the 12 oclock position. (3) Place timing chain around camshaft sprocket and place the timing mark to the 6 oclock position. (4) Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up
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REMOVAL AND INSTALLATION (Continued)
with the dot on the sprocket and install camshaft sprocket into position. (5) Use a straight edge to check alignment of timing marks (Fig. 50). (6) Install camshaft bolt and washer. Tighten to 54 Nm (40 ft. lbs.). (7) Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up remove cam sprocket and realign. (8) Check camshaft end play. With new thrust plate the specification is 0.0127 to 0.304 mm (0.005 to 0.012 in.). Old thrust plate specification is 0.31 mm (0.012 in.) maximum. If not within these limits install new thrust plate.
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CAMSHAFT
REMOVALENGINE REMOVED FROM VEHICLE Remove intake manifold, cylinder head covers, cylinder heads, timing chain case cover and timing chain. (1) Remove rocker arm and shaft assemblies. (2) Remove push rods and tappets; identify so each part will be replaced in its original location. (3) Remove camshaft thrust plate (Fig. 51). (4) Install a long bolt into front of camshaft to facilitate removal of the camshaft; remove camshaft, being careful not to damage cam bearings with the cam lobes. INSTALLATION (1) Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2 inches of its final position in cylinder block.
(2) Install camshaft thrust plate with two screws as shown in (Fig. 51). Tighten to 12 Nm (105 in. lbs.) torque. (3) Rotate crankshaft so the timing arrow is at the 12 oclock position. (4) Place timing chain around camshaft sprocket and place the timing mark to the 6 oclock position. (5) Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up with the dot on the sprocket and install camshaft sprocket into position. (6) Using straight edge to check alignment of timing marks (Fig. 52). (7) Install the camshaft bolt. Tighten bolt to 54 Nm (40 ft. lbs.). (8) Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up, remove cam sprocket and realign. (9) Measure camshaft end play. End Play should measure 0.0127 to 0.304 mm (0.005 to 0.012 inches.)
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CAMSHAFT BEARINGS
REMOVAL (1) With engine removed from vehicle and completely disassembled, drive out rear cam bearing core hole plug. (2) Install proper size adapters and horseshoe washers (part of Tool C-3132-A) at back of each bearing shell to be removed and drive out bearing shells (Fig. 53).
INSTALLATION (1) Clean surfaces and apply a 1/8 inch bead of Mopar Silicone Rubber Adhesive Sealant or equivalent, at the parting line of the chain case cover and the rear seal retainer (Fig. 54). (2) Use a new pan gasket (Fig. 55). (3) Install pan and tighten screws to 12 Nm (105 in. lb.).
OIL PAN
REMOVAL (1) Disconnect negative cable from battery and remove engine oil dipstick. (2) Raise vehicle on hoist and drain engine oil.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLING PISTON AND CONNECTING ROD ASSEMBLY (1) Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 58). (2) Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 58). (3) Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor. Be sure position of rings does not change during this operation. (4) Install connecting rod bolt protectors on rod bolts (Fig. 57).
Fig. 59 PistonInstallation
(5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
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CRANKSHAFT
MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to insure correct assembly (Fig. 62). Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 3 and 4 are interchangeable. Upper main bearing halves of 1, 3 and 4 are interchangeable. CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for excessive wear, taper and scoring. (Fig. 61) Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 in.). Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter. Do NOT grind thrust faces of Number 2 main bearing. Do NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth pol-
REMOVAL (1) Remove oil pan and identify bearing caps before removal. (2) Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059. (Fig. 64) into the oil hole of crankshaft.
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(5) Rotate the crankshaft until number 6 piston is at TDC. (6) To ensure correct thrust bearing alignment the following procedure must be done: a. Move crankshaft all the way to the rear of its travel. b. Then, move crankshaft all the way to the front of its travel. c. Wedge a appropriate tool between the rear of the cylinder block and rear crankshaft counterweight. This will hold the crankshaft in its most forward position. d. Tighten the #2 Thrust Bearing cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the holding tool. (7) Install oil pan. (8) Fill engine crankcase with proper oil to correct level.
Fig. 64 Removing and Installing Upper Main Bearing With Special Tool C-3059
INSTALLATION
NOTE: Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. (1) Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft (Fig. 64). (2) Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059. (3) Install each main cap and tighten bolts finger tight. (4) Tighten number 1, 3 and 4 main cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).
INSTALLATION (1) Install new seal by using Tool C-4992 (Fig. 67). (2) Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. (3) Install crankshaft pulley using plate L-4524. Thrust Bearing/washer and 5.9 inch screw (Fig. 68).
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CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. (1) Place Special Tool 6926-1 magnetic pilot tool on crankshaft (Fig. 70). (2) Lightly coat seal O.D. with Mopar Stud N Bearing Mount Adhesive or equivalent. (3) Place seal over Special Tool 6926-1 Pilot. Using Special Tool 6926-2 Installer with C-4171 Handle, drive seal into the retainer housing (Fig. 70).
REAR CRANKSHAFT SEAL RETAINER When retainer removal is required, remove retainer and clean engine block and retainer of old gasket. Make sure surfaces are clean and free of oil.
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REMOVAL AND INSTALLATION (Continued)
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OIL FILTER
CAUTION: When servicing the oil filter (Fig. 71) avoid deforming the filter can by installing the remove/install tool band strap against the can-tobase lock seam. The lock seam joining the can to the base is reinforced by the base plate. (1) Using Tool C-4065, turn filter counterclockwise to remove from base. Properly discard filter. (2) Wipe base clean, then inspect gasket contact surface. (3) Lubricate gasket of new filter with clean engine oil. (4) Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft. lbs.). Use filter wrench if necessary. (5) Start engine and check for leaks.
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OIL PUMP ASSEMBLY (1) Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover. (2) Tighten cover screws to 12 Nm (105 in. lbs.). (3) Prime oil pump before installation by filling rotor cavity with engine oil. (4) Install chain case cover. Refer to Timing Chain Cover Installation of this section.
HYDRAULIC TAPPETS
DISASSEMBLY (1) Pry out plunger retainer spring clip (Fig. 74). (2) Clean varnish deposits from inside of tappet body above plunger cap. (3) Invert tappet body and remove plunger cap, plunger, flat or ball check valve, check valve spring, check valve retainer and plunger spring. Check valve could be flat or ball. ASSEMBLY (1) Clean all tappet parts in a solvent that will remove all varnish and carbon. (2) Replace tappets that are unfit for further service with new assemblies.
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CLEANING AND INSPECTION (Continued)
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OIL PAN
(1) Clean oil pan in solvent and wipe dry with a clean cloth. Clean all gasket material from mounting surfaces of pan and block. (2) Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary. Install a new drain plug gasket. Tighten to 27 Nm (20 ft. lbs.). (3) Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. (4) Clean oil screen and pipe in clean solvent. Inspect condition of screen.
OIL PUMP
INSPECTION AND REPAIR (1) Clean all parts thoroughly. Mating surface of the chain case cover should be smooth. Replace pump cover if scratched or grooved. (2) Lay a straightedge across the pump cover surface (Fig. 77). If a 0.025 mm (0.001 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced. (3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 7.64 mm (0.301 in.) or less (Fig. 78), or if the diameter is 79.95 mm (3.148 inches.) or less, replace outer rotor. (4) If inner rotor measures 7.64 mm (0.301 in.) or less replace inner rotor (Fig. 79).
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CLEANING AND INSPECTION (Continued)
CYLINDER BORE AND PISTON SPECIFICATION CHART
Standard Bore 92.993 93.007 mm (3.661 3.6617 in.) 95.993 96.007 mm 3.7792 3.780 in. Maximum Out-OfRound 0.076 mm (0.003 in.) Same Maximum Taper 0.51 mm (0.002 in.) Same
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Engine 3.3L
3.8L
Standard Piston Size 3.3L 92.950 - 92.968 mm (3.6594 - 3.6602 in.) 3.8L 95.950 - 95.968 mm (3.7776 - 3.7783 in.) Piston to Bore Clearance: 0.025 - 0.057 mm (0.0009 - 0.0022 in.) Measurements taken at Piston Size Location.
Type. . . . . . . . . . . . . . . . . . . . . . . . .60 V-6 Engine Bore3.3L . . . . . . . . . . . . . . . . . .93.0 mm (3.66 in.) Bore3.8L . . . . . . . . . . . . . . . . .96.0 mm (3.779 in.) Stroke3.3L . . . . . . . . . . . . . . .81.0 mm (3.188 in.) Stroke3.8L . . . . . . . . . . . . . . .87.0 mm (3.425 in.) Compression Ratio3.3L . . . . . . . . . . . . . . . . .8.9:1 Compression Ratio3.8L . . . . . . . . . . . . . . . . .9.6:1 Displacement3.3L. . . . . . . . . .3.3L (201 Cubic in.) Displacement3.8L. . . . . . . . . .3.8L (231 Cubic in.) Brake Horsepower3.3L . . . . . . . .158 @ 4850 RPM Brake Horsepower3.8L . . . . . . . .180 @ 4400 RPM Torque3.3L . . . . . . . . . . . .203 lb. ft. @ 3600 RPM Torque3.8L . . . . . . . . . . . .240 lb. ft. @ 3600 RPM Firing Order . . . . . . . . . . . . . . . . . . . .123456 Compression Pressure.Refer to Engine Performance in Standard Service Procedures. Cylinder Number (Front to Rear) Front Bank . . . . . . . . . . . . . . . . . . . . . . . . . . .2,4,6 Rear Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,3,6 Cylinder Block Cylinder Bore (Standard)3.3L . . . . . . . . .93.0 mm (3.66 in.) Cylinder Bore (Standard)3.8L . . . . . . . . .96.0 mm (3.779 in.) Out-of-Round (Max.) . . . . . . . .0.076 mm (0.003 in.) Taper (Max.) . . . . . . . . . . . . . .0.051 mm (0.002 in.) Cylinder Bore Oversize (Max.). . . . . . . . .0.508 mm (0.020 in.) Tappet Bore Diameter . . . . .22.9896 - 23.0099 mm (0.9051 - 0.9059 in.) Pistons Type Material . . . . . . .Aluminum Alloy Tin Coated Clearance at Size Location. . . . . .0.025 - 0.057 mm (0.001 - 0.0022 in.) Weight (Standard Only)3.3L . . . . . .381 5 grams (13.4394 0.1764 oz.) Weight (Standard Only)3.8L . . . . . .438 5 grams (15.4501 0.1764 oz.) Pistons for Service . . . . . . . . . . . . . .Standard Only Piston Pins Type . . . . . . . . . . . . . . . . . . . . . . .Press Fit in Rod (Serviced as an Assembly) Diameter . . . . . . . . . . . . . . . . . . . . . . . . .22.88 mm (0.9009 - 0.9007 in.) Length3.3L . . . . . . . . . . . . . . . .67.25 - 67.75 mm (2.648 - 2.667 in.) Lenth3.8L . . . . . . . . . . . . . . . . .71.25 - 71.75 mm (2.805 - 2.824 in.) Clearance in Piston @ 70 . . . . . .0.006 - 0.019 mm (0.0002 - 0.0007 in.) Clearance in Rod . . . . . . . . . . . . . . . .(Interference)
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SPECIFICATIONS (Continued)
Piston Rings Number of Rings . . . . . . . . . . . . . . . . . . . . . . . . . .3 Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Oil Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Oil Ring Type . . .3Piece, Steel Rail, Chrome Face Piston Ring Gap Top & 2nd Compression ing. . . . . . .0.30 - 0.55 mm (0.0118 - 0.0217 in.) Oil Control (Steel Rails) . . . . . . . . .0.25 - 1.00 mm (0.0098 - 0.0394 in.) Service Rings Ring GapCompression . . . . . . . .0.300 - 0.550 mm (0.0118 - 0.0217 in.) Ring GapOil Control . . . . . . . . . .0.250 - 1.00 mm (0.0098 - 0.0394 in.) Piston Ring Side Clearance Top & 2nd Compression Rings . . .0.030 - 0.095 mm (0.0012 - 0.0037 in.) Oil Ring (Steel Rails) . . . . . . . . . .0.014 - 0.226 mm (0.0005 - 0.0089 in.) Piston Ring Width Compression Rings . . . . . . . . . . . . .1.46 - 1.50 mm (0.0575 - 0.0591 in.) Oil Ring (Steel Rails). . . . . . . . . . . . . . . .0.510 mm (0.0201 in.) Connecting Rods Bearing Type . . . . . . . . .Aluminum Lead (Bimetal) Bearing Clearance . . . . . . . . . . . .0.019 - 0.065 mm (0.00075 - 0.0026 in.) Max. Allowable . . . . . . . . . .0.076 mm (0.003 in.) Side Clearance . . . . . . . . . . . . . .0.127 - 0.381 mm (0.005 - 0.015 in.) Crankshaft Type . . . . . . . . . . . . . . . . . . . . . .Cast Nodular Iron Bearing Type . . . . . . . . .Aluminum Lead (Bimetal) Thrust Location. . . . . . . . . . . . . . . . .No. 2 Bearing Connecting Rod Journal Diameter . . . . . . . . . .53.950 - 53.975 mm (2.124 - 2.125 in.) Main Bearing Diametrical Clearance No. 1- 4. . . . . . . . . . . .0.011 - 0.059 mm (0.0043 - 0.0023 in.) Max. Allowable . . . . . . . . . .0.102 mm (0.004 in.) End Play . . . . .0.09 - 0.24 mm (0.0036 - 0.0095 in.) Max. Allowable . . . . . . . . . .0.381 mm (0.015 in.) Main Bearing Journals Diameter . . . . . . . . . . . . . . . . .64.013 - 63.993 mm (2.5202 - 2.5195 in.) Out-of-Round (Max.) . . . . . . . .0.025 mm (0.001 in.) Taper (Max.) . . . . . . . . . . . . . .0.025 mm (0.001 in.) Connecting Rod Journals Diameter . . . . . . . . . . . . . . . . .58.005 - 57.979 mm (2.2837 - 2.2827 in.) Out-of-Round (Max.) . . . . . . . .0.025 mm (0.001 in.) Taper (Max.) . . . . . . . . . . . . . .0.025 mm (0.001 in.) Camshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain Bearings. . . . . . . . . . . . . . . . .Steel Backed Babbitt Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Diametrical Clearance . . . . . . . . .0.025 - 0.101 mm (0.001 - 0.004 in.) Max. Allowable . . . . . . . . . .0.127 mm (0.005 in.) Thrust Taken By . . . . . . . . . . . . . . . . .Thrust Plate End Play . . . . . . . . . . . . . . . . . . .0.127 - 0.304 mm (0.005 - 0.012 in.) Max. Allowable . . . . . . . . . .0.304 mm (0.012 in.) Camshaft Journals Bearing Journal Diameter No. 1 . . . . . . . . . . . .50.724 - 50.775 mm (1.997 - 1.999 in.) Bearing Journal Diameter No. 2 . . . . . . . . . . . .50.317 - 50.368 mm (1.9809 - 1.9829 in.) Bearing Journal Diameter No. 3 . . . . . . . . . . . .49.936 - 49.987 mm (1.9659 - 1.9679 in.) Bearing Journal Diameter No. 4 . . . . . . . . . . . .49.530 - 49.581 mm (1.9499 - 1.9520 in.) Camshaft Bearings Diameter No. 1. . . . . . . . . . . . .50.825 - 50.800 mm (2.0009 - 1.9999 in.) Diameter No. 2. . . . . . . . . . . . .50.419 - 50.393 mm (1.9849 - 1.9839 in.) Diameter No. 3. . . . . . . . . . . . .50.038 - 50.013 mm (1.9699 - 1.9690 in.) Diameter No. 4. . . . . . . . . . . . .49.632 - 49.606 mm (1.954 - 1.9529 in.) Oil Clearance . . . . . . . . . . . . . .0.0254 - 0.0762 mm (0.001 - 0.003 in.) Valve Timing Exhaust Valve Closes (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Opens (BBC) . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 Valve Timing Intake Valve Closes (BTDC) . . . . . . . . . . . . . . . . . . . . . . . . . .58 Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 Valve Overlap . . . . . . . . . . . . . . . . . . . . . . . . . .14 Timing Chain Number of Links . . . . . . . . . . . . . . . . . . . . . . . . .64 Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.375 inch Width . . . . . . . . . . . . . . . . . . . . . . . . . . .0.750 inch Hydraulic Tappets Type . . . . . . . . . . . . . . . . . . . . . . .Roller Hydraulic Body Diameter. . . . . . . . . . . . . . .22.95 - 22.96 mm (0.9035 - 0.9040 in.) Clearance in Block. . . . . . . . . . . . . .0.02 - 0.06 mm (0.0007 - 0.0024 in.)
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SPECIFICATIONS (Continued)
Service Tappets Available . . . . . . . .Std., 0.025 mm (0.001), 0.20 mm (0.008 in.), 0.762 mm (0.030 in.) Cylinder Head Gasket Thickness (Compressed) . . . . . . . .1.78 mm (0.070 in.) Cylinder Head Valve Seat AngleIntake and Exhaust . . . . . . . . . . .45 - 45.5 Runout (Max) . . . . . . . . . . . .0.0762 mm (0.003 in.) Width (Finish)Intake . . . . . . . . . . .1.75 - 2.25 mm (0.069 - 0.088 in.) Width (Finish)Exhaust . . . . . . . . .1.50 - 2.00 mm (0.057 - 0.078 in.) Valve Guides Type. . . . . . . . . . . . . . . . . .Powdered Metal Inserts Guide Bore Diameter. . . . . . . . . . .7.975 - 8.00 mm (0.314 - 0.315 in.) ValvesIntake Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . .44.5 Head Diameter . . . . . . . . . . . . . .45.5 mm (1.79 in.) Length (Overall) . . . . . . . . . .127.005 - 128.036 mm (5.000 - 5.041 in.) Minimum Valve Length After Tip Grinding . . . . . . . . . . . . . . . . . . .124.892 (4.916 in.) Lift (Zero Lash) . . . . . . . . . . .10.16 mm (0.400 in.) Stem Diameter (Standard). . . . . .7.935 - 7.953 mm (0.312 - 0.313 in.) Valve Tip Height (From Cylinder Head Surface) . . . . . .49.541 - 51.271 mm (1.950 - 2.018 in.) Stem-to-Guide Clearance . . . . . . .0.025 - 0.095 mm (0.001 - 0.003 in.) Max. Allowable (Rocking Method) . . . .0.247 mm (0.010 in.) Valves for Service (Oversize Stem Diameters) . . . . . . .Std., 0.015 mm (0.005 in.), 0.40 mm (0.015 in.), 0.80 mm (0.030 in.) ValvesExhaust Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Head Diameter . . . . . . . . . . . . .37.5 mm (1.476 in.) Length Overall . . . . . . . . . . . . . .127.825 - 128.465 (5.032 - 5.058 in.) Minimum Valve Length After Tip Grinding . . . . . . .125.512 mm (4.941 in.) Lift (Zero Lash) . . . . . . . . . . . .10.16 mm (0.40 in.) Valve Tip Height (From Cylinder Head Surface) . . . . . .49.541 - 51.271 mm (1.950 - 2.018 in.) Stem Diameter (Standar). . . . . . .7.906 - 7.924 mm (0.3112 - 0.3119 in.) Stem to Guide Clearance . . . . . . .0.051 - 0.175 mm (0.002 - 0.006 in.)
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Max. Allowable (Rocking Method) . . . . . .0.414 mm (0.016 in.) Valves for Service (Oversize Stem Diameters) . . . . . .Std., 0.015 mm (0.005 in.), 0.40 mm (0.015 in.), 0.80 mm (0.030 in.) Valve Springs Free Length (Approx.) . . . . . . .48.5 mm (1.909 in.) Wire Diameter . . . . . . . . . . . . .4.75 mm (0.187 in.) Number of Coils . . . . . . . . . . . . . . . . . . . . . . . . .6.8 Spring Tension (Valve Closed) . . . . . . .95 - 100 lbs. @ 1.57 in. Spring Tension (Valve Open) . . . . . . .207 - 229 lbs. @ 1.169 in. Installed Height (Spring Seat to Bottom of Retainer) . . . . . . 41.2 - 42.7 mm (1.622 - 1.681 in.) Oil Pump Pump Type . . . . . . . . . . . . . . .Rotary Full Pressure Clearance Over Rotors (Inner & Outer Max.). . . . . . . .0.10 mm (0.004 in.) Cover Out-of-Flat (Max.). . . . .0.025 mm (0.001 in.) Inner Rotor Thickness (Min.) . .7.64 mm (0.301 in.) Outer Rotor Thickness (Min.) . .7.64 mm (0.301 in.) Outer Rotor Diameter (Min.) .79.95 mm (3.148 in.) Outer Rotor Clearance . . . . . . .0.39 mm (0.015 in.) Tip Clearance Between Rotors (Max.) . . . .0.20 mm (0.008 in.) Oil Pressure Minimum Pressure at Idle (Engine Fully Warmed Up) *. . . . . . . . . . .34.47 kPa (5 psi) At 3000 rpm . . . . . . . . .205 - 551 kPa (30 - 80 psi) Oil Filter Bypass Valve Setting . . . . . .62 - 103 kPa (9 - 15 psi) Oil Filter Type . . . . . . . . . . . . . . . . . . . . .Full Flow Oil Pressure Switch Actuating Pressure (Min.). . . . . . . . . . .14 - 28 kPa (2 - 4 psi) CAUTION: * If pressure is ZERO at curb Idle, DO NOT run engine at 3,000 rpm.
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SPECIFICATIONS (Continued)
TORQUE CHART
DESCRIPTION TORQUE A/C Compressor Mounting Compressor Bracket to Water Pump Bolt . .41 Nm (30 ft. lbs.) Compressor to Bracket Bolt. . . .68 Nm (50 ft. lbs.) Compressor Support Bolt . . . . .41 Nm (30 ft. lbs.) Camshaft Sprocket Bolt . . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. lbs.) Camshaft Thrust Plate Bolt . . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Connecting Rod Nut . . . . . . . . . . . . . . .54 Nm (40 ft. lbs.) +14 Turn Crankshaft Damper Pulley to Crankshaft Bolt . . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. lbs.) Cylinder Head Bolts . . . . . . .Refer to Cylinder Head Removal and Installation Procedure in this Section Cylinder Head Cover Bolts . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Exhaust Manifold Bolts . . . . . . . . . . . . . . . . . . . .23 Nm (200 in. lbs.) Exhaust Crossover Pipe Flange Fasteners. . . . . . . . . . . . . . . . . .33 Nm (25 ft. lbs.) Generator Mounting Adjusting Strap Bolt . . . . . . . .23 Nm (200 in. lbs.) Adjusting Strap Mounting Bolt . . . . . . . . . .41 Nm (30 ft. lbs.) Bracket Bolt . . . . . . . . . . . . . . .41 Nm (30 ft. lbs.) Pivot Nut. . . . . . . . . . . . . . . . . .41 Nm (30 ft. lbs.) Intake Manifold Bolts . . . . . . . . . . . . . . . . . . . .23 Nm (200 in. lbs.) Intake Manifold Gasket Retaining Screws . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Intake Manifold Plenum Bolts . . . . . . . . . . . . . . . . . . . .28 Nm (250 in. lbs.) Main Bearing Cap Bolts . . . . . . . . . . . . . .41 Nm (30 ft. lbs.) +14 Turn Oil Filter Attaching Nipple . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. lbs.)
DESCRIPTION TORQUE Oil Pan Bolts . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Drain Plug. . . . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Level Sensor Plug . . . . . . . . . . .41 Nm (30 ft. lbs.) Oil Pressure Gauge Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . . .7 Nm (60 in. lbs.) Oil Pump Cover Bolts . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Pick-up Tube Bolt . . . . . . . . . .28 Nm (250 in. lbs.) Rocker Shaft Bracket Bolts . . . . . . . . . . . . . . . . . . . .28 Nm (250 in. lbs.) Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Starter Mounting Bolt . . . . . . . . . . . . . . . . . . . . . .68 Nm (50 ft. lbs.) StrutIntake Manifold to Cylinder Head Bolt . . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. lbs.) Tappet Retainer Yoke Bolt . . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.) Temperature Gauge Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . . .7 Nm (60 in. lbs.) Timing Chain Case Cover BoltM8 1.25 . . . . . . . . . . . . .27 Nm (20 ft. lbs.) BoltM10 1.5 . . . . . . . . . . . . .54 Nm (40 ft. lbs.) Water Pump to Chain Case Cover Bolts . . . . . . . . . . . . . . . . . . . .12 Nm (105 in. lbs.)
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3.3/3.8L ENGINE
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Adaptor 6912
Dolly 6135
Puller 1023
Cradle 6710
Adaptor 6909
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3.3/3.8L ENGINE
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Adaptor Valve Compressor 6412 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2
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ENGINE
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ENGINE
CONTENTS
page page
2.5L VM DIESEL
. . . . . . . . . . . . . . . . . . . . . . . 40
3 1 2 2 3 6 4 5 6 4 12 7 20 21 6 10 18 24 24
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ENGINE
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GENERAL SPECIFICATION
Type . . . . . . . . . . . . . In-Line OHV, DOHC & SOHC Bore . . . . . . . . . . . . . . . . . . . . . 87.5mm (3.445 Inch) Stroke . . . . . . . . . . . . . . . . . . . 83.0mm (3.268 inch) Compression Ratio . . . . DOHC - 9.6:1 SOHC - 9.8:1 Displacement . . . . . . . . . 2.0 Liters (122 Cubic Inch) Firing Order . . . . . . . . . . . . . . . . . . . . . . . . 1, 3, 4, 2 Compression Pressure . . . . . . . . . . . 1172 - 1551 kPa (170 - 225 psi) Maximum Variation Between Cylinders . . . . . . 25% Lubrication . . . Pressure Feed - Full Flow Filtration (Crankshaft Driven Pump) Engine Oil Capacity . . Refer to Group 0, Lubrication and Maintenance
bearings with further routing. Rod bearing oil throwoff lubricates the pistons from directed slots on the side of the connecting rod assemblies. Camshaft and valve mechanisms are lubricated from a full-length cylinder head oil gallery supplied from the crankcase main oil gallery.
PRESSURE LUBRICATION Oil drawn up through the pickup tube is pressurized by the pump and routed through the full flow filter to the main oil gallery running the length of the cylinder block. A cylinder head restrictor, located in the block, provides increased oil flow to the main oil gallery (Fig. 2). MAIN/ROD BEARINGS A diagonal hole in each bulkhead feeds oil to each main bearing. Drilled passages within the crankshaft route oil from main bearing journals to connecting rod journals. CAMSHAFT/HYDRAULIC LASH ADJUSTERS A vertical hole at the number five bulkhead routes pressurized oil through a restrictor up into the cylinder head. The rocker shafts route oil to the rocker arms/hydraulic lash adjuster assemblies.
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DESCRIPTION AND OPERATION (Continued)
ENGINE
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ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEMBLY: A partial open deck is used for cooling and weight reduction with water pump molded into the block. Nominal wall thickness is 4 mm. The bedplate incorporates main bearing caps. Rear seal retainer is integral with the block. CRANKSHAFT: A nodular cast iron crankshaft is used. The engine has 5 main bearings, with number 3 flanged to control thrust. The 52 mm diameter main and 48 mm diameter crank pin journals (all) have undercut fillet radiuses that are deep rolled for added strength. To optimize bearing loading 8 counterweights are used. Hydrodynamic seals provide end sealing, where the crankshaft exits the block. Anaerobic gasket material is used for parting line sealing. A sintered iron timing belt sprocket is mounted on the crankshaft nose. This sprocket transmits crankshaft movement, via timing belt to the camshaft sprocket providing timed valve actuation. PISTONS: The SOHC Engine DOES NOT have provision for a free wheeling valve train. Non free wheeling valve train means, in the event of a broken timing belt Pistons will contact the Valves. All engines use pressed-in piston pins to attach forged powdered metal connecting rods. The connecting rods are a cracked cap design and are not repairable. Hex
head cap screw are used to provide alignment and durability in the assembly. Pistons And Connecting rods are serviced as an assembly. PISTON RINGS: The piston rings include a molybdenum faced top ring for reliable compression sealing and a taper faced intermediate ring for additional cylinder pressure control. Oil Control Ring Package consist of 2 steel rails and a expander spacer. CYLINDER HEADSOHC: It features a Single Over Head Camshaft, four-valves per cylinder cross flow design. The valves are arranged in two inline banks, with the two intake per cylinder facing toward the radiator. The exhaust valves facing toward the dash panel. Rocker arm shafts mount directly to the cylinder head. It incorporates powder metal valve guides and seats. The hollow rocker arm shafts supplies oil to the hydraulic lash adjusters, camshaft and valve mechanisms. CAMSHAFTSOHC: The nodular iron camshaft has five bearing journals and 3 cam lobes per cylinder. Provision for cam position sensor on the cam at the rear of cylinder head which also acts as thrust plate. A hydrodynamic oil seal is used for oil control at the front of the camshaft. VALVESSOHC: Four valves per cylinder are actuated by roller rocker arms/hydraulic lash adjusters assemblies which pivot on rocker arm shafts. All valves have 6 mm diameter chrome plated valve stems. The valve train has 33 mm (1.299 inch) diameter intake valves and 28 mm (1.10 inch) diameter exhaust valves. Viton rubber valve stem seals are integral with spring seats. Valve springs, spring retainers, and locks are conventional design. INTAKE MANIFOLD: The intake manifold is a molded plastic composition, attached to the cylinder head with ten fasteners. This long branch design enhances low and mid-range torque. EXHAUST MANIFOLD: The exhaust manifold is made of nodular cast iron for strength and high temperatures. Exhaust gasses exit through a machined, articulated joint connection to the exhaust pipe.
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ENGINE
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Standard Piston Size 87.463 - 87.481 mm (3.4434 - 3.4441 in.) 87.456 - 87.474 mm (3.4432 - 3.4439 in.)
Piston to Bore Clearance Federal 0.012 - 0.044 mm Emission: (0.0004 - 0.0017 in.) Low Emission 0.18 - 0.050 mm Vehicle (LEV): (0.0008 - 0.0020 in.) Measurements Taken at Piston Size Location tom of the skirt as shown in (Fig. 4). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in (Fig. 3). Refer to Cylinder Bore and Specifications Table. Correct piston to bore clearance must be established in order to assure quiet and economical operation.
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SERVICE PROCEDURES (Continued)
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ENGINE
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FEELER GAGE METHOD (1) Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek, using care not to damage any bearing surface. Do not loosen main bearing cap. (2) Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play.
48.000
0.008 mm (1.8897
0.0003 in.)
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REMOVAL AND INSTALLATION (Continued)
ENGINE
9-7
of the spark plug tubes. If these seals show signs of hardness and/or cracking they should be replaced.
CAMSHAFT
NOTE: TO REMOVE CAMSHAFT THE CYLINDER HEAD MUST BE REMOVED.
REMOVAL (1) Perform fuel system pressure release procedure before attempting any repairs. Refer to Group 14, Fuel System (2) Remove the cylinder head cover. Refer to procedure outlined in this section. (3) Mark rocker arm shaft assemblies so that they are installed in their original positions. (4) Remove rocker arm shaft bolts. Refer to procedure outlined in this section. (5) Remove timing belt, timing belt tensioner, and camshaft sprocket. Refer to timing belt service outlined in this section. (6) Remove inner timing belt cover. (7) Remove cylinder head. Refer to procedure outlined in this section. (8) Remove camshaft sensor and camshaft target magnet. (9) Remove camshaft from the rear of cylinder head.
SPARK PLUG TUBE SEALS The spark plug tube seals are located in the cylinder head cover (Fig. 12). These seals are pressed into the cylinder head cover to seal the outside perimeter
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ENGINE
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INSTALLATION (1) Lubricate the camshaft journals with oil and install camshaft without rocker arm assemblies installed. (2) Install camshaft target magnet into the end of the camshaft. Tighten mounting screw to 3.4 Nm (30 in. lbs.). (3) Install camshaft position sensor and tighten mounting screws to 9 Nm (80 in. lbs.). (4) Measure camshaft end play using the following procedure: Mount dial indicator C-3339 or equivalent, to a stationary point on cylinder head (Fig. 13). Using a suitable tool, move camshaft to rearward limits of travel. Zero the dial indicator. Move camshaft forward to limits of travel and read dial indicator. End play travel: 0.13 - 0.33 mm (0.005 - 0.013 in.).
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REMOVAL AND INSTALLATION (Continued)
ENGINE
9-9
partially full of oil. This is indicated by little or no plunger travel when the lash adjuster is depressed. If there is excessive plunger travel. Place the rocker arm assembly into clean engine oil and pump the plunger until the lash adjuster travel is taken up. If travel is not reduced, replace the assembly. Hydraulic lash adjuster and rocker arm are serviced as an assembly. (2) Install rocker arm and shaft assemblies with NOTCH in the rocker arm shafts pointing up and toward the timing belt side of the engine (Fig. 17). Install the retainers in their original positions on the exhaust and intake shafts (Fig. 15). CAUTION: When installing the intake rocker arm shaft assembly be sure that the plastic spacers do not interfere with the spark plug tubes. If the spacers do interfere rotate until they are at the proper angle. To avoid damaging the spark plug tubes, do not attempt rotating the spacers by forcing down the shaft assembly. (3) Tighten bolts to 28 Nm (250 in. lbs.) in sequence shown in (Fig. 18).
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ENGINE
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CYLINDER HEAD
REMOVAL (1) Perform fuel system pressure release procedure before attempting any repairs. Refer to Group 14, Fuel System (2) Disconnect negative battery cable. Drain cooling system. Refer to Group 7, Cooling System. (3) Disconnect all vacuum lines, electrical wiring and fuel lines from throttle body. (4) Remove throttle linkage. (5) Remove accessory drive belts. Refer to Group 7, Cooling System for procedure. (6) Remove power brake vacuum hose from intake manifold. (7) Raise vehicle and remove exhaust pipe from manifold. (8) Remove power steering pump assembly and set aside. (9) Disconnect coil pack wiring connector and remove coil pack and bracket from engine. (10) Remove cylinder head cover. (11) Remove cam sensor and fuel injectors wiring connectors. (12) Remove intake manifold. Removal procedure outline in Group 11.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Before installing the bolts the threads should be oiled with engine oil. The 4 short bolts 110 mm (4.330 in.) are to be installed in positions 7, 8, 9, and 10 (Fig. 23). (2) Tighten the cylinder head bolts in the sequence shown in (Fig. 23). Using the 4 step torque method, tighten according to the following values: First All to 34 Nm (25 ft. lbs.) Second All to 68 Nm (50 ft. lbs.) Third All to 68 Nm (50 ft. lbs.) Fourth Turn an additional 1/4 Turn, Do not use a torque wrench for this step. For the rest of installation, reverse removal procedure.
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ENGINE
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(4) Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Install camshaft seal flush with cylinder head using Special Tool MD 998306 (Fig. 27).
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Remove the access plug from the outer timing belt cover (Fig. 28). Check the timing mark on the camshaft sprocket, it should align with the arrow on the rear belt cover (Fig. 29).
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ENGINE
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(3) When plunger is compressed into the tensioner body install a 1.9 mm (5/64) allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed. (4) Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC (Fig. 35).
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
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OIL PAN
REMOVAL (1) Drain engine oil. (2) Remove transmission inspection cover. (3) If equipped with air conditioning remove oil filter and adaptor. Refer to Oil Filter Adapter Removal and Installation in this section. (4) Remove oil pan.
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ENGINE
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Install new seal by using Tool 67801 (Fig. 56).
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ENGINE
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INSTALLATION
CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal.
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REMOVAL AND INSTALLATION (Continued)
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CRANKSHAFT
REMOVAL (1) Remove oil filter and adapter from bedplate.
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ENGINE
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CRANKSHAFT MAIN BEARINGS LOCATION The crankshaft is supported in five main bearings. All upper bearing shells in the crankcase have oil grooves. All lower bearing shells installed in the (bedplate) main bearing cap are plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal (Fig. 64).
NOTE: The upper and lower main Bearing shells are Not interchangeable. The lower shells have a revised tab to prevent improper installation.
CRANKSHAFT MAIN JOURNALS INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to .025 mm (.001 inch). Journal grinding should not exceed .305 mm (.012 inch) under the standard journal diameter. DO NOT grind thrust faces of Number 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 64). All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersized: 0.016 mm (.0006 inch), .032 mm (.0012 inch), .250 mm (.010 inch). Never install an undersize bearing that will reduce clearance below specifications.
INSTALLATION (1) Install the main bearing shells with the lubrication groove in the cylinder block. Install O-ring into recess in the block (Fig. 65). (2) Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots.
CAUTION: Do Not get oil on the bedplate mating surface. It will affect the sealer ability to seal the bedplate to cylinder block.
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REMOVAL AND INSTALLATION (Continued)
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ENGINE
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OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 69) avoid deforming the filter, install tool band strap against the seam at the base of the filter. The seam, joining the can to the base is reinforced by the base plate. (1) Turn counterclockwise to remove. (2) To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw
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REMOVAL AND INSTALLATION (Continued)
filter on until gasket contacts base. Tighten to 21 Nm (15 ft. lbs.).
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(2) Apply Mopar Gasket Maker to oil pump as shown in (Fig. 72). Install oring into oil pump body discharge passage. (3) Prime oil pump before installation. (4) Align oil pump rotor flats with flats on crankshaft as you install the oil pump to the block. NOTE: Front crankshaft seal MUST be out of pump to align, or damage may result. (5) Torque all oil pump attaching bolts to 28 Nm (250 in. lbs.) (6) Install new front crankshaft seal using Special Tool 6780 (Fig. 73). (7) Install crankshaft sprocket, using Special Tool 6792 (Fig. 74). (8) Install oil pump pick-up tube and oil pan. (9) Install Timing Belt. Refer to procedure outlined in this section. (10) Connect negative cable to battery.
OIL PUMP
REMOVAL (1) Disconnect negative cable from battery. (2) Remove Timing Belt. Refer to Timing Belt System, in this section. (3) Remove Oil Pan. Refer to Oil Pan Removal in this section. (4) Remove Crankshaft Sprocket using Special Tool 6793 and insert C-4685-C2 (Fig. 70).
INSTALLATION (1) Make sure all surfaces are clean and free of oil and dirt.
PISTON RINGREMOVAL (1) ID mark on face of upper and intermediate piston rings must point toward piston crown.
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ENGINE
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PISTON RINGSINSTALLATION (1) Install rings with manufacturers I.D. mark facing up, to the top of the piston (Fig. 78).
CAUTION: order: Install piston rings in the following
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REMOVAL AND INSTALLATION (Continued)
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VIBRATION DAMPER
NOTE: If a gap is found in the crankshaft damper, in the area where the Poly-V Generator belt rides this is normal and is acceptable (Fig. 82).
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Install crankshaft damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.) (Fig. 84). (2) Install accessory drive belts. Refer to Group 7, Cooling System Accessory Drive section for procedure.
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(4) Remove oil pump cover screws, and lift off cover. (5) Remove pump rotors. (6) Wash all parts in a suitable solvent and inspect carefully for damage or wear (Fig. 86).
TESTING VALVE SPRINGS (1) Whenever valves have been removed for inspection, reconditioning or replacement, valve springs
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ENGINE
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Valve Guide Clearance Intake Valve Exhaust Valve 0.023 - 0.066 mm 0.051 - 0.094 mm (0.001 - 0.0025 in.) (0.002 - 0.0037 in.) 0.25 mm (0.010 in.)
REFACING VALVES AND VALVE SEATS (1) The intake and exhaust valve seats and valve face have a 45 degree angle. (2) Inspect the remaining margin after the valves are refaced (Fig. 90). Intake valves with less than 0.95 mm (1/32 inch.) margin and Exhaust valves with less than 1.05 mm (3/64 inch) margin should be discarded.
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DISASSEMBLY AND ASSEMBLY (Continued)
VALVE SPECIFICATION CHART
Face Angle 45 - 45 1/2 Head Diameter 33.12 - 33.37 mm (1.303 - 1.313 in.) 28.57 - 28.83 mm (1.124 - 1.135 in.) Length (Overall) 114.69 - 115.19 mm (4.515 - 4.535 in.) 116.94 - 117.44 mm (4.603 - 4.623 in.) Stem Diameter 5.934 - 5.952 mm (0.2337 - 0.2344 in.) 5.906 - 5.924 mm (0.2326 - 0.2333 in.) Valve Margin 1.15 - 1.48 mm (0.0452 - 0.0582 in.) 1.475 - 1.805 mm (0.0580 - 0.0710 in.)
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Intake and Exhaust: Intake: Exhaust: Intake: Exhaust: Intake: Exhaust: Intake: Exhaust:
Total runout should not exceed. 0.051 mm (0.002 inch.) (total indicator reading). (5) Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of the valve face, lower valve seat with a 15 degrees stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone. Intake valve seat diameter is 33 mm (1.299 in.) Exhaust valve seat diameter is 28 mm (1.102 in.) (6) Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. The intake valve seat must be serviced when the valve seat width is 2.0 mm (0.079 in.) or greater. The exhaust valve seat must be serviced when the valve seat width is 2.5 mm (0.098 in.) or greater. Otherwise the cylinder head must be replaced. (7) When seat is properly positioned the width of intake and exhaust seats should be 0.75 to 1.25 mm (0.030 to 0.049 in.) (Fig. 91). (8) Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to 43.51 - 44.57 mm (1.71 - 1.75 in.) for exhaust valve and 45.01 - 46.07 mm (1.77 - 1.81 in.) for intake valve over spring seat when installed in the head (Fig. 92). The valve tip chamfer may need to be reground to prevent seal damage when the valve is installed.
Fig. 92 Spring Installed Height and Valve Tip to Spring Seat Dimensions
CLEANING Clean all valve guides, valves and valve spring assemblies thoroughly with suitable cleaning solution before reassembling. VALVE INSTALLATION (1) Coat valve stems with clean engine oil and insert in cylinder head. (2) Install new valve stem seals on all valves using a valve stem seal tool (Fig. 93). The valve stem seals should be pushed firmly and squarely over valve guide.
CAUTION: If oversize valves are used, there is only one oversize valve available. The same stem seal is used on both the standard and oversize valve. (3) Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor.
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ENGINE
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CLEANING Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface.
OIL PUMP
(1) Clean all parts thoroughly. Mating surface of the oil pump should be smooth. Replace pump cover if scratched or grooved. (2) Lay a straightedge across the pump cover surface (Fig. 95). If a 0.076 mm (0.003 inch.) feeler gauge can be inserted between cover and straight edge, cover should be replaced.
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CLEANING AND INSPECTION (Continued)
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Fig. 99 Measuring Clearance Between Rotors Fig. 97 Measuring Inner Rotor Thickness
(5) Slide outer rotor into pump housing, press to one side with fingers and measure clearance between rotor and housing (Fig. 98). If measurement is 0.39 mm (0.015 inch.) or more, replace housing only if outer rotor is in specification. (6) Install inner rotor into pump housing. If clearance between inner and outer rotors (Fig. 99) is .203 mm (.008 inch) or more, replace both rotors. (7) Place a straightedge across the face of the pump housing, between bolt holes. If a feeler gauge of .102 mm (.004 inch) or more can be inserted between rotors and the straightedge, replace pump assembly (Fig. 100). ONLY if rotors are in specs. (8) Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper. (9) The relief valve spring has a free length of approximately 60.7 mm (2.39 inches) it should test between 18 and 19 pounds when compressed to 40.5 mm (1.60 inches). Replace spring that fails to meet specifications.
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CYLINDER BORE INSPECTION The cylinder walls should be checked for out-ofround and taper with Tool C-119 (Fig. 101). The cylinder bore out-of-round is 0.050 mm (.002 inch) maximum and cylinder bore taper is 0.051 mm (0.002 inch) maximum. If the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed, and new pistons and rings fitted. Whatever type of boring equipment is used, boring and honing operation should be closely coordinated with the fitting of pistons and rings in order that specified clearances may be maintained. Refer to Honing Cylinder Bores outlined in the Standard Service Procedures for specification and procedures. Measure the cylinder bore at three levels in directions A and B (Fig. 101). Top measurement should be 10 mm (3/8 inch) down and bottom measurement should be 10 mm (3/8 inch.) up from bottom of bore. Refer to Cylinder Bore and Piston Specification Chart for specifications.
Standard Piston Size 87.463 - 87.481 mm (3.4434 - 3.4441 in.) Piston to Bore Clearance 0.012 - 0.044 mm (0.0005 - 0.0017 in.) Measurements taken at Piston Size Location.
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SPECIFICATIONS (Continued)
Cylinder Block Diameter . . . . . . . . . . . . . . . . 20.998 - 21.003 mm (0.8267 - 0.8269 in.) End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . None Length . . . . . 74.75 - 75.25 mm (2.943 - 2.963 in.) Piston Rings Ring Gap Top Compression Ring . . 0.23 - 0.52 mm (0.009 - 0.020 in.) Ring Gap 2nd Compression Ring . . 0.49 - 0.78 mm (0.019 - 0.031 in.) Ring Gap Oil Control (Steel Rails) . . . 0.23 - 0.66 mm (0.009 - 0.026 in.) Ring Side Clearance Both Compression Rings . . . . 0.025 - 0.065 mm (0.0010 - 0.0026 in.) Oil Ring (Pack) . . . . . . . . . . . . . 0.004 - 0.178 mm (0.0002 - 0.0070 in.) Ring Width Compression Rings . . . 1.17 - 1.19 mm (0.046 - 0.047 in.) Oil Ring (Pack) . . . . . . . . . . . . . 2.854 - 3.008 mm (0.1124 - 0.1184 in.) Connecting Rod Bearing Clearance . . . . . . . . . . . 0.026 - 0.059 mm (0.001 - 0.0023 in.) Piston Pin Bore Diameter . . . . . 20.96 - 20.98 mm (0.8252 - 0.8260 in.) Large End Bore Diameter . . . 50.991 - 51.005 mm (2.0075 - 2.0081 in.) Side Clearance . 0.13 - 0.38 mm (0.005 - 0.015 in.) Total Weight (Less Bearing) . 543 grams (1.20 lbs.) Crankshaft Connecting Rod Journal Diameter . . 47.9924 - 48.0076 mm (1.8894 - 1.8900 in.) Out-of-Round (Max.) . . . . . 0.0035 mm (0.0001 in.) Taper (Max.) . . . . . . . . . . . 0.0038 mm (0.0001 in.) Main Bearing Diametrical Clearance No. 1 - 5 . . 0.022 - 0.062 mm (0.0008 - 0.0024 in.) End Play . . . . 0.09 - 0.24 mm (0.0035 - 0.0094 in.) Main Bearing Journals Diameter . . . . . . . . . . . . . . 51.9924 - 52.0076 mm (2.0469 - 2.0475 in.) Out-of-Round (Max.) . . . . . 0.0035 mm (0.0001 in.) Taper (Max.) . . . . . . . . . . . 0.0038 mm (0.0001 in.)
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ENGINE 2.0L SOHC Rocker Arm Shaft Rocker Arm Shaft Diameter . . 19.996 19.984mm (0.786 0.7867 in.) Rocker Arm Shaft Retainers (Width) Intake (All) . . . . . . . . . . . . . . . 28.46 mm (1.12 in.) Exhaust . . . . . . . . . . . . . 1 & 5 29.20 mm (1.14in.) 2, 3, and 4 - 40.45 mm (1.59 in.) Rocker Arm/Hydraulic Lash Adjuster * Rocker Arm Inside Diameter . . 20.00 20.02 mm (0.787 0.788 in.)
Rocker Arm Shaft Clearance . . . 0.016 0.054 mm (0.0006 0.0021 in.) Body Diameter . . . . . . . . . . . 22.949 22.962 mm (0.9035 0.9040 in.) Plunger Travel Minimum (Dry) . . . . . . . . . 2.2 mm (0.087 in.) Rocker Arm Ratio . . . . . . . . . . . . . . . . . . . 1.4 to 1 Cylinder Head Camshaft Bearing Diameter No. 1 . . . . 41.20 41.221 mm (1.622 1.6228 in.) No. 2 . . . . . . 41.6 41.621 mm (1.637 1.638 in.) No. 3 . . . . . . 42.0 42.021 mm (1.653 1.654 in.) No. 4 . . . . . . 42.4 42.421 mm (1.669 1.670 in.) No. 5 . . . . . 42.8 42.821 mm (1.685 1.6858 in.) Camshaft Journal Diameter No. 1 . . . 41.128 41.147 mm (1.619 1.6199 in.) No. 2 . . . . 41.528 41.547 mm (1.634 1.635 in.) No. 3 . . . . 41.928 41.947 mm (1.650 1.651 in.) No. 4 . . . . 42.328 42.374 mm (1.666 1.668 in.) No. 5 . . . 42.728 42.747 mm (1.682 1.6829 in.) Diametrical Bearing Clearance . 0.053 0.093 mm (0.0027 0.003 in.) Max. Allowable . . . . . . . . . . . 0.12 mm (0.0047 in.) End Play . . . . . . . . . . 0.05 0.39 mm (0.0059 in.) Lift (Zero Lash ) Intake . . . . . . . . . . . . . . . . . . . 7.2 mm (0.283 in.) Exhaust . . . . . . . . . . . . . . . . . 7.03 mm (0.277 in.) Valve Timing Exhaust Valve** Closes (ATDC) . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Opens (BBDC) . . . . . . . . . . . . . . . . . . . . . . . 43.7 Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . 229.1 Valve Timing Intake Valve ** Closes (ABDC) . . . . . . . . . . . . . . . . . . . . . . . 41.1 Opens (ATDC) . . . . . . . . . . . . . . . . . . . . . . . . 13.9 Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . 207.2 Valve Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Cylinder Head Material . . . . . . . . . . . . . . . . . . . . Cast Aluminum Gasket Thickness (Compressed) . . . . . . . 1.15 mm (0.045 in.) Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Runout (Max.) . . . . . . . . . . . . . . 0.050 mm (0.002) Width (Finish) Intake and Exhaust . . . . . 0.75 1.25 mm (0.030 0.049 in.) Valve Guide Finished Diameter I.D. . 5.975 6.000 mm (.235 .236 in.) Guide Bore Diameter (Std.) . . . . . 11.0 11.02 mm (0.4330 0.4338 in.) Valves Face Angle Intake and Exhaust . . . . . 45 45-1/2 Head Diameter Intake . . . . . . . 32.12 33.37 mm (1.303 1.313 in.) Head Diameter Exhaust . . . . . . 28.57 28.83 mm (1.124 1.135 in.)
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SPECIFICATIONS (Continued)
Valve Margin Intake . . . . . 1.15 1.48 mm (0.0452 0.0582 in.) Exhaust . . . . 1.475 1.805 mm (0.058 0.071 in.) Valve Length (Overall) Intake . . . . 114.69 115.19 mm (4.515 4.535 in.) Exhaust . . 109.59 110.09 mm (4.603 4.623 in.) Valve Stem Tip Height Intake . . . . . . . 45.01 46.07 mm (1.77 1.81 in.) Exhaust . . . . . . 43.51 44.57 mm (1.71 1.75 in.) Stem Diameter Intake . . . . . 5.934 5.952 mm (0.234 0.234 in.) Exhaust . . . . 5.906 5.924 mm (0.233 0.233 in.) Stem to Guide Clearance Intake . . . 0.048 0.066 mm (0.0018 0.0025 in.) Exhaust . 0.0736 0.094 mm (0.0029 0.0037 in.) Max. Allowable Intake . . . . . 0.076 mm (0.003 in.) Max. Allowable Exhaust . . . . 0.101 mm (0.004 in.) Valve Springs Free Length (Approx.) . . . . . . 44.4 mm (1.747 in.) Nominal Force (Valve closed) . 91 Nm @ 39.8 mm (67 ft. lbs. @ 1.57 in.) Nominal Force (Valve open) . 239 Nm @ 32.6 mm (176 lbs. @ 1.28 in.) Installed Height . . . . . . . . . . 40.18 mm (1.580 in.) * SERVICE AS AN ASSEMBLY WITH ROCKER ARM. ** ALL READINGS IN CRANKSHAFT DEGREES, AT 0.5 mm (0.019 in.) OF VALVE LIFT. DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE Engine Mounting Bolts . . . . . . . Refer to Engine Mount Installation Exhaust Manifold to Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . 23 Nm (200 in. lbs.) Exhaust Manifold Heat Shield Bolts . . . . . . . . . . . . . . . . . . . 12 Nm (105 in. lbs.) Intake Manifold Bolts . . . . . . . . . . . . . . . . . . . 12 Nm (105 in. lbs.) Oil Filter Adapter Fastener . . . . . . . . . . . . . . . . . 80 Nm (60 ft. lbs.) Oil Filter . . . . . . . . . . . . . . . . . 20 Nm (15 ft. lbs.) Oil Pan Bolts . . . . . . . . . . . . . . . . . . . 12 Nm (105 in. lbs.) Drain Plug . . . . . . . . . . . . . . . 27 Nm (20 ft. lbs.) Oil Pump Attaching Bolts . . . . . . . . . . . . . . . . . . . 28 Nm (250 in. lbs.) Oil Pump Cover Fastener . . . 12 Nm (105 in. lbs.) Oil Pump Pick-up Tube Bolt . 28 Nm (250 in. lbs.) Oil Pump Relief Valve Cap . . . 41 Nm (30 ft. lbs.) Rocker Arm Shaft Bolts . . . . . . . . . . . . . . . . . . . 28 Nm (250 in. lbs.) Spark Plugs . . . . . . . . . . . . . . . 28 Nm (20 ft. lbs.) Thermostat Housing Bolts . . . . . . . . . . . . . . . . . . . 23 Nm (200 in lbs.) Timing Belt Cover Bolts M6 . . . . . . . . . . . . . . . . 12 Nm (105 in. lbs.) Timing Belt Mechanical Tensioner Assembly Bolts . . . . . . . . . . . . . . . . . . . 28 Nm (250 in. lbs.) Timing Belt Hydraulic Tensioner Pulley Bolt . . . . . . . . . . . . . . . 68 Nm (50 ft. lbs.) Pivot Bracket Bolt . . . . . . . . . . 31 Nm (23 ft. lbs.) Tensioner Bolts . . . . . . . . . . . . 31 Nm (23 ft. lbs.) Water Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . 12 Nm (105 in. lbs.)
Puller 1026
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SPECIAL TOOLS (Continued)
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ENGINE
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SPECIAL TOOLS (Continued)
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ENGINE
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2.5L VM DIESEL
INDEX
page GENERAL INFORMATION ENGINE IDENTIFICATION . . . . . . . . . . . GENERAL SPECIFICATION . . . . . . . . . . DESCRIPTION AND OPERATION LUBRICATION SYSTEM . . . . . . . . . . . . . DIAGNOSIS AND TESTING ENGINE DIAGNOSISMECHANICAL . . ENGINE DIAGNOSISPERFORMANCE HYDRAULIC TAPPETS . . . . . . . . . . . . . . SERVICE PROCEDURES CHANGING ENGINE OIL AND FILTER . . CHECKING OIL LEVEL . . . . . . . . . . . . . . CRANKSHAFT END PLAY . . . . . . . . . . . FITTING PISTON RING . . . . . . . . . . . . . TIMING PROCEDURE . . . . . . . . . . . . . . VALVE AND SEAT REFACING . . . . . . . . REMOVAL AND INSTALLATION CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT BEARINGS . . . . . . . . . . . . . CRANKSHAFT MAIN BEARINGS . . . . . . CRANKSHAFTREMOVAL . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER . . . . . . . . . . . CYLINDER LINER . . . . . . . . . . . . . . . . . ENGINE ASSEMBLY . . . . . . . . . . . . . . . . ENGINE MOUNTFRONT . . . . . . . . . . . ENGINE MOUNTREAR . . . . . . . . . . . . ENGINE MOUNTRIGHT . . . . . . . . . . . HYDRAULIC TAPPETS . . . . . . . . . . . . . . INJECTION PUMP . . . . . . . . . . . . . . . . . MOUNTLEFT SIDE . . . . . . . . . . . . . . . OIL FILTER ADAPTER AND OIL COOLER OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP PRESSURE RELIEF VALVE . . . PISTONS AND CONNECTING ROD . . . . . . REAR CRANKSHAFT OIL SEAL . . . . . . . . . ROCKER ARMS AND PUSH RODS . . . . . . TIMING GEAR COVER . . . . . . . . . . . . . . . . TIMING GEAR COVER OIL SEAL . . . . . . . . VACUUM PUMP . . . . . . . . . . . . . . . . . . . . . VALVE SPRINGSCYLINDER HEAD NOT REMOVED . . . . . . . . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGSHEAD OFF VIBRATION DAMPER . . . . . . . . . . . . . . . . . DISASSEMBLY AND ASSEMBLY HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . CLEANING AND INSPECTION CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT MAIN BEARING . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVERS . . . . . . . . . . . . CYLINDER LINER . . . . . . . . . . . . . . . . . . . HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD . . . . . . . ROCKER ARMS AND PUSH RODS . . . . . . TIMING GEAR COVER . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGS . . . . . . . . . SPECIFICATIONS 2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . . . . 67 67 68 72 54 61 61 68
. . . . . 41 . . . . . 40 . . . . . 41 . . . . . 44 . . . . . 43 . . . . . 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 47 50 50 49 49 62 63 63 72 55 54 72 53 51 52 51 60 61 51 68 66
. . . 55 . . 60 . . . 61 . . . 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 77 75 74 78 76 78 76 76 74 75 76
. . . . . . . . . . . . . . . ..
. . . 78 . . . 80 . . . 81
Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B) Engine Oil Capacity . . . . . 6.5 Liters With Oil Filter Change Timing System . Pushrod Operated Overhead valves, With Gear-Driven Camshaft. Air Intake . . . . . . . . . . . . . . . . . . . . . . . . Dry Filter Fuel Feed . . . . . . . . . . . Vacuum Pump Incorporated in Injection Pump. Fuel System . . . . . . . . . . . . . Indirect Fuel Injection (Precombustion Chamber) Combustion Cycle . . . . . . . . . . . . . . . . . . . . 4 Stroke Cooling System . . . . . . . . . . . . . . . . . . Water Cooled Injection Pump . . . . . . . Rotary Pump Electronically Controlled.
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GENERAL INFORMATION (Continued)
Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B) Lubrication . Pressure Lubrication by Rotary Pump, Full-Flow Filtration Engine Rotation . . . . Clockwise Viewed From Front Cover
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ENGINE IDENTIFICATION
The engine model code (3-digit number/letter code) and serial number are stamped on the forward facing side of the engine block (Fig. 1).
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POSSIBLE CAUSES
1. Starting motor operating, but not cranking the engine. 2. Crankshaft rotation restricted. 3. Starting circuit connections loose or corroded. 4. Neutral safety or starter relay inoperative. 5. Battery charge low. 6. No voltage to starter solenoid. 7. Solenoid or starter motor inoperative.
CORRECTION
1. Remove the starter motor. Check for broken flywheel teeth or a broken starter motor spring. 2. Rotate the engine to check for rotational resistance. 3. Clean and tighten connections. 4. Check starter relay supply voltage and proper operation of neutral safety switch (if equipped). Replace defective parts. 5. Check Battery voltage. Replace battery if a charge cannot be held. 6. Check voltage to solenoid. If necessary, replace the solenoid. 7. Replace starter motor. 1. Fill fuel supply. 2. Check for loose wires and verify that the fuel shutdown solenoid is functioning. Check for fault codes in the ECU. 3. Check for fault codes at ECU. Refer to Group 14, Fuel System for repairs procedures. 4. Remove the obstruction. 5. Drain fuel/water separator and replace fuel filter. 6. Check for restriction. Correct cause. 7. Check fuel flow/bleed fuel system. 8. Check/replace bad or improperly operating injectors. 9. Check/correct timing chain sprocket alignment. 1. The fuel shutoff solenoid control must be in the run position. Ensure the proper procedure is being used. 2. Check the battery, starter motor and look for loose or corroded wiring connections. 3. Verify system is working. Verify connection between heater plug relay and ECU. Repair/replace inoperative parts. 4. Inspect or replace air filter and check for obstruction in air supply. 5. Check the fuel flow through the filter and bleed system. Locate and eliminate the air source. 6. Verify by operating the engine with clean fuel from a temporary tank. Check for the presence of gasoline. Drain and flush fuel supply tank. Replace fuel/water separator filter. 7. Check fuel screen. 8. Check/replace improperly operating injectors. 9. Check pump timing. Refer to Group 14, Fuel System for procedure. 10. Check compression to identify the problem. 11. Vacuum modulator defective causing EGR to open in cold condition. Check for fault codes in the ECU.
1. No fuel in supply tank. 2. Electrical fuel shutdown solenoid not operating. 3. Fuel injection system defective: Cranking speed sensor. Loose connection between ECU and harness. No power supply to the ECU. Loose connection between injection pump and harness. 4. Air intake or exhaust plugged. 5. Fuel filter plugged. 6. Excessive fuel inlet restriction. 7. Injection pump not getting fuel or fuel is aerated. 8. One or more injectors worn or not operating properly. 9. Camshaft out of time.
2. Cranking speed to slow. 3. Cylinder head heater plugs defective. 4. Insufficient intake air 5. Air in fuel system or the fuel supply is inadequate. 6. Contaminated fuel.
7. Fuel screen plugged. 8. One or more injectors worn or not operating properly. 9. Injector pump out of time. 10. Engine compression low. 11. Fuel injection system defective.
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ENGINE DIAGNOSISMECHANICAL
CONDITION LUBRICATING OIL PRESSURE LOW POSSIBLE CAUSES 1. Low oil level. CORRECTION 1a. Check and fill with clean engine oil. 1b. Check for severe external oil leaks that could reduce the pressure. 2. Verify the correct oil is being used. Check for oil dilution. 3. Verify the pressure switch is functioning correctly. If not, replace switch/gauge. 4. Check/replace valve. 5. Change oil filter. Oil filter change interval may need to be revised. 6. Check/removed shipping plugs. 7. Check/replace oil pump. 8. Check and replace seal. 9. Inspect and replace connecting rod or main bearings. check and replace piston cooling oil jet. 10. Check oil jets position. 1. Visually inspect for oil leaks. Repair as required. 2. Verify that the correct dipstick is being used. 3a. Make sure the correct oil is being used. 3b. Look for reduced viscosity from dilution with fuel. 3c. Review/reduce the oil change intervals. 4. Check and replace the oil cooler. 5. Check the breather tube area for signs of oil loss.
2. Oil viscosity thin, diluted, or wrong specification. 3. Improperly operating pressure switch/gauge 4. Relief valve stuck open. 5. Plugged oil filter. 6. Oil cooler was replaced, shipping plugs left in cooler. 7. Worn oil pump. 8. Suction tube loose or seal leaking. 9. Worn bearing or wrong bearing installed. 10. Oil jets under piston loose or bad fit. LUBRICATING OIL LOSS 1. External oil leaks. 2. Crankcase being overfilled. 3. Incorrect oil specification or viscosity.
4. Oil cooler leak. 5. High blow-by forcing oil out the breather.
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DIAGNOSIS AND TESTING (Continued)
ENGINE DIAGNOSISMECHANICAL CONT.
CONDITION LUBRICATING OIL LOSS (CONT.) POSSIBLE CAUSES 6. Turbocharger leaking oil into the air intake. 7. Piston rings not sealing (oil being consumed by the engine). 1. Air in fuel system. 2. Poor quality fuel or water/gasoline contaminated fuel.
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CORRECTION 6. Inspect air duct for evidence of oil transfer. 7. Perform blow-by check. Repair as required. 1. Bleed the fuel system (refer to Group 14, Fuel System). 2. Verify by operating from a temporary tank with good fuel. Clean and flush the fuel supply tank. Replace fuel/water separator. 3. Verify the engine load rating is not being exceeded. 4. Check and replace injectors. 5a. Instrumented injection. 5b. Timing solenoid of the fuel pump. 5c. Pre and post heat time of the glow plugs. Check the fault codes in the ECU. 1. Inspect the drive belts. Make sure water pump pulley, generator and power steering all turn freely. 2. Refer to excessive exhaust smoke. (Engine Diagnosis and Testing) 3. Make sure the rocker arms are not bent. Defective hydraulic lash adjuster. 4. Check turbocharger impeller and turbine wheel for housing contact. 5. Check and replace rod and main bearings. 6a. Instrumented injection. 6b. Timing solenoid of the fuel pump. 6c. Pre and post heat time of the glow plugs. Check the fault codes in the ECU.
COMPRESSION KNOCKS
1. Drive belt squeal, insufficient tension or abnormally high loading. 2. Intake air and exhaust leak. 3. Excessive valve lash.
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DIAGNOSIS AND TESTING (Continued)
ENGINE
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HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending unit. The pressure should be between 3.5 bars to 5.0 bars at 4000 RPM. Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these 2 conditions could be responsible for noisy tappets.
caused by a tappet check valve not seating or by foreign particles becoming wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. (4) The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. In general, if more than one tappet seems to be noisy, its probably not the tappets.
OIL LEVEL HIGH If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily. OIL LEVEL LOW Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than 1 tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out. TAPPET NOISE DIAGNOSIS (1) To determine source of tappet noise, operate engine at idle with cylinder head covers removed. (2) Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation.
NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. (3) Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak down around the unit plunger or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is
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ENGINE
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ENGINE OIL
ENGINE OIL QUALITY Use only oils conforming to API (American Petroleum Institute) quality SG/CD, or CCMC G4. Use only Diesel engine oil meeting standard MIL-2104C or API service classification SG/CD or CCMM PD1 . OIL VISCOSITY Grade 15W-40 is recommended for temperatures between +35C to 10C (95F to 14F). Low viscosity oils must have the proper API quality or the CCMC G5 designation. Low viscosity oils are preferred when minimum temperatures consistently fall below 12C (10F).
ENGINE OIL FILTER CHANGE (1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise to remove it from the oil filter base (Fig. 6).
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SERVICE PROCEDURES (Continued)
(3) Add oil, verify crankcase oil level and start engine. Inspect filter area for oil leaks.
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TIMING PROCEDURE
CAUTION: If a timing gear is removed you must loosen the rocker arm supports before rotating the crankshaft or camshaft. This will prevent the valves hitting the pistons. For the engine components to be in proper timing order, the timing gear marks (dots) must be aligned as shown in (Fig. 7). To facilitate reassembly, align the timing marks as shown in (Fig. 7), or mark the timing gear positions before removal of any marked gears or gear driven component(s).
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SERVICE PROCEDURES (Continued)
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(4) Remove thru bolt in engine mount (Fig. 14). Remove mount. (5) Reverse removal procedure for installation. (6) Torque engine mount thru bolt to 65 Nm (48 ft. lbs.) (7) Torque crossmember bolts for tow bracket and engine mount to 54 Nm (40 ft. lbs.)
ENGINE MOUNTRIGHT
Fig. 12 Piston Ring Side Clearance
(6) Refer to crankshaft main bearing Installation if not in specification. (1) Remove the right engine mount top support bracket bolt (Fig. 15). (2) Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. (3) Remove the engine mount to frame bolts. (4) Remove the thru bolt from the mount assembly. Remove insulator (5) If replaceing or removing right engine mount bracket the torque on the mounting bolts is 40 Nm (30 ft. lbs.) (6) Reverse removal procedure for installation. (7) Torque engine mount top bolt (Vertical) to 101 Nm (75 ft. lbs.) (8) Torque engine mount thru bolt (Horizontal) to 145 Nm (107 ft. lbs.) (9) Torque engine mount to frame bolts to 68 Nm (50 ft. lbs.)
MOUNTLEFT SIDE
Fig. 13 Measuring Crankshaft End Play
NOTE: If engine is disassembled refer to Crankshaft Main Bearing Removal and Installation for this procedure. (1) Raise vehicle on hoist and remove left front wheel. (2) Remove inner splash shield. (3) Support the transmission with a transmission jack. (4) Remove the insulator thru bolt from the mount (Fig. 16). (5) Remove the transmission mount bolts and remove mount. It may be necessary to lower transmission slightly to remove mount. (6) Reverse removal procedure for installation. (7) Install mount. Torque transmission mount bolts to 54 Nm (40 ft. lbs.). (8) Align mount into frame bracket with transmission jack, install thru bolt. Torque thru bolt to 71 Nm (53 ft. lbs.).
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ENGINE
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ENGINE MOUNTREAR
(1) Raise vehicle on hoist. (2) Support the engine and transmission assembly with a transmission jack so it will not rotate. (3) Remove the thru bolt from the insulator at crossmember connection (Fig. 17). (4) Remove the bolts holding the mount to the engine and transmission.
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REMOVAL AND INSTALLATION (Continued)
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ENGINE ASSEMBLY
REMOVAL (1) Disconnect the battery. (2) Remove the air cleaner assembly and inlet hose. (3) Remove both hoses at intercooler and engine. (4) Disconnect EGR vacuum hose. (5) Disconnect brake booster vacuum hose. (6) Disconnect oil pressure switch connector (Fig. 19). (7) Disconnect Wiring harness bracket at transaxle shift tower. (8) Disconnect transaxle wiring at speed sensor, crank sensor, and backup light switch. (9) Remove both transmission shift cables at transmission. (10) Remove negative battery cable at cylinder block (Fig. 19). (11) Remove oil separator. (12) Remove connectors at coolant temperature sensor and A/C compressor. (13) Disconnect fuel injection pump wiring connectors (Fig. 19). (14) Disconnect glow plug connectors. (15) Disconnect electrical connector at number 1 fuel injector. (16) Raise vehicle on hoist. (17) Remove right side splash shield (Fig. 20).
WARNING: THE COOLANT IN A RECENTLY OPERATED ENGINE IS HOT AND PRESSURIZED. USE CARE TO PREVENT SCALDING BY HOT COOLANT.
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INSTALLATION (1) Install cylinder head cover, torque nuts to 23.5 Nm (208 in. lbs.). (2) Install coolant pressure tank. (3) Install breather hose. (4) Install generator bracket, tighten bolts to 7 Nm (4 ft. lbs.). (5) Connect battery cable.
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REMOVAL AND INSTALLATION (Continued)
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psi) of air pressure in the cylinder to hold the valves against their seats. (7) Tap the retainer or tip with a rawhide hammer to loosen the lock from the retainer. Use Valve Spring Compressor Tool to compress the spring and remove the locks. (8) Remove valve spring and retainer. Inspect the valve stems, especially the grooves. An Arkansas smooth stone should be used to remove nicks and high spots.
INSTALLATION (1) Install valve spring and retainer. (2) Compress the valve spring with Valve Spring Compressor Tool and insert the valve locks. Release the spring tension and remove the tool. Tap the spring from side-to-side to ensure that the spring is seated properly on the engine cylinder head. (3) Disconnect the air hose. Remove the adaptor from the fuel injector hole and install the fuel injector. (4) Repeat the procedures for each remaining valve spring to be removed. (5) Install the push rods. Ensure the bottom end of each rod is centered in the plunger cap seat of the hydraulic valve tappet. (6) Install the rocker arm assemblies, at their original location. (7) Tighten the rocker arm assembly nut to 106 Nm (78 ft. lbs.) torque. (8) Install the engine cylinder head cover, refer to cylinder head cover installation in this section.
CYLINDER HEAD
REMOVAL (1) Disconnect the battery cable.
WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRESSURIZED BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR. (2) Drain the cooling system. Refer to Group 7, Cooling. (3) Remove wiper module. Refer to Group 8K, Windshield Wiper Unit Removal for procedure. (4) Remove coolant pressure bottle. (5) Remove intercooler hose at intake manifold (Fig. 23). (6) Remove intercooler hose at turbocharger intercooler tube. (7) Remove the upper radiator hose. (8) Remove water manifold. (9) Disconnect the heater hoses and coolant pressure bottle hoses.
REMOVAL Each valve spring is held in place by a retainer and a set of conical valve locks. The locks can be removed only by compressing the valve spring. (1) Remove the engine cylinder head cover, refer to cylinder head cover removal in this section. (2) Remove rocker arms assemblies for access to each valve spring to be removed. (3) Remove push rods. Retain the push rods, and rocker arms assemblies in the same order and position as removed. (4) Inspect the springs and retainer for cracks and possible signs of weakening. (5) Install an air hose adaptor in the fuel injector hole. (6) Connect an air hose to the adapter and apply air pressure slowly. Maintain at least 621 kPa (90
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Fig. 24 Turbocharger
(10) Disconnect EGR tube from EGR valve (Fig. 25). (11) Remove exhaust pipe from turbocharger elbow and. (12) Disconnect oil feed line from turbo (Fig. 24). (13) Disconnect oil drain line from turbo. (14) Remove Intake manifold. Refer to Group 11, Exhaust System and Intake Manifold. (15) Remove lift eye and brake vacuum tube at rear of exhaust manifold.
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REMOVAL AND INSTALLATION (Continued)
(22) Remove the injector sensor wire at the connector, and glow plug Connectors. NOTE: The attachment point for the injector sensor wire at the injector is not a connector. The connector is located in the wire 4 to 6 inches away from the injector. (23) Remove injector fuel lines from injectors to pump. (24) Remove fuel injectors with tool VM-1012A (Fig. 27) and (Fig. 28) Refer to Group 14, Fuel System.
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ENGINE
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REMOVAL AND INSTALLATION (Continued)
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ENGINE
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REMOVAL (1) Remove the engine cylinder head from the cylinder block. Refer to cylinder head removal in this section. (2) Use Valve Spring Compressor Tool and compress each valve spring. (3) Remove the valve locks, retainers, and springs. (4) Use an Arkansas smooth stone or a jewelers file to remove any burrs on the top of the valve stem, especially around the groove for the locks. (5) Remove the valves, and place them in a rack in the same order as removed. INSTALLATION (1) Fit each valve to its respective valve guide.
NOTE: If valves and valve seats have been refaced refer to Service Procedures in this section. Follow The Valve Stand Down procedure. (2) Install lower, washer and spring. (3) Install upper spring collar, and compress valve spring with spring compressor tool. Install split cone retainers.
HYDRAULIC TAPPETS
REMOVAL (1) Remove coolant pressure bottle. (2) Remove cylinder head cover. Refer to cylinder head cover removal in this section. (3) Remove rocker assembly and push rods. Identify push rods to ensure installation in original location (Fig. 34). (4) Remove cylinder head, intake manifold, and exhaust manifold. Refer to cylinder head removal in this section. (5) Remove yoke retainer and aligning yokes (Fig. 35). (6) Slide Hydraulic Tappet Remover/Installer Tool through opening in block and seat tool firmly in the head of tappet. (7) Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location. (8) If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet.
INSTALLATION (1) Lubricate tappets. (2) Install tappets and yoke retainers in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft).
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REMOVAL AND INSTALLATION (Continued)
(3) Install cylinder head, intake manifold, and exhaust manifold. Refer to cylinder head installation in this section. (4) Install push rods in original positions. (5) Install rocker arms in original positions. (6) Install cylinder head cover. Refer to cylinder valve cover installation in this section. (7) Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
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(4) Install both accessary drive belts. Refer to Group 7, Cooling. (5) Install right splash shield. (6) Lower vehicle. (7) Connect the battery cable.
VIBRATION DAMPER
REMOVAL (1) Disconnect the battery cable. (2) Raise vehicle on hoist. (3) Remove right side lower splash shield. (4) Remove generator, power steering belt. Refer to Group 7, Cooling. (5) Remove water pump belt. Refer to Group 7, Cooling. (6) Remove engine starter. Refer to Group, 8B for procedure (7) Install flywheel locking tool VM.1014 to prevent engine rotation.
NOTE: Crankshaft thread. damper nut is left handed
(8) Remove vibration damper nut. (9) Remove vibration damper. No special tool is needed for removal. CAUTION: If thread sealant is used it is important to remove all the old thread sealant from the threads on the crankshaft.
INJECTION PUMP
For removal and installation of injection pump refer to Group 14, Fuel.
INSTALLATION
NOTE: Before installing damper be sure the O-ring inside the center of the damper is in its grove. (1) Install vibration damper. CAUTION: Correct torque on the vibration damper nut is important or engine damage can occur. (2) Install vibration damper nut and tighten to 441 Nm (325 ft. lbs.). (3) Remove flywheel locking tool, and install engine starter.
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CAMSHAFT
INSTALLATION (1) Apply a continuous 3 mm bead of Silicone Sealer to timing cover, install within 10 minutes, tighten Torx bolts to 11 Nm (96 in. lbs) (Fig. 37). REMOVAL (1) To service the camshaft (Fig. 38) the engine must be removed from the vehicle.
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REMOVAL AND INSTALLATION (Continued)
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(2) Install hydraulic tappets and retaining yokes. (3) Install cylinder heads. (4) Push rods, and rocker arm assemblies. In there original location. (5) Install valve cover. (6) Install Timing case cover. (7) Install Vibration damper. (8) Reinstall Engine.
CAMSHAFT BEARINGS
This procedure requires that the engine is removed from the vehicle.
REMOVAL (1) With engine completely disassembled, drive out rear cam bearing core hole plug. (2) Install proper size adapters and horseshoe washers (part of Camshaft Bearing Remover/Installer Tool) at back of each bearing shell. Drive out bearing shells. INSTALLATION (1) Install new camshaft bearings with Camshaft Bearing Remover/Installer Tool by sliding the new camshaft bearing shell over proper adapter. (2) Position rear bearing in the tool. Install horseshoe lock and by reversing removal procedure, carefully drive bearing shell into place. (3) Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. If the camshaft bearing shell oil holes are not in exact alignment, remove and install them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak.
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INSTALLATION
NOTE: Assemble engine according to sequence described, thus saving time and preventing damages to engine components. Clean parts with a suitable solvent and dry them with compressed air
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REMOVAL AND INSTALLATION (Continued)
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OIL PAN
REMOVAL (1) Disconnect battery cable. (2) Raise vehicle on hoist.
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REMOVAL AND INSTALLATION (Continued)
(3) Drain oil. (4) Remove oil pan bolts (Fig. 48). (5) Remove oil pan.
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OIL PUMP
REMOVAL (1) Raise vehicle on hoist. (2) Remove right splash shield. (3) Remove both accessory drive belts. Refer to Group 7, Cooling. (4) Remove pump shaft support bracket assembly. (5) Remove vibration damper. Refer to Vibration Damper Removal in this section.
NOTE: Crankshaft thread. damper nut is left handed
(6) Remove front cover. Refer to Timing Gear Cover Removal in this section. (7) Remove oil pump.
INSTALLATION (1) Install new O-ring and lubricate with clean engine oil. (2) Install oil pump and tighten retaining screws to 27.5 Nm (240 in. lbs.).
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VACUUM PUMP
REMOVAL (1) Remove the front cover refer to front cover removal in this section. (2) Remove 4 bolts.
INSTALLATION (1) To install the vacuum pump, align the outer part of the gear with the inner part using a screwdriver or similar tool, align with timing marks on gear set and install. (2) Install bolts and tighten to 20 Nm (15 ft. lbs.). (3) Install front cover.
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REMOVAL AND INSTALLATION (Continued)
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PISTON PINREMOVAL (1) Secure connecting rod in a soft jawed vice. (2) Remove 2 clips securing piston pin (Fig. 57). (3) Push piston pin out of piston and connecting rod.
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PISTON RINGSINSTALLATION (1) Install rings on the pistons using a suitable ring expander (Fig. 58). (2) Top compression ring is tapered and chromium plated. The second ring is of the scraper type and must be installed with scraping edge facing bottom of the piston. The third is an oil control ring (Fig. 61). Ring gaps must be positioned, before inserting piston into the liners, as follows (Fig. 62). (3) Top ring gap must be positioned at 30 degrees to the right of the combustion chamber recess (looking at the piston crown from above). (4) Second piston ring gap should be positioned on the opposite side of the combustion chamber recess. (5) Oil control ring gap to be located 30 degrees to the left of combustion chamber recess. (6) When assembling pistons check that components are installed in the same position as before dis-
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REMOVAL AND INSTALLATION (Continued)
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CAUTION: Ensure combustion recess in piston crown and the bearing cap numbers on the connecting rod are on the same side. (4) Install piston pin. (5) Install clips in piston to retain piston pin. (6) Remove connecting rod from vice.
PISTONINSTALLATION (1) Before installing pistons, and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 62).
PISTON PININSTALLATION (1) Secure connecting rod in soft jawed vice. (2) Lubricate piston pin and piston with clean oil. (3) Position piston on connecting rod.
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CYLINDER LINER
REMOVAL (1) Remove cylinder heads (refer to cylinder head removal in this section). (2) Remove Oil pan (refer to oil pan removal in this section). (3) Remove pistons (refer to piston removal in this section). (4) Use tool VM-1001 to remove liners (Fig. 64). (5) Remove shims from cylinder liner or cylinder block recess. Keep shims with each cylinder liner. INSTALLATION (1) Carefully clean residual sealer from liner and crankcase, and degrease the crankcase where it comes into contact with the liners. Referring to (Fig. 65), install the liners in the crankcase as shown (A), rotating them back and forth by 45 in order to guarantee correct positioning. (2) Measure the liner recess relative to block deck with a dial indicator mounted on a special tool VM-1010 A. All the measurements must be taken on camshaft side. Zero dial gauge on block deck. (3) Move dial gauge to cylinder liner record reading on dial gauge. (4) Remove liner and special tool. (5) Then select the correct shim thickness to give proper protrusion (0.01 - 0.06 mm). (6) Fit the shim and the O-rings onto the liner. (7) Lubricate the lower liner location in the block. Apply LOCTITE 275 to the corner of the liner seat. Apply LOCTITE 275 uniformly to the upper part of the liner at area. (8) Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat. Lock
CRANKSHAFTREMOVAL
Refer to CRANKSHAFT REMOVAL in this section. MAIN BEARING
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Fig. 67 Flywheel
retainer and plunger spring. Check valve could be flat or ball. Assemble tappets in reverse order.
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CLEANING AND INSPECTION (Continued)
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CYLINDER HEAD
CLEANING Thoroughly clean the engine cylinder head and cylinder block mating surfaces. Clean the intake and exhaust manifold and engine cylinder head mating surfaces. Remove all gasket material and carbon. Check to ensure that no coolant or foreign material has fallen into the tappet bore area. Remove the carbon deposits from the combustion chambers and top of the pistons. INSPECTION Use a straightedge and feeler gauge to check the flatness of the engine cylinder head and block mating surfaces (Fig. 70). Minimum cylinder head thickness 89.95mm (3.541 in.)
CAUTION: If only one cylinder head is found to be distorted and requires machining, it will also be necessary to machine the remaining cylinders heads and end plates by a corresponding amount to maintain correct cylinder alignment.
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OIL PUMP
CLEANING Wash all parts in a suitable solvent and inspect carefully for damage or wear (Fig. 74). INSPECTION (1) Before installing oil pump check pump bore depth in block (A) and pump body height (B) (Fig. 73). Difference between A and B should be 0.020-0.082 mm. (2) Check clearance between rotors (Fig. 75).
HYDRAULIC TAPPETS
(1) Clean all tappet parts in a solvent that will remove all varnish and carbon. (2) Replace tappets that are unfit for further service with new assemblies. (3) If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from seating, install a new tappet assembly.
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CLEANING AND INSPECTION (Continued)
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number on both the rod and the cap. These numbers must both face the camshaft as well as the recess on the piston crown (Fig. 76). Lightly heat the piston in oven. Insert piston pin in position and secure it with provided snap rings. The Four digit numbers marked on con rod big end and rod cap must be on the same side as the camshaft (Fig. 76). After having coated threads with Molyguard, tighten con rod bolts to 29 Nm (21 ft. lbs.) plus 60.
CRANKSHAFT
CRANKSHAFT JOURNALS (1) Using a micrometer, measure and record crankshaft connecting rod journals, take reading of each journal 120 apart. Crankshaft journal diameter is 53.84 to 53.955mm (2.1196 to 2.1242 in.). (2) Crankshaft journals worn beyond limits or show signs of out of roundness must be reground or replaced. Minimum reground diameter is 53.69mm (2.1137 in.). BEARING-TO-JOURNAL CLEARANCE Compare internal diameters of connecting rod with crankshaft journal diameter. Maximum clearance between connecting rod and crankshaft journals .022 to .076mm (.0008 to .0029 in.) (Fig. 78).
CONNECTING ROD (1) Assemble bearing shells and bearing caps to their respective connecting rods ensuring that the serrations on the cap and reference marks are aligned. (2) Tighten bearing cap bolts to 29 Nm (21 ft. lbs.) plus 60. (3) Check and record internal diameter of crank end of connecting rod. Note: When changing connecting rods, all four must have the same weight and be stamped with the same number. Replacement connecting rods will only be supplied in sets of four. (4) Connecting rods are supplied in sets of four since they all must be of the same weight category. Max allowable weight difference is 18 gr. NOTE: On one side of the big end of the con-rod there is a twodigit number which refers to the weight category. On the other side of the big end there is a four digit
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CYLINDER LINER
INSPECTION The cylinder walls should be checked for out-ofround and taper with dail bore gauge. The cylinder bore out-of-round is 0.100 mm (.0039 inch) maximum and cylinder bore taper is 0.100 mm (0.0039 inch) maximum. If the cylinder walls are badly scuffed or scored, new liners should be installed and honed, and new pistons and rings fitted. Measure the cylinder bore at three levels in directions A and B (Fig. 79). Top measurement should be 10 mm (3/8 inch) down and bottom measurement should be 10 mm ( 3/8 inch.) up from bottom of bore.
OIL PAN
Remove all gasket material from cylinder block. Be careful not gouge pan sealing surface.
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SPECIFICATIONS (Continued)
DESCRIPTION . . . . . . . . . . . SPECIFICATIONS Nominal . . . . . . . . . . . . . . . . . 63.00563.020 mm 0.25 . . . . . . . . . . . . . . . . . . . . 62.75562.770 mm 0.125 . . . . . . . . . . . . . . . . . . . 62.88062.895 mm Center Bearing Diameter . . . . . . . . . . . . . . . . . . . Nominal . . . . . . . . . . . . . . . . . 63.05063.093 mm 0.25 . . . . . . . . . . . . . . . . . . . . 62.80062.843 mm 0.125 . . . . . . . . . . . . . . . . . . . 62.92562.968 mm Clearance Between Journal and Bearing: 0.0300.088 mm . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Journal Diameter . . . . . . . . . . . . . . . . . . . . . Nominal . . . . . . . . . . . . . . . . . 79.98080.000 mm 0.25 . . . . . . . . . . . . . . . . . . . . 79.73079.750 mm 0.125 . . . . . . . . . . . . . . . . . . . 79.85579.875 mm Rear Bearing Diameter . . . . . . . . . . . . . . . . . . . . . Nominal . . . . . . . . . . . . . . . . . 80.04580.070 mm 0.25 . . . . . . . . . . . . . . . . . . . . 79.79579.820 mm 0.125 . . . . . . . . . . . . . . . . . . . 79.92079.945 mm Clearance Between Journal and Bearing: 0.0450.090 mm (Wear Limit: 0.200 mm) . . . . . . . Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . Nominal . . . . . . . . . . . . . . . . . 53.94053.955 mm 0.25 . . . . . . . . . . . . . . . . . . . . 53.69053.705 mm 0.125 . . . . . . . . . . . . . . . . . . . 53.81553.830 mm Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . Nominal . . . . . . . . . . . . . . . . . 53.97754.016 mm 0.25 . . . . . . . . . . . . . . . . . . . . 53.72753.766 mm 0.125 . . . . . . . . . . . . . . . . . . . 53.85253.891 mm Clearance Between Journal and Bearing: 0.0220.076 mm (Wear Limit: 0.200 mm) . . . . . . . Crankshaft End Play End Play . . . . . . . . . . . . . . . . . . . . . 0.080.21 mm Adjustment . . . . . . . . . . . . . . . . . Thrust Washers Thrust Washers Available . . . . . . . . 2.312.36 mm Thrust Washers Available . . . . . . . . 2.412.46 mm Thrust Washers Available . . . . . . . . 2.512.56 mm Main Bearing Carriers Front . . . . . . . . . . . . . . . . . . . . 67.02567.050 mm Center . . . . . . . . . . . . . . . . . . . 66.67066.690 mm Rear . . . . . . . . . . . . . . . . . . . . 85.98586.005 mm Liners Internal Diameter . . . . . . . . . . 92.00092.010 mm Protrusion . . . . . . . . . . . . . . . . . . . . 0.010.06 mm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Shims Available Shims: . . . . . . . . . . . . . . . . . . . 0.15 mm Available Shims: . . . . . . . . . . . . . . . . . . . 0.17 mm Available Shims: . . . . . . . . . . . . . . . . . . . 0.20 mm Available Shims: . . . . . . . . . . . . . . . . . . . 0.23 mm Available Shims: . . . . . . . . . . . . . . . . . . . 0.25 mm Cylinder Head Minimum Thickness . . . . . . . . . . 89.9590.05 mm Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Gasket thickness: . . . . . . . 1.42 0.1 mm 0 Holes Gasket thickness: . . . . . . . 1.62 0.1 mm 1 Holes
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DESCRIPTION . . . . . . . . . . . SPECIFICATIONS Gasket thickness: . . . . . . . 1.52 0.1 mm 2 Holes End Plates Height . . . . . . . . . . . . . . . . . . . . . 89.0290.00 mm Connecting Rods Weight (Without the crank bearing) . . . . . . . . . . . . . . . . . . 11291195 grams Small End Bearing Internal Diameter Minimum . . . . . . . . . . . . . . . . . . . . . . . 30.035 mm Maximum . . . . . . . . . . . . . . . . . . . . . . 30.050 mm Crankshaft Bearings Standard Internal Diameter . . . . . . . . . . . . . . . . . 53.99754.016 mm Pistons Skirt Diameter . . . . . . . . . . . . 91.93591.945 mm (Measured at approximately 15 mm above the bottom of the skirt) Piston Clearance . . . . . . . . . . . . . 0.0550.075 mm Top of Piston to Cylinder Head . . . . 0.800.89 mm Piston Protrusion . . . . . 0.530.62 mm Fit Gasket (1.42), 0 Holes Piston Protrusion . . . . . 0.730.82 mm Fit Gasket (1.62), 1 Hole Piston Protrusion . . . . . 0.630.72 mm Fit Gasket (1.52), 2 Holes Piston Pins Type . . . . . . . . . . . . . . . . . . . . . . . . . Full Floating Pin Diameter . . . . . . . . . . . . . . 29.99029.996 mm Clearance . . . . . . . . . . . . . . . . . . 0.0040.014 mm Piston Rings (Clearance in Groove) Top . . . . . . . . . . . . . . . . . . . . . . . 0.0800.130 mm Second . . . . . . . . . . . . . . . . . . . . . 0.0700.102 mm Oil Control . . . . . . . . . . . . . . . . . 0.0400.072 mm Piston Rings (Fitted Gap) Top . . . . . . . . . . . . . . . . . . . . . . . . . 0.250.50 mm Second . . . . . . . . . . . . . . . . . . . . . . 0.200.35 mm Oil Control . . . . . . . . . . . . . . . . . . . 0.250.58 mm Camshaft Journal Diameter Front . . . . . 53.46053.480 mm Bearing Clearance . . . . . . . . . . . . . 0.060.13 mm Journal Diameter Center . . . . 53.46053.480 mm Bearing Clearance . . . . . . . . . . . . . 0.060.13 mm Journal Diameter Rear . . . . . . 53.46053.480 mm Bearing Clearance . . . . . . . . . . . . . 0.060.13 mm Tappets Outside Diameter . . . . . . . . . . 22.19522.212 mm Rocker Gear Shaft Diameter . . . . . . . . . . . . . 21.97922.00 mm Bushing internal diameter . . . 22.02022.041 mm Assembly Clearance . . . . . . . . . . 0.0200.062 mm Valves (Intake) Opens . . . . . . . . . . . . . . . . . . . . . . . . 26 B.T.D.C. Closes . . . . . . . . . . . . . . . . . . . . . . . . 58 A.B.D.C. Valves (Exhaust) Opens . . . . . . . . . . . . . . . . . . . . . . . . 64 B.B.D.C. Closes . . . . . . . . . . . . . . . . . . . . . . . . 38 A.T.D.C.
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SPECIFICATIONS (Continued)
DESCRIPTION . . . . . . . . . . . SPECIFICATIONS Valve Face Angle Intake . . . . . . . . . . . . . . . . . . . . . . . 5530 5550 Exhaust . . . . . . . . . . . . . . . . . . . . . 4525 4535 Valve Head Diameter Intake . . . . . . . . . . . . . . . . . . . . . 40.0540.25 mm Exhaust . . . . . . . . . . . . . . . . . . . . . 33.834.0 mm Valve Head Stand Down Intake . . . . . . . . . . . . . . . . . . . . . . . 1.081.34 mm Exhaust . . . . . . . . . . . . . . . . . . . . . 1.991.25 mm Valve Stem Diameter Intake . . . . . . . . . . . . . . . . . . . . . 7.9407.960 mm Exhaust . . . . . . . . . . . . . . . . . . . . 7.9227.940 mm Valve Clearance in Guide Intake . . . . . . . . . . . . . . . . . . . . . 0.0400.075 mm Exhaust . . . . . . . . . . . . . . . . . . . . 0.0600.093 mm Valve Guide Inside Diameter . . . . . . . . . . . . . . . 8.08.015 mm Fitted Height . . . . . . . . . . . . . . . . . 13.514.0 mm Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . 44.65 mm Fitted Length . . . . . . . . . . . . . . . . . . . . . 38.6 mm Load at Fitted Length . . . . . . . . . . . . 34 6% Kg Load at Top of Lift . . . . . . . . . . . . . 92.5 4% Kg Number of Coils . . . . . . . . . . . . 5.33 Valve Timing Oil Pressure at 4000 rpm . . . . . 3.0 to 4.5 bar (Oil at 90100C) Pressure Relief Valve Opens . . . . . . . . . . 6.38 bar Pressure Relief ValveFree Length . . . . . 57.5 mm Oil Pump Outer Rotor End Float . . . . . . . . . . 0.030.09 mm Inner Rotor End Float . . . . . . . . . . 0.030.09 mm Outer Rotor to Body Diameter Clearance . . . . . . . . . . . . . . . . . . 0.1300.230 mm Rotor Body to Drive Gear Clearance (Pump Not Fitted) . . . . . . . . . . . . . . . . . . . . . . 3.273.73 mm DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE EGR Tube to EGR Valve Bolts . . . . . . . . . . . . . . . . . . . . 26 Nm (19 ft. lbs.) Engine MountFront Support Bracket Engine Bolts . 68 Nm (50 ft. lbs.) Support Bracket Transmission Bolts . . . . . . . . . . . . . . . . . . . 101 Nm (75 ft. lbs.) Support Cushion Crossmember Bolts . . . . . . . . . . . . . . . . . . . . 54 Nm (40 ft. lbs.) Support Cushion Thru Bolt . . . 65 Nm (48 ft. lbs.) Engine MountRear Support Bracket Transmission Bolts . . . . . . . . . . . . . . . . . . . 101 Nm (75 ft. lbs.) Support Bracket to Engine Bracket . . . . . . . . . . . . . . . . . 101 Nm (75 ft. lbs.) Support Cushion Thru Bolt . . . 68 Nm (50 ft. lbs.) Engine MountLeft Transmission Mounting Bolts . 54 Nm (40 ft. lbs.) Support Cushion Thru Bolt . . . 71 Nm (53 ft. lbs.) Engine MountRight Mount to Frame Rail Bolts . . . 68 Nm (50 ft. lbs.) Mount Bolt (Horizontal) . . . 145 Nm (107 ft. lbs.) Mount Bolt (Vertical) . . . . . . . 101 Nm (75 ft. lbs.) Right Engine Mount Bracket Bolts . . . . . . . . . . . . . . . . . . . . 40 Nm (30 ft. lbs.) Exhaust Pipe to Turbocharger Bolts . . . . . . . . . . . . . . . . . . . 28 Nm (250 in. lbs.) Exhaust Manifold Outlet to Turbo Nuts . . . . . . . . . . . . . . . . . . . . 32 Nm (24 ft. lbs.) Exhaust Elbow to Turbo Bolts . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft. lbs.) Exhaust Manifold Mounting Nuts . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft. lbs.) Flywheel Bolts . . . . . See Rear Crankshaft Seal Installation Procedure Engine Adaptor Plate Bolts . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. lbs.) Front Timing Gear Cover Bolts . . . . . . . . . . . . . . . . . . . . 11 Nm (96 in. lbs.) Fuel Filter Nuts . . . . . . . . . . . . . . . . . . . 28 Nm (250 in. lbs.) Glow Plugs Plugs . . . . . . . . . . . . . . . . . . 14 Nm (120 in. lbs.) Idler Pulley Pump Support Bracket Nuts . . . . . . . . . . . . . . . . . . . 26 Nm (228 in. lbs.) Idler Pulleys (left handed threads) Bolts . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. lbs.) Injector Pump fuel lines Nuts . . . . . . . . . . . . . . . . . . 17.6 Nm (156 in. lbs.) Injector Pump Gear Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Nm Injector Pump Mounting Nuts . . . . . . . . . . . . . . . . . . 27.5 Nm (240 in. lbs.)
TORQUE
DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE Generator Mounting Bracket Bolts . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. lbs.) Camshaft Thrust Plate Retaining Bolts Bolt . . . . . . . . . . . . . . . . . . . . . 24 Nm (18 ft. lbs.) Cylinder Head Bolts . . See Cylinder Head Installation Procedure Connecting Rod Bolts . . . . . . . . . . . 29.5 Nm +60 (22 ft. lbs. +60) Crankshaft Bearing Carrier Bolts . . . . . . . . . . . . . . . . . . . . 44 Nm (32 ft. lbs.) Crankshaft damper (Pulley) Nut . . . . . . . . . . . . . . . . . . . 441 Nm (325 ft. lbs.) EGR Valve to Intake Manifold Tube . . . . . . . . . . . . . . . . . . . . 26 Nm (19 ft. lbs.)
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DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE Injector Tighten to . . . . . . . . . . . . . . . . 65 Nm (48 ft. lbs.) Intake Manifold Mounting Nuts . . . . . . . . . . . . . . . . . . . 30 Nm (264 in. lbs.) Main Bearing Oil Delivery Union Bolts . . . . . . . . . . . . . . . . . . . . 54 Nm (40 ft. lbs.) Oil Feed Line To Rocker Arms Bolts . . . . . . . . . . . . . . . . . 12.7 Nm (108 in. lbs.) Oil Feed Line to Block Bolts . . . . . . . . . . . . . . . . . 12.7 Nm (108 in. lbs.) Oil Feel Line to Vacuum Pump Bolts . . . . . . . . . . . . . . . . . 16.7 Nm (145 in. lbs.) Oil Filter Tighten to . . . . . . . . . . . . . . . 9.8 Nm (85 in. lbs.) Oil Filter Adaptor Fastener . . . . . . . . . . . . . . . . . 49 Nm (36 ft. lbs.) Oil Filter Base Fastener . . . . . . . . . . . . . . . . . 49 Nm (36 ft. lbs.) Oil Pan Mounting Bolts . . . . . . . . . . . . . . . . . . . 12 Nm (108 in. lbs.) Oil Pickup Tube Bolts . . . . . . . . . . . . . . . . . . 11.3 Nm (100 in. lbs.) Oil Pump Mounting Bolts . . . . . . . . . . . . . . . . . 27.5 Nm (240 in. lbs.) Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . 54 Nm (40 ft. lbs.) Power Steering Pressure Hose Fastener . . . . . . . . . . . . . . . . 28 Nm (240 in. lbs.) Power Steering Pulley Nut . . . . . . . . . . . . . . . . . . . 170 Nm (125 ft. lbs.) Rear Crankshaft Bearing Carrier Bolts . . . . . . . . . . . . . . . . . . 10.8 Nm (95 in. lbs.) Rocker Arm Cover Bolts . . . . . . . . . . . . . . . . . 14.7 Nm (132 in. lbs.) Rocker Arm Mounting Nuts . . . . . . . . . . . . . . . . . . 29.4 Nm (264 in. lbs.) Power Steering Pump Mounting Nuts . . . . . . . . . . . . . . . . . . 24.5 Nm (216 in. lbs.) Turbocharger Mounting Nuts . . . . . . . . . . . . . . . . . . . 32 Nm (288 in. lbs.) Turbocharger Oil Delivery Bolt . . . . . . . . . . . . . . . . . . 27.5 Nm (240 in. lbs.) Turbocharger Oil Drain Bolts . . . . . . . . . . . . . . . . . . 10.8 Nm (95 in. lbs.) Vacuum Pump Mounting Bolts . . . . . . . . . . . . . . . . . . 10.8 Nm (95 in. lbs.) Water Manifold Mounting Bolts . . . . . . . . . . . . . . . . . . 11.8 Nm (108 in. lbs.) Water Pump Pulley Bolts . . . . . . . . . . . . . . . . . 27.5 Nm (240 in. lbs.)
ENGINE
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ENGINE
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SPECIAL TOOLS (Continued)
ENGINE
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ENGINE
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GENERAL INFORMATION CATALYTIC CONVERTERS . . . . . . . . . . . . . . . . . EXHAUST FLEX-JOINT COUPLING . . . . . . . . . . . EXHAUST GAS RECIRCULATION (EGR) . . . . . . . EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION INTAKE/EXHAUST MANIFOLD2.4L ENGINE . . INTAKE/EXHAUST MANIFOLD3.0L ENGINE . . INTAKE/EXHAUST MANIFOLD3.3/3.8L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
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REMOVAL AND INSTALLATION EXHAUST MANIFOLD2.4L ENGINE . . . . . . . . 8 EXHAUST MANIFOLD3.0L ENGINE . . . . . . . 11 EXHAUST MANIFOLDS3.3/3.8L ENGINE . . . 16 EXHAUST PIPES, MUFFLERS AND TAILPIPES . 4 INTAKE MANIFOLD LOWER2.4L ENGINE . . . . 6 INTAKE MANIFOLD3.0L ENGINE . . . . . . . . . . 8 INTAKE MANIFOLD3.3/3.8L ENGINE . . . . . . 12 UPPER INTAKE MANIFOLD2.4L ENGINE . . . . 4 CLEANING AND INSPECTION EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 17 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 17 SPECIFICATIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 18
CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country. The combustion reaction caused by the catalyst releases additional heat in the exhaust system. Causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust system if equipped with
CATALYTIC CONVERTERS
There is no regularly scheduled maintenance on any Chrysler catalytic converter. If damaged, the converter must be replaced.
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HEAT SHIELDS
Heat shields (Fig. 2) are needed to protect both the vehicle and the floor pan from the high temperatures developed near the catalytic converter and muffler. Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped. Light over spray near the edges is permitted. Application of coating will greatly
Fig. 3 Flex-Joint
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GENERAL INFORMATION (Continued)
CAUTION: When servicing, care must be exercised not to dent or bend the bellows of the flex-joint. Should this occur, the flex-joint will eventually fail and require the catalytic converter be replaced.
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Both exhaust manifolds are a log style made of ductile cast iron. Exhaust gasses, collected from the front cylinder bank, leave the front manifold through an end outlet and are fed through an upper crossover tube to the rear manifold. The collected exhaust from both manifolds are combined at the exhaust outlet, to the exhaust pipe.
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INSTALLATION (1) Assemble pipes, muffler support and clamp loosely to permit alignment of all parts. (2) Beginning at front of system, align and clamp each component to maintain position and proper clearance with underbody parts. (3) Tighten the clamp and support to the proper torques and clearances (Fig. 4).
REMOVAL (1) Disconnect negative cable from battery. (2) Disconnect air intake tube and resonator box from throttle body and remove. (3) Remove connector from throttle position sensor (Fig. 6). (4) Remove connector from idle air control motor (Fig. 6). (5) Remove connector from MAP sensor (Fig. 11).
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL (1) Perform fuel system pressure release procedure before attempting any repairs. (2) Remove upper intake manifold. Refer to procedure in this section.
CAUTION: Cover intake manifold to prevent foreign material from entering engine. (3) Disconnect electrical connector from intake air temperature sensor (Fig. 12).
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION
If the following items were removed, install and torque to: Fuel Rail Bolts 22 Nm (200 in. lbs.) Engine Outlet Connector Bolts 28 Nm (250 in. lbs.) Coolant Temperature Sensor 7 Nm (60 in. lbs.) Intake Air Temperature Sensor 28 Nm (250 in. lbs.) (1) Using a new intake gasket, position intake manifold on the engine and install retaining bolts.
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INSTALLATION (1) Install exhaust manifold with a new gasket and tighten attaching nuts in the order shown in (Fig. 17) to 20 Nm (175 in. lbs.). (2) Attach exhaust pipe to exhaust manifold and tighten bolt to 28 Nm (250 in. lbs.). (3) Connect heated oxygen sensor lead (Fig. 17).
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REMOVAL AND INSTALLATION (Continued)
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Fig. 24 Vacuum Connections for Fuel Rail and Fuel Pressure Regulator
(15) Disconnect Fuel Injector wiring harness from engine wiring harness.
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INSTALLATION (1) Position new intake manifold gaskets on cylinder head and install intake (cross) manifold. (2) Install nuts and washers and tighten in several steps in order shown in (Fig. 26) to 20 Nm (174 in. lbs.). (3) Make sure the injector holes are clean and all plugs have been removed. (4) Lube injector O-ring with a drop of clean engine oil to ease installation. (5) Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports. (6) Install the fuel rail attaching bolts and torque to 13 Nm (115 in. lbs.).
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Fig. 45 EGR Tube, Heated Oxygen Sensor and Generator/Power Steering Strut
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EXHAUST MANIFOLD
INSPECTION Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust cross-over mounting surface with a straightedge and thickness gauge (Fig. 48).
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FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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INSTALLATION (1) Position rear bumper reinforcement on vehicle. (2) Loosely install nuts to hold rear bumper reinforcement to frame rail extensions (Fig. 4). (3) Align nuts to previously made marks on frame rail extensions. Tighten nuts to 27 Nm (20 ft. lbs.) torque. (4) Install rear bumper fascia.
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FRAME
INDEX
page REMOVAL AND INSTALLATION FRONT CROSSMEMBER MOUNT BUSHINGS . . . 5 FRONT CROSSMEMBER . . . . . . . . . . . . . . . . . . . 3 page SPECIFICATIONS FRAME AND BODY OPENING DIMENSIONS . . . . 5
REMOVAL (1) Disconnect battery negative cable. (2) Remove steering column lower cover from instrument panel. Refer to Group 8E, Instrument Panel and Systems. (3) Remove knee blocker reinforcement. Refer to Group 8E, Instrument Panel and Systems. (4) Position steering so front wheels are straight ahead.
CAUTION: Do not rotate steering wheel after disengaging lower coupling from steering gear, damage to airbag clock spring can result. (5) Remove clinch bolt holding steering column coupling to steering gear shaft (Fig. 1). (6) Remove steering column coupling from telescoping steering gear shaft. (7) Hoist and support vehicle on safety stands. (8) Position a drain pan under power steering pump and oil return hose coupling. (9) Using a hose pinch-off pliers (C-4390), pinch power steering oil return hose off between the crossmember coupling and the pump. (10) Loosen hose clamp at the crossmember coupling. (11) Disconnect return hose from metal tube. (12) While holding pressure relief valve nut on back of power steering pump, Remove flare nut holding high pressure hose to back of pump.
(13) Separate high pressure hose from pump. (14) Allow power steering fluid to drain into pan. (15) Remove bolts holding anti-lock brake sensor leads to crossmember. (16) Position anti-lock brake leads out of the way. (17) Disconnect stabilizer bar links from ends of stabilizer bar. Refer to Group 2, Suspension. (18) Disconnect lower ball joints from lower control arms. Refer to Group 2, Suspension. (19) Remove bolt holding rear engine mount to crossmember (Fig. 2). (20) Using paint or grease pencil, mark outline of crossmember on frame rails to aid installation. (21) Support crossmember on suitable lifting device (Fig. 4). (22) Remove bolts holding crossmember to front frame rails (Fig. 3). (23) Remove crossmember from vehicle (Fig. 4).
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Fig. 4 Crossmember
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REMOVAL AND INSTALLATION (Continued)
(7) Connect lower ball joints to lower control arms. Refer to Group 2, Suspension. (8) Connect stabilizer bar links to ends of stabilizer bar. Refer to Group 2, Suspension. (9) Install bolts to hold anti-lock brake sensor leads to crossmember. (10) Install high pressure hose to pump. (11) Connect return hose to metal tube. (12) Tighten hose clamp at the crossmember coupling. (13) Remove pinch-off pliers. (14) Position steering so front wheels are straight ahead. (15) Install steering column coupling to telescoping steering gear shaft. (16) Install clinch bolt to hold steering column coupling to steering gear shaft. (17) Install knee blocker reinforcement. Refer to Group 8E, Instrument Panel and Systems. (18) Install steering column lower cover from instrument panel. Refer to Group 8E, Instrument Panel and Systems. (19) Connect battery negative cable.
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(2) Insert lower half of bushing into square hole in crossmember. (3) Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. (4) Squeeze bushing halves together to ensure they are properly mated. (5) Lift crossmember upward to close gap between the bushing and frame. (6) Verify that lower bushing is fully seated into crossmember and upper bushing. (7) Install bolt to hold bushing and crossmember to frame rail hand tight. (8) Align crossmember to reference marks on frame rails. (9) Tighten crossmember to frame rails attaching bolts to 163 Nm (120 ft. lbs.) torque.
VEHICLE PREPARATION Position the vehicle on a frame alignment rack, refer to instructions provided with equipment being used. Adjust the vehicle PLP heights to the specified dimension above the work surface (datum line). Vertical dimensions can be taken from the datum line to the locations indicated were applicable. Refer to (Fig. 5), (Fig. 6), (Fig. 7), (Fig. 8), (Fig. 9), (Fig. 10) and (Fig. 11) for proper dimensions.
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INDEX
page REMOVAL AND INSTALLATION FRONT TOW HOOK BRACKET . . . . . . . . . . . . . 1 REAR TOW HOOK BRACKET page .............. 1
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FUEL SYSTEM
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FUEL SYSTEM
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INDEX
page GENERAL INFORMATION CRUISING RANGE . . . . . . . . . . E-85 GENERAL INFORMATION ETHANOL FUEL (E-85) . . . . . . FUEL REQUIREMENTS . . . . . . FUEL REQUIREMENTS . . . . . . GASOLINE/OXYGENATE BLENDS INTRODUCTION . . . . . . . . . . . . . PCM REPLACEMENT . . . . . . . . . REPLACEMENT PARTS . . . . . . . . STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . . . . . . 2 1 1 3 2
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FUEL REQUIREMENTS
Your vehicle was designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline. Use unleaded gasolines having a minimum posted octane of 87. If your vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful. However; continued heavy knock at high speeds can cause damage and should be reported to your dealer immediately. Engine damage as a result of heavy knock operation may not be covered by the new vehicle warranty. In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended. Using gasolines that have these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle.
PCM REPLACEMENT
USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
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GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with materials that contain oxygen such as alcohol, MTBE (Methyl Tertiary Butyl Ether) and ETBE (Ethyl Tertiary Butyl Ether). Oxygenates are required in some areas of the country during winter months to reduce carbon monoxide emissions. The type and amount of oxygenate used in the blend is important. The following are generally used in gasoline blends: Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle. MTBE/ETBE - Gasoline and MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline and ETBE (Ethyl Tertiary Butyl Ether) are blends of gasoline and up to 17 percent ETBE. Gasoline blended with MTBE or ETBE may be used in your vehicle. Methanol - Methanol (Methyl or Wood Alcohol) is used in a variety of concentrations blended with unleaded gasoline. You may encounter fuels containing 3 percent or more methanol along with other alcohols called cosolvents. DO NOT USE GASOLINES CONTAINING METHANOL. Use of methanol/gasoline blends may result in starting and driveability problems and damage critical fuel system components. Problems that are the result of using methanol/ gasoline blends are not the responsibility of Chrysler Corporation and may not be covered by the vehicle warranty. Reformulated Gasoline Many areas of the country are requiring the use of cleaner-burning fuel referred to as Reformulated Gasoline. Reformulated gasolines are specially blended to reduce vehicle emissions and improve air quality. Chrysler Corporation strongly supports the use of reformulated gasolines whenever available. Although your vehicle was designed to provide optimum performance and lowest emissions operating on high quality unleaded gasoline, it will perform equally well and produce even lower emissions when operating on reformulated gasoline. Materials Added to Fuel Indiscriminate use of fuel system cleaning agents should be avoided. Many of these materials intended for gum and varnish removal may contain active solvents of similar ingredients that can be harmful to fuel system gasket and diaphragm materials.
FUEL REQUIREMENTS
Your vehicle will operate on both unleaded gasoline with an octane rating of 87, or E-85 fuel, or any mixture of these two. For best results, a refueling pattern that alternates between E-85 and unleaded gasoline should be avoided. When you do switch fuels, it is recommended that you do not switch when the fuel gauge indicates less than 1/4 full you do not add less than 5 gallons when refueling you operate the vehicle immediately after refueling for a period of at least 5 minutes Observing these precautions will avoid possible hard starting and/or significant deterioration in drivability during warm up. NOTE: When the ambient temperature is above 90F, you may experience hard starting and rough idle following start up even if the above recommendations are followed.
STARTING
The characteristics of E-85 fuel make it unsuitable for use when ambient temperatures fall below 0F. In the range of 0F to 32F, you may experience an increase in the time it takes for your engine to start, and a deterioration in drivability (sags and/or hesitations) until the engine is fully warmed up.
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FUEL SYSTEM
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CRUISING RANGE
Because E-85 fuel contains less energy per gallon than gasoline, you will experience an increase in fuel consumption. You can expect your MPG and your driving range to decrease by about 30% compared to gasoline operation.
Always be sure that your vehicle is serviced with correct ethanol compatible parts. CAUTION: Replacing fuel system components with non-ethanol compatible components can damage your vehicle and may void the warranty.
REPLACEMENT PARTS
Many components in your Flexible Fuel Vehicle (FFV) are designed to be compatible with ethanol.
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Fuel pressure regulator Fuel gauge sending unit Fuel supply line connection The inlet strainer, fuel pressure regulator and fuel level sensor are the only serviceable items. If the fuel pump or electrical wiring harness requires service, replace the fuel pump module.
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DESCRIPTION AND OPERATION (Continued)
check valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump relay provides voltage to the fuel pump. The fuel pump has a maximum deadheaded pressure output of approximately 635 kPa (95 psi). The regulator adjusts fuel system pressure to approximately 338 kPa (49 psi).
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FUEL PUMP ELECTRICAL CONTROL Voltage to operate the electric pump is supplied through the fuel pump relay. For an electrical operational description of the fuel pump refer to fuel Pump RelayPCM Output. ELECTRICAL PUMP REPLACEMENT The electric fuel pump is not serviceable. If the fuel pump or electrical wiring harness needs replacement, the complete fuel pump module must be replaced. Perform the Fuel System Pressure Release procedure before servicing the fuel pump.
FUEL TANK
The fuel tanks of all Chrysler Motors built vehicles are equipped with fuel and vapor controls that allow the vehicle to pass a full 360 rollover without fuel leakage. Front Wheel Drive fuel delivery systems contain a fuel tank rollover valve. The valve is mounted on top of the fuel tank. The valve functions as a tank pressure control valve while the vehicle is upright, but contains a check valve that prevents fuel from escaping from the fuel tank when the vehicle is turned over. The fuel filler cap acts as a pressure/vacuum relief valve. When air pressure inside the fuel tank gets too high or too low, the fuel filler cap opens to relieve the difference in pressure. An evaporation control system restricts fuel evaporation into the atmosphere and reduces unburned
FUEL INJECTORS
The fuel injectors are 12 ohm electrical solenoids (Fig. 2). The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The injectors are positioned in the intake manifold. Fuel injectors are not interchangeable between engines.
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QUICK-CONNECT FITTINGS
Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Refer to the Removal/Installation section for more information. CAUTION: The interior components (o-rings, spacers) of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable O-ring seals (Fig. 4). CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quickconnect fittings or fuel tubes. Replace the complete fuel tube/quick-connect fitting assembly. The quick-connect fitting consists of the O-rings, retainer and casing (Fig. 4). When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the O-rings seal the tube.
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DIAGNOSIS AND TESTING (Continued)
FUEL SYSTEM
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FUEL SYSTEM
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DIAGNOSIS AND TESTING (Continued)
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FUEL INJECTORS
For fuel injector diagnosis, refer to the Fuel Injector Diagnosis charts. For poor fuel economy diagnosis or engine miss, also refer to Transmission Driveplate in this section.
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FUEL SYSTEM
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FUEL SYSTEM
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CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail. Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. (5) Unplug connector from any injector. (6) Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. (7) Connect the other end of the jumper wire to the positive side of the battery. (8) Connect one end of a second jumper wire to the remaining injector terminal. CAUTION: Supplying power to an injector for more than 4 seconds will permantely damage the injector. Do not leave the injector connected to power for more than 4 seconds.
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FUEL SYSTEM
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INSTALLATION
CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quickconnect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. (1) Using a clean lint free cloth, clean the fuel tube nipple and retainer. (2) Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. (3) Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. (4) The plastic quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed (Fig. 12). Do not rely upon the audible click to confirm a secure connection.
QUICK-CONNECT FITTINGS
REMOVAL When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE. (1) Disconnect negative cable from battery. (2) Perform Fuel Pressure Release Procedure. Refer to the Fuel Pressure Release Procedure in this section. (3) Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL (1) Remove fuel filler cap and perform Fuel System Pressure Release procedure. (2) Disconnect negative cable from battery. (3) Insert fuel siphon hose into fuel filler neck and push it into the tank. (4) Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container. (5) Raise vehicle on hoist. (6) Use a transmission jack to support the fuel tank. Remove bolts from fuel tank straps. Lower tank slightly. (7) Clean area around fuel tank module and tank to keep dirt and foreign material out of tank. (8) Disconnect fuel lines from fuel pump module by depressing quick connect retainers with thumb and fore finger (Fig. 14).
REMOVAL (1) Perform fuel system pressure release. (2) Disconnect quick-connect fittings from fuel pump module and chassis fuel supply tube. Refer to Quick-Connect Fittings in this section. (3) Remove filter retaining screw (Fig. 13) and remove filter from tank. INSTALLATION (1) Install fuel filter to tank. (2) The fuel supply (to filter) tube, return tube (to pump module) and fuel supply (to chassis fuel line) are permanently attached the fuel filter. The ends of the fuel supply and return tubes have different size quick-connect fittings. (3) Apply a light coating of clean 30 weight engine oil to the fuel filter nipples. Install fuel tubes. Refer to Fuel Tubes and Quick-Connect Fittings in this section.
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FUEL SYSTEM
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INSTALLATION (1) Wipe seal area of tank clean and place a new O-ring seal in position on pump. (2) Position fuel pump in tank with locknut. (3) Tighten locknut to 53 Nm (43 ft. lbs.). (4) Connect fuel lines. (5) Plug in electrical connector. Slide connector lock into position. (6) Raise fuel tank, install bolts into fuel tank straps and tighten. (7) Lower vehicle on hoist. (8) Connect negative cable from battery. (9) Fill fuel tank. Check for leaks. (10) Install fuel filler cap.
REMOVAL (1) Spread tangs on pressure regulator retainer (Fig. 18). (2) Pry fuel pressure regulator out of housing. (3) Ensure both upper and lower O-rings were removed with regulator. INSTALLATION (1) Lightly lubricate the O-rings with clean engine oil and place them into opening in pump module (Fig. 19). (2) Push regulator into opening in pump module.
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REMOVAL AND INSTALLATION (Continued)
(3) Fold tangs on regulator retainer over tabs on housing.
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reservoir body lock over the locking tangs on the strainer. (4) Install fuel pump module. Refer to Fuel Pump Module Installation in this section.
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FUEL SYSTEM
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INSTALLATION (1) Insert level sensor wires into bottom of opening in module. (2) Wrap wires into groove in back of level sensor (Fig. 27).
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REMOVAL AND INSTALLATION (Continued)
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(7) Disconnect fuel supply lines from the steel supply line. The fuel pump module electrical connector has a retainer that locks it in place. (8) Slide fuel pump module electrical connector lock to unlock (Fig. 29).
FUEL TANK
Fig. 29 Fuel Line Retainers and Pump Connector Lock
(9) Push down on connector retainer (Fig. 30) and pull connector off module.
Fuel Tank
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
REMOVAL (1) Disconnect negative cable from battery. (2) Remove fuel filler cap and perform Fuel System Pressure Release procedure. (3) Insert fuel siphon hose into fuel filler neck and push it into the tank. (4) Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container. (5) Raise vehicle on hoist. (6) Disconnect both the fuel fill and fuel vent rubber hoses at the fuel tank.
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FUEL SYSTEM
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REMOVAL AND INSTALLATION (Continued)
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(10) With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
INSTALLATION (1) Ensure injector holes are clean. Replace O-rings if damaged. (2) Lubricate injector O-rings with a drop of clean engine oil to ease installation.
REMOVAL (1) Perform the Fuel Pressure Release Procedure. (2) Disconnect negative cable from battery.
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FUEL SYSTEM
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REMOVAL AND INSTALLATION (Continued)
(10) Remove air intake plenum to intake manifold mounting fasteners (Fig. 41). (11) Remove ignition coil.
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(5) Install fuel rail attaching bolts. Tighten bolts to 13 Nm (115 in. lbs.) torque. (6) Install fuel supply and return tube holddown bolt and the vacuum crossover tube holddown bolt. Tighten bolts to 10 Nm (95 in. lbs.) torque. (7) Connect fuel injector wiring harness to engine wiring harness. (8) Remove covering from lower intake manifold and clean surface. (9) Place intake manifold gaskets with beaded sealer upon lower manifold. Put air intake in place. Install ignition coil. Install attaching fasteners and tighten to 13 Nm (115 in. lbs.) torque. (10) Connect fuel line to fuel rail. (11) Connect vacuum harness to air intake plenum. (12) Connect coolant temperature sensor electrical connector to sensor. (13) Connect PCV and brake booster supply hose to intake plenum. (14) Connect idle air control motor and Throttle Position Sensor (TPS) electrical connectors. (15) Connect vacuum vapor harness to throttle body. (16) Install throttle cable. (17) Install air inlet resonator. (18) Connect negative cable to battery. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. (19) With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
INSTALLATION (1) Ensure injectors are seated into the receiver cup of fuel rail with lock ring in place. (2) Make sure the injector holes in the manifold are clean. (3) To ease installation, lubricate injector O-ring with a drop of clean engine oil. (4) Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports.
REMOVAL (1) Perform fuel system pressure release procedure. (2) Disconnect negative cable from battery. (3) Remove intake manifold cover. (4) Remove air inlet resonator (Fig. 36). (5) Remove throttle cable and speed control cable (if equipped) (Fig. 43) from throttle lever and bracket.
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FUEL SYSTEM
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Fig. 46 EGR Tube3.3L/3.8 Fig. 44 Electrical and Vacuum Connection to Throttle Body
(7) Remove vacuum hose harness from throttle body and intake manifold (Fig. 45). (8) Remove EGR tube to intake manifold flange bolts (Fig. 46). (9) Remove cylinder head to intake plenum strut. (10) Disconnect electrical connector from the MAP sensor (Fig. 47) (11) Remove engine mounted ground strap. (12) Remove the fuel hose quick connect fitting from the chassis tube (Fig. 48). Refer to Fuel Hoses, Clamps and Quick Connect Fittings in this Section. WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.
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REMOVAL AND INSTALLATION (Continued)
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(15) Remove intake mounting manifold bolts and rotate manifold back over rear valve cover (Fig. 50).
INSTALLATION (1) Ensure injector holes are clean. Replace O-rings if damaged. (2) Lubricate injector O-rings with a drop of clean engine oil to ease installation. (3) Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports.
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FUEL SYSTEM
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FUEL INJECTOR2.4L
Fig. 53 Fuel Rail Removal
(4) Install the fuel rail mounting bolts. Tighten bolts to 22 Nm (200 in. lbs.) torque (Fig. 51). (5) Install fuel tube retaining bracket screw. Tighten screw to 4 Nm (35 in. lbs.) torque. (6) Connect electrical connectors to camshaft position sensor and engine coolant temperature sensor. (7) Remove covering on lower intake manifold and clean surface. (8) Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight. (9) Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts (do not tighten.) The fuel rail must be removed first. Refer to Fuel Injector Rail Removal in this section.
REMOVAL (1) Disconnect injector wiring connector from injector. (2) Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 54). (3) Rotate injector and pull injector out of fuel rail. The clip will stay on the injector. (4) Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on the injector tip to prevent damage. Replace the injector clip if it is damaged. (5) Repeat for remaining injectors.
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REMOVAL AND INSTALLATION (Continued)
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FUEL INJECTORS3.0L
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 330 KPA (48 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL INJECTORS.
REMOVAL (1) Perform the Fuel Pressure Release Procedure. (2) Disconnect negative cable from battery. (3) The fuel rail must be removed first to service the injectors. Refer to Fuel Injector Rail Assembly Removal in this section. (4) Label each injector connector with its cylinder number. Disconnect electrical connector from injector. (5) Position fuel rail assembly so that the fuel injectors are easily accessible. (6) Remove injector clip from fuel rail and injector (Fig. 54). (7) Pull injector straight out of fuel rail receiver cup (Fig. 55). (8) Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is to be reused, a protective cap must be installed on the injector tip to prevent damage. (9) Repeat procedure for remaining injectors. INSTALLATION (1) Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Being careful not to damage O-ring, install injector nozzle end into fuel rail receiver cap. (3) Install injector clip by sliding open end into top slot of the injector. The edge of the receiver cup will slide into the side slots of clip (Fig. 55) (4) Repeat steps for remaining injectors. (5) Install fuel rail assembly. Refer to Fuel Rail Assembly Installation in this section. (6) Connect electrical connectors to injectors in correct order. (7) Connect negative battery cable.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. (8) With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
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FUEL SYSTEM
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FUEL INJECTOR3.3/3.8L
The fuel rail must be removed first. Refer to Fuel Injector Rail Assembly Removal in this section.
REMOVAL (1) Disconnect injector wiring connector from injector. (2) Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 54). (3) Rotate injector and pull injector out of fuel rail. The clip will stay on the injector. (4) Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on the injector tip to prevent damage. Replace the injector clip if it is damaged. (5) Repeat for remaining injectors. INSTALLATION (1) Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. (2) Install injector clip by sliding open end into the top slot of the injector. The edge of the receiver cup will slide into the side slots of clip (Fig. 56). (3) Install injector top end into fuel rail receiver cap. Be careful not to damage O-ring during installation (Fig. 56). (4) Repeat steps for remaining injectors. (5) Connect fuel injector wiring.
REMOVAL (1) Working from the engine compartment, remove the throttle control shield. (2) Hold the throttle body throttle lever in the wide open position. Remove the throttle cable from the throttle body cam. (3) From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft (Fig. 57) and (Fig. 58).
Fig. 58 Accelerator Pedal and Throttle CableRear View Fig. 56 Servicing Fuel InjectorTypical
ACCELERATOR PEDAL
CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing.
(4) Working from the engine compartment, remove nuts from accelerator pedal attaching studs (Fig. 57). Remove assembly from vehicle.
INSTALLATION (1) Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 Nm (105 in. lbs.) torque.
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REMOVAL AND INSTALLATION (Continued)
(2) From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the upper end of the pedal shaft. (3) From the engine compartment, hold the throttle body lever in the wide open position and install the throttle cable. Install the throttle control shield.
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THROTTLE CABLE
CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing.
REMOVAL (1) Working from the engine compartment, hold the throttle body throttle lever in the wide open position. (2) Remove the throttle cable from the throttle body cam (Fig. 59), (Fig. 60) and (Fig. 61). (3) From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft (Fig. 57). (4) Remove retainer clip from throttle cable and grommet at dash panel (Fig. 58). (5) From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. (6) Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simultaneously. Then gently pull the throttle cable from throttle bracket.
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FUEL SYSTEM
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SPECIFICATIONS TORQUE
DESCRIPTION TORQUE Fuel Pump Module Locknut . . . . .58 Nm (43 ft. lbs.) Fuel Tank Strap Bolts . . . . . . . . .54 Nm (40 ft. lbs.) Fuel Rail Bolts2.4L . . . . . . . .22 Nm (200 in. lbs.) Fuel Rail Bolts3.0L. . . . . . . . .13 Nm (115 in. lbs.) Fuel Rail Bolts3.3/3.8L. . . . . . .10 Nm (95 in. lbs.) Fuel Tube Holddown Bolts3.0L . . . . . . . . . .22 Nm (200 in. lbs.) Fuel Tube Holddown Screw . . . . . .4 Nm (35 in. lbs.) Intake Manifold Bolts2.4L . . .22 Nm (200 in. lbs.) Intake Manifold Bolts3.0L . . .13 Nm (115 in. lbs.) Intake Manifold Bolts3.3/3.8L. . . . . . . . . . .28 Nm (250 in. lbs.) Accelerator Pedal to Dash Nuts . . . . . . . . . . .12 Nm (105 in. lbs.)
Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerance and refill procedure.
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FUEL SYSTEM
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30 30
41 33 33 33 42 44 33 33 33 32 35 44 43 43 36 44 42 42 37 42 45 41 38 46 39 32 43 46 46 39
. 40 . 46 . 40 . 41 . 59 . . . . 61 61 61 61
. 60 . . . . . . . . . . 62 62 47 52 55 70 64 68 68 69
. 70 . 71 . . . . . 71 64 65 72 70
. 66 . 66 . 67 . 66
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FUEL SYSTEM
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SPECIFICATIONS (Continued)
THROTTLE BODY . . . . . . . . . . . THROTTLE POSITION SENSOR UPSTREAM OXYGEN SENSOR . SPECIFICATIONS TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 . . . . . . . . . . . . 65 . . . . . . . . . . . . 68 . . . . . . . . . . . . 72 programming. Input from the oxygen (O2S) sensor is not monitored during OPEN LOOP modes. During CLOSED LOOP modes the PCM does monitor the O2S sensor input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The multi-port fuel injection system has the following modes of operation: Ignition switch ON (zero RPM) Engine start-up Engine warm-up Cruise (Idle) Acceleration Deceleration Wide Open Throttle Ignition switch OFF The engine start-up (crank), engine warm-up, and wide open throttle modes are OPEN LOOP modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature are CLOSED LOOP modes. SPECIAL TOOLS FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
MODES OF OPERATION
As input signals to the PCM change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for Wide Open Throttle (WOT). There are several different modes of operation that determine how the PCM responds to the various input signals. There are two different areas of operation, OPEN LOOP and CLOSED LOOP. During OPEN LOOP modes the PCM receives input signals and responds according to preset PCM
IGNITION SWITCH ON (ZERO RPM) MODE When the multi-port fuel injection system is activated by the ignition switch, the following actions occur: The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. The PCM monitors the coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the key is in the ON position and the engine is not running (zero rpm), the Automatic Shutdown (ASD) relay and fuel pump relay are not energized. Therefore battery voltage is not supplied to the fuel pump, ignition coil, fuel injectors or oxygen sensor heating element. ENGINE START-UP MODE This is an OPEN LOOP mode. The following actions occur when the starter motor is engaged. If the PCM receives the camshaft position sensor and crankshaft position sensor signals, it energizes the ASD relay and fuel pump relay. These relays supply battery voltage to the fuel pump, fuel injectors,
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GENERAL INFORMATION (Continued)
ignition coil, and oxygen sensor heating element. If the PCM does not receive the camshaft position sensor and crankshaft position sensor signals within approximately one second, it de-energizes the ASD relay and fuel pump relay. The PCM energizes all injectors until it determines crankshaft position from the camshaft position sensor and crankshaft position sensor signals. The PCM determines crankshaft position within 1 engine revolution. After determining crankshaft position, the PCM begins energizing the injectors in sequence. The PCM adjusts injector pulse width and controls injector synchronization by turning the individual ground paths to the injectors On and Off. When the engine idles within 64 RPM of its target RPM, the PCM compares current MAP sensor value with the atmospheric pressure value received during the Ignition Switch On (zero RPM) mode. If the PCM does not detect a minimum difference between the two values, it sets a MAP diagnostic trouble code into memory. Once the ASD and fuel pump relays have been energized, the PCM: Determines injector pulse width based on engine coolant temperature, MAP and the number of engine revolutions since cranking was initiated. Monitors the engine coolant temperature sensor, camshaft position sensor, crankshaft position sensor, MAP sensor, and throttle position sensor to determine correct ignition timing.
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Engine coolant temperature Manifold absolute pressure Engine speed (crankshaft position sensor) Throttle position Exhaust gas oxygen content A/C control positions Battery voltage The PCM adjusts injector pulse width and controls injector synchronization by turning the individual ground paths to the injectors On and Off. The PCM adjusts engine idle speed and ignition timing. The PCM adjusts the air/fuel ratio according to the oxygen content in the exhaust gas.
ACCELERATION MODE This is a CLOSED LOOP mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased fuel demand. DECELERATION MODE This is a CLOSED LOOP mode. During deceleration the following inputs are received by the PCM: Engine coolant temperature Manifold absolute pressure Engine speed Throttle position Exhaust gas oxygen content A/C control positions Battery voltage The PCM may receive a closed throttle input from the Throttle Position Sensor (TPS) when it senses an abrupt decrease in manifold pressure. This indicates a hard deceleration. The PCM may reduce injector pulse width or the number of injectors firing per engine revolution. This helps maintain better control of the air/fuel mixture (as sensed through the O2S sensor). WIDE OPEN THROTTLE (WOT) MODE This is an OPEN LOOP mode. During WOT operation, the following inputs are received by the PCM: Engine coolant temperature Manifold absolute pressure Engine speed Throttle position When the PCM senses WOT condition through the Throttle Position Sensor (TPS) it will: De-energize the air conditioning relay. This disables the air conditioning system. The exhaust gas oxygen content input is not accepted by the PCM during WOT operation. The PCM will adjust injector pulse width to supply a predetermined amount of additional fuel.
ENGINE WARM-UP MODE This is a OPEN LOOP mode. The following inputs are received by the PCM: Engine coolant temperature Manifold absolute pressure Engine speed (crankshaft position sensor) Throttle position A/C switch Battery voltage The PCM adjusts injector pulse width and controls injector synchronization by turning the individual ground paths to the injectors On and Off. The PCM adjusts ignition timing and engine idle speed. Engine idle speed is adjusted through the idle air control motor. CRUISE OR IDLE MODE This is a CLOSED LOOP mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased fuel demand. When the engine is at operating temperature this is a CLOSED LOOP mode. During cruising speed the following inputs are received by the PCM:
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FUEL SYSTEM
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CCD BUS
Various controllers and modules exchange information through a communications port called the CCD Bus. The PCM transmits the malfunction indicator (check engine) lamp On/Off signal, engine RPM and vehicle load information on the CCD Bus.
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DESCRIPTION AND OPERATION (Continued)
Engine coolant temperature Engine speed (crankshaft position sensor) Intake air temperature (2.4L only) Manifold absolute pressure Throttle position Transaxle gear selection (park/neutral switch) The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. Air conditioning select switch head pressure Brake switch Engine coolant temperature Engine speed (crankshaft position sensor) Manifold absolute pressure Throttle position Transaxle gear selection (park/neutral switch) Vehicle distance (speed) The Automatic Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor (distributor pick-up signal 3.0L) and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute pressure sensor, throttle position sensor and engine coolant temperature sensor.
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3.3/3.8L The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives two camshaft pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder one are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number two crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder four crankshaft timing marks follow. One camshaft pulse after the three pulses indicates cylinder five. The two camshaft pulses after cylinder 5 signals cylinder six (Fig. 3). The PCM can synchronize on cylinders 1 or 4.
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DESCRIPTION AND OPERATION (Continued)
FUEL SYSTEM
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FUEL SYSTEM
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DESCRIPTION AND OPERATION (Continued)
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FUEL SYSTEM
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DESCRIPTION AND OPERATION (Continued)
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FUEL SYSTEM
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DESCRIPTION AND OPERATION (Continued)
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The speed and distance signals, along with a closed throttle signal from the TPS, determine if a closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired MAP value. Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine speed.
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FUEL SYSTEM
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DESCRIPTION AND OPERATION (Continued)
(brake, park/neutral, air conditioning). Deceleration die out is also prevented by increasing airflow when the throttle is closed quickly after a driving (speed) condition.
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EVAP canister to the throttle body. The PCM operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold.
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DESCRIPTION AND OPERATION (Continued)
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High tension leads route to each cylinder from the coil. The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the other cylinder fires on the exhaust stroke. The PCM determines which of the coils to charge and fire at the correct time.
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FUEL SYSTEM
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DESCRIPTION AND OPERATION (Continued)
ances the two solenoids to maintain the set speed. Refer to Group 8H for speed control information.
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TACHOMETERPCM OUTPUT
The PCM supplies engine RPM to the instrument panel tachometer through the CCD Bus. The CCD Bus is a communications port. Various modules use the CCD Bus to exchange information. Refer to Group 8E for more information.
THROTTLE BODY
On all engine assemblies (2.4, 3.0, and 3.3/3.8L) the throttle bodys are located on the left side of the intake manifold plenum. The throttle body houses the throttle position sensor and the idle air control motor. Air flow through the throttle body is controlled by a cable operated throttle blade located in the base of the throttle body (Fig. 43) or (Fig. 44) or (Fig. 45).
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DIAGNOSIS AND TESTING (Continued)
FUEL SYSTEM
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FUEL SYSTEM
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DIAGNOSIS AND TESTING (Continued)
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FUEL SYSTEM
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DIAGNOSIS AND TESTING (Continued)
(5) Verify that the electrical connector is attached to the MAP sensor (Fig. 64).
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Fig. 66 Engine Ground Strap Fig. 64 Map Sensor Electrical and Vacuum Connections
(6) Check generator wiring connections. Ensure the accessory drive belt has proper tension. (7) Verify that hoses are securely attached to the evaporative canister (Fig. 65).
Fig. 68 Coolant Temperature Sensor Electrical Connections and Vacuum Hose Connections at the Air Intake Plenum
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FUEL SYSTEM
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DIAGNOSIS AND TESTING (Continued)
terminals. Verify the connectors are fully inserted into the socket of the PCM (Fig. 74). Ensure that wires are not stretched or pulled out of the connector.
FUEL SYSTEM
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(2) Check direct ignition system (DIS) coil electrical connection for damage and a complete connection to the coil pack (Fig. 75).
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FUEL SYSTEM
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Fig. 78 Knock Sensor and Oil Pressure Sending Unit Electrical Connection
(8) Verify the electrical connector is attached to the Proportional purge solenoid (Fig. 79) and not damaged. (9) Verify the vacuum connection at the Proportional purge solenoid is secure and not leaking (Fig. 79).
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DIAGNOSIS AND TESTING (Continued)
(13) Check the vacuum connections at the throttle body and intake plenum (Fig. 81).
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Fig. 83 Automatic Transaxle Electrical Connections Fig. 81 Throttle Body Vacuum Connections
(14) Ensure the idle air control motor and TPS electrical connectors are fully seated and not damaged (Fig. 82). (16) Inspect the PCV system connections for damage (Fig. 84).
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FUEL SYSTEM
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DIAGNOSIS AND TESTING (Continued)
inserted into the PDC (Fig. 90). A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC.
FUEL SYSTEM
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FUEL SYSTEM
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TESTING The following procedure applies to the ASD and fuel pump relays. (1) Remove relay from connector before testing. (2) With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 5 ohms. (3) Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. (4) Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. (5) Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. (6) Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST.
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DIAGNOSIS AND TESTING (Continued)
PCM. If OK, replace MAP sensor. If not OK, repair or replace the wire harness as required.
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KNOCK SENSOR
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing, cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
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FUEL SYSTEM
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DIAGNOSIS AND TESTING (Continued)
IDLE SPECIFICATIONS3.0L ENGINE
Odometer Reading Idle RPM Below 1000 Miles . . . . . . . . . . . . . . . . .560-910 RPM Above 1000 Miles . . . . . . . . . . . . . . . . .610-910 RPM
FUEL SYSTEM
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FUEL SYSTEM
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INSTALLATION (1) Reverse procedure for installation. Tighten throttle body mounting nuts to 25 Nm (225 in. lbs.) torque.
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REMOVAL AND INSTALLATION (Continued)
FUEL SYSTEM
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REMOVAL (1) Disconnect negative cable from battery. (2) Remove electrical connector from idle air control motor. (3) Remove idle air control motor mounting screws (Fig. 112). (4) Remove motor from throttle body. Ensure the O-ring is removed with the motor.
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FUEL SYSTEM
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REMOVAL AND INSTALLATION (Continued)
FUEL SYSTEM
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FUEL SYSTEM
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INSTALLATION (1) Connect 2 40-Way electrical connectors to PCM (Fig. 120). (2) Install PCM. Tighten mounting screws. (3) Install PDC bracket. (4) Install battery.
REMOVAL (1) Raise and support vehicle. (2) Unplug oxygen sensor electrical connector. (3) Use a socket such as Snap-On YA8875 or equivalent to remove sensor.
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REMOVAL AND INSTALLATION (Continued)
FUEL SYSTEM
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Fig. 123 Upstream Heated Oxygen Sensor3.0L Fig. 125 Oxygen Sensor Grommet Cover
(3) Push locking tab back and unplug oxygen sensor electrical connector (Fig. 126).
INSTALLATION (1) Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
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FUEL SYSTEM
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INSTALLATION (1) Reverse removal procedure to install a new sensor. New sensors are packaged with compound on the threads and no additional compound is required. The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
KNOCK SENSOR
For removal/installation procedures refer to Group 8D- Ignition System, Service Procedures.
INSTALLATION (1) Install a new element in housing. (2) Position left side of housing. (3) Snap clamps into place.
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REMOVAL AND INSTALLATION (Continued)
FUEL SYSTEM
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INSTALLATION (1) Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. (2) Attach electrical connector to sensor. (3) Fill cooling system. Refer to Group 7, Cooling System.
REMOVAL (1) With the engine cold, drain coolant until level drops below cylinder head. Refer to Group 7, Cooling System. (2) Disconnect coolant sensor electrical connector. (3) Remove coolant sensor. INSTALLATION (1) Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. (2) Attach electrical connector to sensor. (3) Fill cooling system. Refer to Group 7, Cooling System.
REMOVAL (1) With the engine cold, drain coolant until level drops below cylinder head. Refer to Group 7, Cooling System. (2) Disconnect coolant sensor electrical connector. (3) Remove coolant sensor.
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FUEL SYSTEM
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Extractor C4334
SPECIFICATIONS TORQUE
DESCRIPTION TORQUE Generator Brkt. to Intake Manifold Bolts3.3/3.8L.54 Nm (40 ft. lbs.) Coolant Sensor2.4L . . . . . . . . . .7 Nm (62 in. lbs.) Coolant Sensor3.0L . . . . . . . . . .7 Nm (62 in. lbs.) Coolant Sensor3.3/3.8L. . . . . . . .7 Nm (62 in. lbs.) Cly. Head to Intake Manifold Strut Bolts3.3/3.8L. . . . . . . . 54 Nm (40 ft. lbs.) EGR Tube to Intake Manifold Screws . . . . . . . . . . . . . . . . . .22 Nm (200 in. lbs.) Idle Air Control Motor . . . . . . . . . .2 Nm (18 in. lbs.) Ignition Coil Fasteners . . . . . . .12 Nm (105 in. lbs.) Intake Air Temperature Sensor . .28 Nm (20 ft. lbs.) MAP Sensor2.4L . . . . . . . . . . . .4 Nm (35 in. lbs.) MAP Sensor3.0L . . . . . . . . . . . .4 Nm (35 in. lbs.) MAP Sensor3.3/3.8L. . . . . . . . . .4 Nm (35 in. lbs.) Upstream O2S . . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Downstream O2S . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Throttle Body Bolts . . . . . . . . . .26 Nm (225 in. lbs.)
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SPECIAL TOOLS (Continued)
FUEL SYSTEM
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Metering Orifice
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FUEL DELIVERY SYSTEM2.0L ENGINE . . . . 28 FUEL DELIVERY SYSTEM2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FUEL INJECTION SYSTEM2.0L ENGINE . . . 32
GENERAL INFORMATION
INDEX
page GENERAL INFORMATION FUEL REQUIREMENTS2.0L ENGINE . . . . . . . 2 FUEL REQUIREMENTS2.5L DIESEL . . . . . . . . 2 page GASOLINE/OXYGENATE BLENDS . . . . . . . . . . . 2 INTRODUCTION2.0L ENGINE . . . . . . . . . . . . . 2 INTRODUCTION2.5L DIESEL . . . . . . . . . . . . . 1
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INTRODUCTION2.0L ENGINE
Refer to the introduction in group 14 for the 2.4/ 3.0/3.3/3.8l engines.
GASOLINE/OXYGENATE BLENDS
Fig. 2 PCM Location
Refer to Gasoline/Oxygenate blends for the 2.4/3.0/ 3.3/3.8l engines in group 14.
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7 4 4 8 8 5 6 5 3 4 3 6 7 3 7 8 11 12 12 12 12 13 13
HIGHPRESSURE FUEL LEAKS. INSPECT FOR HIGHPRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD (Fig. 1). HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN.
FUEL TANK
The fuel tank and tank mounting used with the diesel powered engine is the same as used with gasoline powered models, although the fuel tank module is different. The fuel tank contains the fuel tank module and two rollover valves. Two fuel lines are routed to the fuel tank module. One line is used for fuel supply to the fuel filter/water separator. The other is used to return excess fuel back to the fuel tank. The fuel tank module contains the fuel gauge electrical sending unit. An electrical fuel pump is not used with the diesel engine.
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FUEL INJECTORS
Fuel drain tubes (Fig. 6) are used to route excess fuel back to the overflow valve (Fig. 4) at the rear of the injection pump. This excess fuel is then returned to the fuel tank through the fuel return line.
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FUEL HEATER
The fuel heater is used to prevent diesel fuel from waxing during cold weather operation. The fuel heater is located in the bottom plastic bowl of the fuel filter/water separator (Fig. 10).
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and Intake Manifold for information.
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the relay within the PDC, refer to label on PDC cover. (4) Verify that the electrical connections for the fuel heater relay are clean and free of corrosion. This relay is located in the PDC. For the location of the relay within the PDC, refer to label on PDC cover. (5) Be sure the electrical connectors at the ends of the glow plugs (Fig. 13) are tight and free of corrosion.
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incorrectly routed wires and hoses should be made before attempting to diagnose or service the diesel fuel injection system. A visual check will help find these conditions. It also saves unnecessary test and diagnostic time. A thorough visual inspection of the fuel injection system includes the following checks: (1) Be sure that the battery connections are tight and not corroded. (2) Be sure that the 68 way connector is fully engaged with the PCM (Fig. 12).
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WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and Intake Manifold for information.
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FUEL INJECTION PUMP BLEEDING (1) If the fuel injection pump has been replaced, air should be bled at the overflow valve before attempting to start engine. (a) Loosen the overflow valve (Fig. 25) at the rear of the injection pump. (b) Place a towel below the valve.
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(3) Loosen 2 clamps holding air cleaner housing halves together. (4) Remove left side of air cleaner housing. (5) Remove element from air cleaner housing.
REMOVAL
INSTALLATION (1) Install a new element in housing. (2) Position left side of housing. (3) Snap clamps into place. (4) Install hoses and clamps.
INSTALLATION (1) Place accelerator pedal assembly over studs protruding from floor pan. Tighten mounting nuts to 5 Nm (46 in. lbs.) torque. (2) Connect electrical connector. (3) Before starting the engine, operate the accelerator pedal to check for any binding.
DRAINING WATER FROM FILTER BOWL Moisture (water) collects at the bottom of the filter/ separator in a plastic bowl. Water entering the fuel injection pump can cause serious damage to the pump. Note that the bulb will be illuminated for approximately 2 seconds each time the key is initially placed in the ON position. This is done for a bulb check.
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FUEL HEATER
Fig. 29 Fuel Filter/Water Separator Location
WARNING: DO NOT ATTEMPT TO DRAIN WATER FROM THE FILTER/SEPARATOR WITH THE ENGINE HOT. (1) The bottom of the filter/separator bowl is equipped with a drain valve (Fig. 29). The drain valve is equipped with a fitting. Attach a piece of rubber hose to this fitting. This hose is to be used as a drain hose. (2) Place a drain pan under the drain hose. (3) With the engine not running, open the drain valve (unscrewdrain valve has right hand threads) from the filter/separator bowl. To gain access to this fitting, the two filtertomounting bracket nuts (Fig. 29) may have to be loosened a few turns. (4) Hold the drain open until clean fuel exits the drain. (5) After draining, close drain valve. (6) Remove rubber drain hose. (7) Dispose of mixture in drain pan according to applicable local or federal regulations. If the fuel heater element needs replacement, the plastic filter bowl assembly must be replaced. Refer to Fuel Filter/Water Separator for information.
FUEL FILTER REMOVAL (1) Drain all fuel and/or water from fuel filter/water separator assembly. Refer to the previous Draining Water From Filter Bowl. (2) Unplug the electrical connectors at bottom of plastic bowl. (3) Remove plastic bowl from bottom of fuel filter (unscrews). (4) Remove fuel filter from bottom of filter base (unscrews).
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INSTALLATION/ADJUSTING PUMP TIMING (1) Clean the mating surfaces of injection pump and timing gear cover. (2) Install a new injection pumptotiming gear cover gasket.
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FUEL INJECTORS
Four fuel injectors are used on each engine. Of these four, two different types are used. The fuel injector used on cylinder number one is equipped with a fuel injector sensor (Fig. 47). The other three fuel injectors are identical. Do not place the fuel injector equipped with the fuel injector sensor into any other location except the cylinder number one position.
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INSTALLATION (1) Clean the injector threads in cylinder head. (2) Install new copper washer (seal) to injector. (3) Install injector to engine. Tighten to 70 Nm (52 ft. lbs.) torque. (4) Install highpressure fuel lines. Refer to HighPressure Fuel Lines in this group for procedures. (5) Install fuel drain hoses (tubes) to each injector. Do not use clamps at fuel drain hoses. (6) Connect negative battery cable to battery. (7) Bleed the air from the highpressure lines. Refer to the Air Bleed Procedure section of this group.
FUEL TANK
REMOVAL (1) Disconnect negative cable from battery. (2) Insert fuel siphon hose into fuel filler neck and push it into the tank. (3) Drain fuel tank dry into holding tank or a properly labeled diesel safety container.
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Fuel Tank
(4) Raise vehicle on hoist. (5) Disconnect both the fuel fill and fuel vent rubber hoses at the fuel tank. (6) Disconnect fuel supply and return lines from the steel supply line (Fig. 51).
INSTALLATION (1) Position fuel tank on transmission jack. Connect fuel filler tube vent hose and replace clamp. (2) Raise tank into position and carefully work filler tube into tank. A light coating of clean engine oil on the tube end may be used to aid assembly. (3) Feed filler vent line thru frame rail. Careful not to cross lines. (4) Tighten strap bolts to 54 Nm (40 ft. lbs.) torque. Remove transmission jack.
CAUTION: Ensure straps are not twisted or bent before or after tightening strap nuts. (5) Connect module electrical connector. Place retainer in locked position. (6) Lubricate the fuel supply and return lines with clean 30 weight engine oil, install the quick connect
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INSTALLATION (1) Wipe seal area of tank clean and place a new O-ring seal in position on pump. (2) Position fuel reservoir module in tank with locknut. (3) Tighten locknut to 58 Nm (43 ft. lbs.). (4) Connect fuel lines. (5) Plug in electrical connector. Slide connector lock into position. (6) Raise fuel tank, install bolts into fuel tank straps and tighten. (7) Lower vehicle on hoist. (8) Connect negative cable from battery. (9) Fill fuel tank. Check for leaks. (10) Install fuel filler cap.
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HIGH-PRESSURE LINES
All highpressure fuel lines are of the same length and inside diameter. Correct highpressure fuel line usage and installation is critical to smooth engine operation. CAUTION: The highpressure fuel lines must be clamped securely in place in the holders. The lines cannot contact each other or other components. Do not attempt to weld highpressure fuel lines or to repair lines that are damaged. Only use the recommended lines when replacement of highpressure fuel line is necessary.
REMOVAL (1) Disconnect negative battery cable from battery. (2) Remove the necessary clamps (Fig. 58) holding the lines to the engine. (3) Clean the area around each fuel line connection. Disconnect each line at the top of each fuel injector (Fig. 59). (4) Disconnect each highpressure line fitting at each fuel injection pump delivery valve. (5) Very carefully remove each line from the engine. Note the position (firing order) of each line while removing. Do not bend the line while removing.
CAUTION: Be sure that the highpressure fuel lines are installed in the same order that they were removed. Prevent the injection pump delivery valve holders (Fig. 58) from turning when removing or installing highpressure lines from injection pump.
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IDLE SPEED
900 rpm 25 rpm with engine at normal operating temperature.
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. . . . . . .
. . . . . . .
. . . . . . .
. . . . . . .
. . . . . . .
. . . . . . .
. . . . . . .
28 28 28 28 28 28 28
. . 29 . . 29 . 29 . . . . . . . . 31 29 30 30
. . . . . . . 28 . . . . . . . 28 . . . . . . . 29 . . . . . . . 28 . . . . . . . 28
. . 29 . . . . . . . . 29 29 30 31
FUEL TANK
Refer to the Fuel Tank for the 2.4/3.0/3.3/3.8L engines in the Fuel Delivery System section of group 14 for more information.
FUEL INJECTORS
Refer to the Fuel Injectors for the 2.4/3.0/3.3/3.8L engines in the Fuel Delivery System section of group 14 for more information.
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FUEL INJECTORS
Fig. 5 Fuel Injector Retainer
REMOVAL (1) Disconnect negative cable from battery. (2) Release fuel system pressure. Refer to Fuel System Pressure Release procedure in this section. (3) Disconnect fuel supply tube from rail. Refer to Quick-Connect Fittings in the Fuel Delivery section of this group. (4) Disconnect electrical connectors from fuel injectors (Fig. 4). (5) Remove fuel rail mounting screws. (6) Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold. (7) Remove fuel injector retainer (Fig. 5). (8) Pull injector out of fuel rail. Replace fuel injector O-rings (Fig. 6). INSTALLATION (1) Apply a light coating of clean engine oil to the upper O-ring. (2) Install injector in cup on fuel rail. (3) Install retaining clip. (4) Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
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TORQUE SPECIFICATION
DESCRIPTION TORQUE Accelerator Pedal to Dash Nuts . . . . . . . . . . . . . . 12 Nm (105 in. lbs.) Fuel Pump Module Locknut . . . . 58 Nm (43 ft. lbs.) Fuel Tank Strap Bolts . . . . . . . . . 54 Nm (40 ft lbs.) Fuel Rail Bolts . . . . . . . . . . . . . 23 Nm (195 in. lbs.) Ignition Coil Mounting Bolts . . . 11 Nm (95 in. lbs.) Intake Manifold Bolts . . . . . . . . 11 Nm (95 in. lbs.) Throttle Control Shield . . . . . . . 5.6 Nm (50 in. lbs.)
ACCELERATOR PEDAL
Refer to the Accelerator Pedal for the 2.4/3.0/.3.3/ 3.8L engines under Removal and Installation in the Fuel Delivery section of group 14 for more information.
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32 32
. 34 . 36
35
. 34 . 33 . 36 . 36 . 34 . 35 . 33 . 36 . 36
33 33 33 35 33 33 33 35 35 33 35 35 35 33 35 36
. 35
. 39 . 40 . 40 . 40 . . . . 39 41 40 36
. 42
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Refer to the Electronic EGR Transducer for 2.4/3.0/ 3.3/3.8L engines under Description and Operation in the Fuel Injection System section of group 14 for more information.
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Fig. 17 Starter Motor and Ground Strap Fig. 20 Electronic EGR Transducer
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SPECIFICATIONS TORQUE
DESCRIPTION TORQUE Air Cleaner Wingnut . . . . . . . . . 1.5 Nm (15 in. lbs.) Air Cleaner Mount. Stud-To-Thrott. Body . . 10 Nm (90 in. lbs.) Crankshaft Position Sensor Mounting Bolts . . 8 Nm (70 in. lbs.) Engine Coolant Temperature Sensor . . . . . . 18 Nm (165 in. lbs.) IAC Motor-To-Throttle Body Bolts . . . . . . . . . 7 Nm (60 in. lbs.) MAP/IAT Sensor . . . . . . . . . . . . . 2 Nm (20 in. lbs.) MAP/IAT Sensor . . . . . . . . . . . . . 3 Nm (30 in. lbs.) Oxygen Sensor . . . . . . . . . . . . . . 28 Nm (20 ft. lbs.) Powertrain Control Module (PCM) Mounting Screws . . . . . 4 Nm (35 in. lbs.) Throttle Cable Cover . . . . . . . . 4.5 Nm (40 in. lbs.). Throttle Body Mounting Bolts . . . . . . . . . . . 23 Nm (200 in. lbs.) Throttle Position Sensor Mounting Screws . . . 2 Nm (20 in. lbs.) Vehicle Speed Sensor Mounting Bolt . . . . . . 2.2 Nm (20 in. lbs.)
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43
47 48 45 45 47 47 48 48 46 48 46 50 48 46 48 48 49 49 45 45 45 44 45
. . . . 53 . . . . 53 . . . . . . . . . .. . . . . . . . . . . . . 54 53 55 54 55 55
. . . . 56 . . . . 57
where, if possible, it will ignore the failed sensor, set a code related to the sensor, and operate the engine in a Limp Home mode. When the PCM is operating in a Limp Home mode, the Diesel Glow Plug lamp on the instrument panel will be constantly illuminated, and the engine will most likely have a noticeable loss of performance. An example of this would be an Accelerator Pedal Position Sensor failure, and in that situation, the engine would run at a constant 1100 RPM, regardless of the actual position of the pedal. This is the most extreme of the three Limp Home modes. In addition to indicating that the glow plugs are hot enough to start combustion, the Glow Plug Lamp is also used in the diagnosis of the PCM, and when
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If the PCM is put it on a vehicle without VTA the Glow Plug Lamp will start to blink and the vehicle will not start. The PCM cannot be flashed to remove the VTA.
POWER GROUND
Provides a common ground for power devices (solenoid and relay devices).
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TACHOMETERPCM OUTPUT
The PCM supplies engine rpm values to the Body Controller that then supplies the instrument cluster mounted tachometer (if equipped). Refer to Group 8E for tachometer information.
GLOW PLUGS
Glow plugs are used to help start a cold or cool engine. The plug will heat up and glow to heat the combustion chamber of each cylinder. An individual plug is used for each cylinder. Each plug is threaded into the cylinder head above the fuel injector (Fig. 12).
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(3) Test continuity of the wire harness. Do this between the PCM wire harness connector and the sensor connector terminal. Also test continuity of wire harness to the sensor connector terminal. Refer
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RELAYSOPERATION/TESTING
The following description of operation and tests apply only to the Diesel PCM and other relays. The terminals on the bottom of each relay are numbered (Fig. 17).
OPERATION Terminal number 30 is connected to battery voltage. For both the Diesel and other relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the Diesel PCM and other relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay.
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TESTING The following procedure applies to the Diesel PCM and other relays. (1) Remove relay from connector before testing. (2) With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 5 ohms. (3) Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. (4) Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. (5) Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. (6) Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. (7) Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohm-
REMOVAL (1) Disconnect the harness (on the sensor) from the main electrical harness.
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GLOW PLUGS
The glow plugs are located above each fuel injector (Fig. 20). Four individual plugs are used.
INSTALLATION (1) Install the sensor flush against the opening in the transmission housing. (2) Install and tighten the sensor mounting bolt to 19 Nm (14 ft. lbs.) torque. (3) Connect the electrical connector to the sensor.
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. REFER TO GROUP 7, COOLING. (1) Partially drain cooling system. Refer to Group 7, Cooling. (2) Disconnect electrical connector from sensor. (3) Remove sensor from cylinder head.
INSTALLATION (1) Install a new copper gasket to sensor. (2) Install sensor to cylinder head. (3) Tighten sensor to 18 Nm (13 ft. lbs.) torque. (4) Connect electrical connector to sensor. (5) Replace any lost engine coolant. Refer to Group 7, Cooling System.
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INSTALLATION (1) Check condition of electrical connector for damage or corrosion. Repair as necessary. (2) Install electrical connector to relay. (3) Install relay to inner fender. (4) Connect battery cable to battery.
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SPECIFICATIONS (Continued)
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STEERING
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STEERING
CONTENTS
page page
GENERAL INFORMATION
INDEX
page GENERAL INFORMATION STEERING SYSTEM AND COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 page DIAGNOSIS AND TESTING STEERING SYSTEM DIAGNOSIS CHARTS . . . . . 2
steering effort increases, as in a turn, the torsion bar twists, causing relative rotary motion between the rotary valve body and the valve spool. This movement directs oil behind the integral rack piston, which, in turn, builds up hydraulic pressure and assists in the turning effort. Drive tangs on the power steering gear pinion shaft, mate loosely with the shaft of the steering gear. This is to allow manual steering control to be maintained, if the drive belt on the power steering pump should break. However, under these conditions, steering effort will significantly increase.
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STEERING
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Rattle Or Clunk
2. Front suspension crossmember to frame bolts or studs loose. 3. Tie rod is loose (outer or inner).
4. Loose lower control arm to front suspension crossmember bolts. 5. Loose upper control arm/ shock absorber mounting bracket to body attaching bolts. 6. Power steering fluid pressure hose touching the body of the vehicle. 7. Noise internal to power steering gear. 8. Damaged front suspension crossmember. 9. Loose stabilizer bar attaching link mounting nuts. Chirp or squeal (in the area of the power steering pump). Particularly noticeable at full wheel travel and during standstill parking. 1. Loose power steering pump drive belt.
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DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES
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CORRECTION
Power steering pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be objectionable. Abnormal situations, such as a low oil level causing aeration or hose touching the vehicle body, can create a noise level that could bring complaints. WHINE OR GROWL (PUMP NOISE) 1. Low fluid level. 1. Fill power steering fluid reservoir to proper level and perform leakage diagnosis. (Recheck fluid level after power steering fluid is free of air.) 2. Reposition power steering hose. Replace hose if tube ends are bent. 3. Replace power steering pump and flush system. 1. Tighten or replace hose clamp. 2. Inspect connection and replace O-Ring as required. 3. Fill power steering fluid reservoir to proper level and perform leakage diagnosis. 4. Inspect and/or replace power steering fluid reservoir or supply hose as required. 1.Check for squeak in steering column. Inspect for contact between shroud, intermediate shaft, column, and steering wheel. Realign if necessary. Note: Check steering column for noise without clockspriing installed and with the steering column shaft removed from the steering intermediate shaft. This must be done before removing the steering column for a noise complaint. 2. Check for lack or grease on steering column dash panel to lower coupler seal. 3. Replace Clockspring 4. Replace steering gear assembly. 1. Verify that tire size on vehicle is the same as originally supplied. 2. Correct as necessary.
2. Power steering hose touching vehicle body or frame. 3. Extreme wear of power steering pump internal parts. SUCKING AIR SOUND 1. Loose clamp on power steering fluid low pressure hose. 2. Missing O-Ring on power steering pressure hose connection. 3. Low power steering fluid level 4. Air leak between power steering fluid reservoir and power steering pump. SQUEAK OR RUBBING SOUND 1. Sound coming from steering column.
2.Clockspring 3. Sound internal to steering gear. SCRUBBING OR KNOCKING SOUND 1. Incorrect tire size. 2. Check clearance between tires and other vehicle components, through the full travel of the suspension. 3. Check for interference between steering gear and other components. 4.Incorrect steering gear supplied.
3.Correct as necessary. 4. Replace steering gear with correct steering gear for specific vehicle.
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2. Tires not inflated to specified pressure. 3. Lack of lubrication in front suspension lower control arm ball joints. 4. Worn lower ball joint. 5. Lack of lubrication in steering gear outer tie rod ends. 6. Loose power steering pump drive belt.
4. Replace the lower ball joint. 5. Replace tie rod end. 6. Tighten the power steering pump drive belt to the specified tension. See accessory drive in service manual. 7. Replace power steering pump.
7. Faulty power steering pump flow control. (Verify cause using Power Steering Pump Test Procedure.) 8. Excessive friction in steering column or intermediate shaft. 9. Steering column coupler binding. 10. Binding lower ball joint. 11. Excessive friction in steering gear.
8. Correct condition. (See Steering Column Service Procedure) 9. Realign the steering column to eliminate the binding condition. 10. Replace the lower ball joint. 11. Replace steering gear assembly.
2. Tires not properly inflated. 3. Excessive engine vibration. 4. Loose tie rod end.
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DIAGNOSIS AND TESTING (Continued)
LOW ASSIST, NO ASSIST, HARD STEERING
CONDITION
STIFF, HARD TO TURN, SURGES, MOMENTARY INCREASE IN EFFORT WHEN TURNING.
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POSSIBLE CAUSES
1. Tires not properly inflated. 2. Low power steering fluid level.
CORRECTION
1. Inflate tires to specified pressure. 2. Add power steering fluid as required to power steering fluid reservoir to obtain proper level. Perform leakage diagnosis on power steering system. 3. Tighten the power steering pump drive belt to the specified tension. If drive belt is defective, replace and correctly tension. 4. Replace lower ball joint. 5. Replace lower ball joint. 6. Verify cause using the Power Steering System Test Procedure. Replace the power steering pump if necessary. 7. Check steering system using the Power Steering System Test Procedure. If steering gear is defective replace steering gear.
3. Loose power steering pump drive belt. 4. Lack of lubrication in lower control arm ball joint. 5. Worn lower ball joint. 6. Low power steering pump pressure. (Verify using Power Steering System Test Procedure) 7. High internal leak in steering gear assembly.
POSSIBLE CAUSES
1. Tires not inflated to specified pressure. 2. Improper front wheel alignment. 3. Steering column U-joints misaligned. 4. Mispositioned dash cover.
CORRECTION
1. Inflate tires to specified pressure. 2. Check and adjust as necessary. 3. Realign steering column U-joints. 4. Reposition dash cover. To evaluate items 6 and 7, disconnect the intermediate shaft. Turn the steering wheel and feel or listen for internal rubbing in steering column. 5. Adjust steering column shrouds to eliminate rubbing condition. 6. Determine condition which exists and correct. 7. Replace the steering column. Note: Before replacing steering column, disconnect intermediate steering coupler from steering column shaft and remove steering wheel, clockspring and shrouds from steering column. This must be done to verify a binding shaft bearing in the steering column before replacing the steering column. 8. Replace steering column coupler. 9. Replace steering gear. 10. Replace the strut mount or strut mount pivot bearing.
5. Steering wheel rubbing. 6. Damaged, mis-positioned or un-lubricated steering column coupler to dash seal. 7. Binding shaft bearing in steering column assembly.
8. Excessive friction in steering column coupler. 9. Excessive friction in steering gear. 10. Excessive friction in front strut mount bearing
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3. Worn, broken or loose steering column to steering gear coupler. 4. Free play in steering column.
5. Loose lower control arm ball joint. 6. Loose steering knuckle to lower ball joint stud attaching nut. 7. Front wheel bearings loose or worn. 8. Loose outer tie rod ends. 9. Loose inner tie rod ends. 10. Defective steering gear rotary valve. 11. Intermediate steering shaft coupler flex joint binding.
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DIAGNOSIS AND TESTING (Continued)
VEHICLE LEADS TO THE SIDE
CONDITION STEERING WHEEL DOES NOT WANT RETURN TO CENTER POSITION. POSSIBLE CAUSES 1. Radial tire lead.
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CORRECTION 1.Rotate tires as recommended in the Tire And Wheel Group of this service manual. 2. Align the front suspension as required. Refer to the Wheel Alignment Procedure in the Suspension Group of this service manual for the required wheel alignment procedure. 3. Check for dragging brakes. Refer to the procedures in the Brake Group of this service manual. 4. Replace steering gear.
3. Wheel braking.
4. Unbalanced steering gear valve. (If this is the cause, the steering efforts will be very light in direction of lead and heavier in the opposite direction. STEERING WHEEL HAS FORE AND AFT LOOSENESS. 1. Steering wheel to steering column shaft retaining nut not properly tightened and torqued. 2. Steering column lower bearing spring retainer slipped on steering column shaft. 3. Loose steering column to instrument panel mounting nuts. 4. Binding intermediate steering shaft coupler.
1. Tighten the retaining nut to its specified torque specification. 2. Replace steering column.
3. Verify that the 4 mounting nuts for the steering column are tightened to the specified torque. 4. Disconnect intermediate steering coupler and see if looseness no longer exists. If yes replace intermendiate steering coupler.
2. Power steering hose connections at the power steering pump or steering gear.
2. Check for loose fittings and if found, tighten the fitting to its specified torque. If fittings are tight examine the fittings for damaged or missing O-ring seals and replace as required. 3. Identify the location of the leak and repair or replace the component as required. Refer to Power Steering Pump and/or Power Steering Gear in this group of the service manual for required procedures.
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4. Water contamination.
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. . 18 . . 21 . . 22
. . 23 . . 23
. . 24 . . 24 . . 25
DIAGNOSIS AND TESTING POWER STEERING PUMP FLOW RATE AND PRESSURE TEST
The following procedure can be used to test the operation of the power steering system on the vehicle. This test will provide the flow rate of the power steering pump along with the maximum relief pressure. This test is to be performed any time a power steering system problem is present to determine if the power steering pump or power steering gear is not functioning properly. The following pressure and flow test is performed using Pressure/Flow Tester, Special Tool 6815 (Fig. 2).
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(8) Remove the catalytic converter from the exhaust manifold. Then remove all the exhaust system hangers/isolators from the brackets on the exhaust system. (9) Move the exhaust system as far rearward and to the left side of the vehicle as possible (Fig. 4).
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Fig. 8 Power Steering Fluid Pressure And Return Hose Fig. 6 Accessory Drive Splash Shield
(12) Remove the power steering fluid supply hose coming from the remote fluid reservoir, from the fitting on the power steering pump (Fig. 7). Drain off excess power steering fluid from hose.
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REMOVAL AND INSTALLATION (Continued)
(18) Remove the 3 previously loosened bolts attaching the front bracket to the power steering pump and separate the power steering pump from the front bracket prior to removing the pump from the vehicle. (19) The power steering pump is removed from the vehicle by pulling it out through the exhaust tunnel area in the floor pan of the vehicle.
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to prevent the overheating of the power steering hoses. (12) When used, properly position the protective heat sleeves on the power steering hoses (Fig. 5). Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. (13) Install the exhaust pipe on the exhaust manifold. Install all exhaust system hangers/isolators on the exhaust system brackets. (14) Connect the oxygen sensor wiring harness to the vehicle wiring harness. Install wiring harness grommet in the floor pan of the vehicle. (15) Lower vehicle. (16) Adjust the power steering pump drive belt. See Cooling, Group 7 for detailed adjustment procedure. (17) Tighten the top nut and bottom bolt on the power steering pump front mounting bracket (Fig. 3) to a torque of 54 Nm (40 ft. lbs.). CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar , Power Steering Fluid, or equivalent. (18) Fill the remote power steering pump fluid reservoir to correct fluid level. (19) Install cap on power steering fluid reservoir. (20) Connect the negative battery cable on the negative battery post. (21) Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. See Checking Fluid Level.
INSTALL (1) Install power steering pump back in vehicle using the reverse order of its removal through the exhaust tunnel are of the vehicle. (2) Install the power steering pump on its cast mounting bracket and loosely install nut to hold pump in place (Fig. 9). (3) Install the front bracket on the power steering pump and loosely install the 3 mounting bolts (Fig. 10). Then install the nut and bolt attaching the front bracket to the cast bracket (Fig. 10). (4) Tighten the 3 power steering pump mounting bolts (Fig. 10) to a torque of 54 Nm (40 ft. lbs.).
NOTE: Before installing power steering fluid pressure hose on power steering pump, inspect the O-ring on the pressure hose for damage and replace if necessary. (5) Install the power steering fluid pressure line onto the output fitting of the power steering pump (Fig. 8). Tighten the pressure line to pump fitting tube nut to a torque of 31 Nm (275 in. lbs.). (6) Install the power steering fluid, low pressure return hose on the power steering pump low pressure fitting (Fig. 8). Be sure hose clamps are properly reinstalled. (7) Install the power steering fluid supply hose from the power steering fluid reservoir, on the power steering pump fluid fitting (Fig. 7). Be sure hose is clear of accessory drive belts all hose clamps are properly reinstalled. (8) Install the power steering pump drive belt on pulley. See Cooling, Group 7 for detailed installation procedure. (9) Install the accessory drive splash shield (Fig. 6). (10) Install the power steering fluid return hose on the steel tube at the front suspension cradle (Fig. 5). (11) Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamps are properly reinstalled.Tighten the screw clamp to a torque of 2 Nm (18 in. lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses (Fig. 5). This is required
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Fig. 12 Exhaust Position For Removing Power Steering Pump Fig. 11 3.0L Serpentine Drive Belt And Routing
(5) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting, in the Lubrication and Maintenance section of this service manual for the required lifting procedure. (6) Disconnect the oxygen sensor wiring harness from the vehicle wiring harness. Access to connection at vehicle wiring harness is through the oxygen sensor wiring harness grommet in the floor pan of the vehicle. NOTE: The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pump from the vehicle. (7) Remove the catalytic converter from the exhaust manifold. Then remove all the exhaust system hangers/isolators from the brackets on the exhaust system. (8) Move the exhaust system as far rearward and to the left side of the vehicle as possible (Fig. 12). (9) Raise the heat sleeve on the power steering return hose to expose the return hose to steel tube connection. Remove the hose from the power steering fluid return line on the front suspension cradle (Fig. 13). Allow the remaining power steering fluid to drain from the power steering pump and reservoir through the removed hose. (10) Remove the accessory drive splash shield (Fig. 14). (11) Remove the power steering fluid supply hose coming from the remote fluid reservoir, from the fitting on the power steering pump (Fig. 15). Drain off excess power steering fluid from hose. (12) Remove the power steering fluid pressure line (Fig. 15) from the power steering pump. Drain excess power steering fluid from tube.
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REMOVAL AND INSTALLATION (Continued)
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mounting bolts (Fig. 16). Tighten the power steering pump mounting bolts to a torque of 54 Nm (40 ft. lbs.). (3) Install the support bracket attaching rear of power steering pump to engine (Fig. 16). Tighten the nut and bolts to a torque of 54 Nm (40 ft. lbs). NOTE: Before connecting the power steering pressure line to the power steering pump, inspect the O-ring on the pressure line for damage and replace if damaged. (4) Install the power steering fluid pressure line onto the output fitting of the power steering pump (Fig. 15). Tighten the pressure line to pump fitting tube nut to a torque of 31 Nm (275 in. lbs.). (5) Install the power steering fluid low pressure return hose on the power steering pump low pressure fitting (Fig. 15). Be sure hose clamps are properly reinstalled and return hose is clear of all accessory drive belts. (6) Install the power steering fluid supply hose from the power steering fluid reservoir, on the power steering pump fluid fitting (Fig. 15). Be sure all hose clamps are properly reinstalled. (7) Install the serpentine drive belt (Fig. 11). See Cooling, Group 7 for detailed installation procedure. (8) Install the power steering fluid return hose on the steel tube at the front suspension cradle (Fig. 13). (9) Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 in. lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses (Fig. 13). This is required to prevent overheating of the power steering hoses. (10) When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. (11) Install the exhaust pipe on the exhaust manifold. Install all exhaust system hangers/isolators on the exhaust system brackets. (12) Connect the oxygen sensor wiring harness to the vehicle wiring harness. Install wiring harness grommet in the floor pan of the vehicle. (13) Install the accessory drive splash shield (Fig. 14). (14) Lower vehicle. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar , Power Steering Fluid, or equivalent.
INSTALL (1) Install power steering pump back in vehicle using the reverse order of its removal through the exhaust tunnel are of the vehicle. (2) Install the power steering pump on its mounting bracket. Install the 2 power steering pump
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REMOVAL AND INSTALLATION (Continued)
(10) Remove the serpentine accessory drive belt from the engine (Fig. 20). See Cooling, Group 7 for detailed removal procedure.
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INSTALL (1) Install power steering pump back in vehicle using the reverse order of its removal through the exhaust tunnel are of the vehicle. (2) Install the power steering pump on its mounting bracket. Install the 3 power steering pump mounting bolts (Fig. 23). Tighten the power steering pump mounting bolts to a torque of 54 Nm (40 ft. lbs.). (3) Install the support bracket attaching rear of power steering pump to engine (Fig. 22). Tighten the nut and bolt holding the strut assembly to bracket and the intake manifold stud to a torque of 54 Nm (40 ft. lbs).
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REMOVAL AND INSTALLATION (Continued)
cation and Maintenance section of this service manual, for the required lifting procedure to be used for this vehicle. (5) Remove at power steering pump, the power steering fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain out of the reservoir and hose. (6) Lower vehicle. (7) Remove hose clamp attaching the power steering fluid supply hose to the power steering fluid reservoir (Fig. 24). (8) Remove the power steering fluid supply hose from the vehicle. Hose is removed from the top of the engine compartment.
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(12) Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. (13) Add power steering fluid if necessary. (14) Lower the vehicle and turn the steering wheel slowly from lock to lock. (15) Stop the engine. Check the fluid level and refill as required. (16) If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure.
INSTALL
CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed under the wiring harness and below the drip tube. This routing will prevent the power steering fluid supply hose from coming in contact with the accessory drive belt. (1) Install and correctly route the power steering fluid supply hose from remote fluid reservoir down to power steering pump. (2) Install the fluid supply hose onto the power steering fluid reservoir (Fig. 24). Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on fluid reservoir fitting. (3) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this service manual, for the required lifting procedure to be used for this vehicle. (4) Install power steering fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on pump fitting. (5) Lower vehicle. (6) Install routing clip on power steering fluid supply hose. Be sure routing clip is installed in a position to correctly align with stud in strut tower. (7) Install routing clip for power steering fluid supply hose on stud in strut tower (Fig. 25). (8) Fill the remote fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. (9) Start the engine and let run for a few seconds. Then turn the engine off. (10) Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. (11) Raise the front wheels off the ground.
REMOVE (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. (3) Raise vehicle See Hoisting, Group 0. Put oil drain pan under vehicle to catch power steering fluid. (4) Raise the heat sleeve on the power steering fluid return hose (Fig. 26) to expose the return hose to steel tube connection. Remove the hose clamp from the power steering fluid return hose (Fig. 26). Remove power steering fluid return hose from steel tube and allow power steering fluid to drain from pump.
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Fig. 29 Power Steering Pressure Hose At Steering Gear Fig. 27 Pressure Hose Connection To Power Steering Pump
(6) Remove bolt, attaching power steering hose routing bracket to front suspension cradle (Fig. 28). (7) Disconnect power steering hose at power steering gear assembly (Fig. 29). Drain the power steering fluid from power steering pump and hose. (8) Discard the O-rings on the ends of power steering fluid pressure hose. not bend tube ends of the power steering hoses when installing. (4) Install the power steering fluid hoses to suspension cradle routing bracket (Fig. 28). Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces of the vehicle. CAUTION: When tightening and torquing the pressure hose at the power steering pump, the pressure hose is to be rotated against the fluid return hose fitting on the pump. (5) Tighten all fasteners shown for specific applications to their correct torques listed below: Pump End Tube Nut 34 Nm (25 ft. lbs.) Gear End Tube Nut 34 Nm (25 ft. lbs.) Pump Bracket Nut 40 Nm (30 ft. lbs.)
INSTALL (1) Using a lint free towel, wipe clean the open power steering hose ends, power steering pump pressure fitting and steering gear ports. (2) Install new O-rings on the ends of the power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. (3) Attach the power steering pressure hose to the fittings on the power steering pump and steering gear. Route hose avoiding tight bends or kinking. Do
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REMOVAL AND INSTALLATION (Continued)
(6) Install the power steering fluid return hose on the steel tube at the front suspension cradle (Fig. 26). (7) Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 in. lbs.). CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses (Fig. 26). (8) When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. (9) After hoses are installed and power steering system is filled with fluid and cap is installed on reservoir. Start the engine and check for leaks. (See Pump Installation).
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INSTALL (1) Using a lint free towel, wipe clean the open power steering hose ends and power steering pump fitting. (2) Attach the power steering return hose to the fitting on the power steering pump. Route hose smoothly avoiding tight bends or kinking. Hose must remain away from the exhaust system and not come in contact with any unfriendly surfaces of the vehicle. (3) Install the power steering fluid return hose on the steel tube at the front suspension cradle (Fig. 30). (4) Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 in. lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses (Fig. 30). This is to prevent overheating of the power steering fluid hoses. (5) When used, position the protective heat sleeves on the power steering hoses so they cover the connection to the power steering pump. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. (6) After hoses are installed and power steering system is filled with fluid and cap is installed on reservoir. Start the engine and check for leaks. (See Pump Installation).
REMOVE (1) Remove cap from power steering fluid reservoir. (2) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. (3) Raise vehicle See Hoisting, Group 0. Put oil drain pan under vehicle to catch power steering fluid. (4) Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube connection. Remove hose clamp where rubber portion of power steering fluid return hose attaches to steel tube on suspension cradle (Fig. 30). Remove rubber hose from steel tube and allow power steering fluid to drain from pump.
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(3) Install the fluid supply hose onto the power steering fluid reservoir fitting (Fig. 31). Install the hose clamp on the fluid supply hose at the fluid reservoir. Be sure hose clamp in installed past bead on fluid reservoir fitting. (4) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this service manual, for the required lifting procedure to be used for this vehicle. (5) Install power steering fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose at the power steering pump. Be sure hose clamp in installed past bead on pump fitting. (6) Lower vehicle. (7) Install routing clip for power steering fluid supply hose on stud in strut tower (Fig. 32).
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(3) Force pulley flush with the end of the power steering pump shaft (Fig. 35).
ASSEMBLY (1) Install the pulley with Installer C-4063 (Fig. 34). Do not use the tool adapters.
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ASSEMBLE (1) Install a new O-Ring seal on the pressure fitting/flow control valve, and wet the O-Ring with clean fresh power steering fluid. (2) Install the pressure fitting/flow control valve in the power steering pump. Tighten the pressure fitting/flow control valve to a torque of 75 Nm (55 ft. lbs.).
CAUTION: When tightening and torquing the pressure hose at the power steering pump, the hose should be rotated against the fluid return hose fitting on the pump.
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Installer C-4063B
Puller C-4333
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. 26 . 27 . 27 . 33
Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth. Power assist steering is provided by an open center, rotary type control valve which directs oil from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. As required steering effort increases, as in a turn, the torsion bar twists, causing relative rotary motion between the rotary valve body and the valve spool. This movement directs oil behind the integral rack piston, which, in turn, builds up hydraulic pressure and assists in the turning effort.
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DESCRIPTION AND OPERATION (Continued)
The drive tangs on the pinion mate loosely with a stub shaft to permit manual steering control to be maintained if the drive belt on the power steering pump should break. However, under these conditions, steering effort will be increased.
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should be in the range of 345-552 kPa (50-80 psi). The flow meter should read between 1.3 and 1.9 GPM CAUTION: The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation. Do not leave valve closed for more than 5 seconds as the pump could be damaged. (8) Close valve fully three times and record highest pressure indicated each time. All three readings must be within the specifications and within 345 kPa (50 psi) of each other. NOTE: Power steering pump maximum relief pressure is 9653 to 10342 kPa (1400 to 1500 psi.). If power steering pump pressures are within specifications but not within 345 kPa (50 psi) of each other, then replace power steering pump. If pressures are within 345 kPa (50 psi) of each other but below specifications, then replace power steering pump. CAUTION: Do not force the pump to operate against the stops for more than 5 seconds at a time because, pump damage will result. (9) Open test valve. Turn steering wheel to the extreme left and right positions until against the stops, recording the highest indicated pressure at each position. Compare pressure gauge readings to power steering pump specifications. If highest output pressures are not the same against either stop, the steering gear is leaking internally and must be replaced.
REMOVE
CAUTION: Positioning the steering column in the locked position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler.
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REMOVAL AND INSTALLATION (Continued)
(10) Remove the 2 bolts and loosen the third (Fig. 7) attaching the antilock brakes hydraulic control unit (HCU) to the front suspension cradle. Then rotate the HCU rearward to allow access to the cradle plate attaching nut and bolt just forward of the HCU.
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Fig. 10 Power Steering Fluid Pressure And Return Hoses At Steering Gear
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INSTALL (1) Install the steering gear up in the front suspension cradle, leaving room to install intermediate coupler. (2) Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear. (3) Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut (Fig. 13). Hold threaded rod stationary while turning nut, this will pull the roll pin into the intermediate coupler. (4) Install steering gear assembly on the front suspension cradle. Install the 3 steering gear to front suspension cradle mounting bolts and nuts (Fig. 11).
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REMOVAL AND INSTALLATION (Continued)
CAUTION: Proper torque on the cradle plate to suspension cradle mounting bolts is very important. (8) Install cradle plate on front suspension cradle and install the 10 cradle plate to cradle attaching bolts and nuts (Fig. 8). Tighten all attaching bolts to a torque of 165 Nm (123 ft. lbs.). (9) Install the bracket (Fig. 9) attaching the power steering fluid tubes to the front suspension cradle. CAUTION: (10) Install the power steering fluid return hose on the steel tube at the front suspension cradle (Fig. 4). (11) Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamp is installed on return tube past the upset bead on the tube. Tighten the screw clamp to a torque of 2 Nm (18 in. lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses (Fig. 4). This is required to prevent the power steering hoses from being overheated. (12) When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. (13) Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to 129 Nm (95 ft. lbs.). (14) Lower the vehicle to a level were the interior of vehicle is accessible. (15) Using the intermediate coupler, turn the front wheels of the vehicle to the left until the intermediate coupler shaft is properly aligned with the steering column coupler. Assemble the steering column shaft coupler (Fig. 3) onto the steering gear intermediate coupler. Install steering column coupler to intermediate shaft retaining pinch bolt (Fig. 3). Tighten the pinch bolt nut to a torque of 28 Nm (250 in. lbs.). CAUTION: Do not use automatic transmission fluid in the power steering system. Only use Mopar, Power Steering Fluid or an exact equivalent product. (16) Fill power steering pump fluid reservoir to the proper level. (17) Start the engine and let run for a few seconds. Then turn the engine off.
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(18) Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. (19) Raise front wheels of vehicle off the ground. (20) Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. (21) Add power steering fluid if necessary. (22) Lower the vehicle and turn the steering wheel slowly from lock to lock. (23) Stop the engine. Check the fluid level and refill as required. (24) If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. (25) Fill power steering reservoir to correct level with Mopar , Power Steering Fluid, or equivalent. (26) Adjust toe (Refer to Group 2 Suspension).
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DISASSEMBLY AND ASSEMBLY (Continued)
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STEERING COLUMN
INDEX
page DESCRIPTION AND OPERATION STEERING COLUMN DESCRIPTION . . . . . . . . . 36 DIAGNOSIS AND TESTING STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 38 SERVICE PROCEDURES STEERING COLUMN SERVICE PROCEDURE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 page REMOVAL AND INSTALLATION STEERING COLUMN ASSEMBLY . . . . . . . . . . . . 38 SPECIFICATIONS STEERING COLUMN FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 45
assembly are the key cylinder, ignition switch, multifunction switch, clockspring, halo lamp, speed control switches, driver airbag, trim shrouds and steering wheel. These replaceable components of the steering column can be serviced without requiring removal of the steering column from the vehicle.
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DESCRIPTION AND OPERATION (Continued)
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CAUTION: Do not attempt to remove the pivot pins to disassemble the tilting mechanism. Damage will occur.
REMOVE (1) Make sure the front wheels of the vehicle are in the straight ahead position before beginning the column removal procedure. (2) Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. (3) Remove the screws attaching the lower steering column cover to the instrument panel (Fig. 2). Remove the lower trim panel from the lower instrument panel.
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REMOVAL AND INSTALLATION (Continued)
STEERING
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steering wheel. Remove air bag module from steering wheel. (8) Remove wiring harness connectors from air bag, horn switch wire, and speed control switches (Fig. 6). Remove the wiring harness routing clip (Fig. 6) from the air bag module studs.
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STEERING
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REMOVAL AND INSTALLATION (Continued)
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PRNDL actuating cable MUST be removed from the pin on the gear shifter prior to removing the gear selector cable from the gear shifter.
Fig. 12 Multi-Function Switch Mounting Housing Attaching Screw Fig. 15 PRNDL Actuating Cable At Steering Column
(21) Remove the attaching clip (Fig. 15) for the PRNDL actuating cable from the steering column/ shift cable bracket. (22) Remove the gear selector cable from the gear shifter the steering column (Fig. 16). Gear selector cable is removed from pin on shift module by carefully prying it off with a screw driver (Fig. 16).
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Fig. 19 Steering Column Fixed Shroud Fig. 21 Steering Column Upper And Lower Mounting Brackets
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REMOVAL AND INSTALLATION (Continued)
(28) Remove steering column assembly from vehicle. Use care to avoid damage to paint or interior trim.
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INSTALL (1) Ensure the plastic mounting capsules (Fig. 22) are installed in the upper mounting bracket of the steering column. Mounting capsules must be installed as shown in (Fig. 22) with the thicker edge of the capsule facing the top of the steering column.
ing column/shift cable bracket. Cable guide tube will bow toward passenger side of vehicle. Verify that actuating cable is operating correctly, then slip the loop on the end of the cable over end of pin on shift lever and install in groove (Fig. 15). (8) Install the steering column fixed shroud on the steering column assembly (Fig. 19). Shroud is mounted to steering column using 2 attaching screws accessed from top of fixed shroud. (9) Install the instrument cluster trim bezel (Fig. 18) on the instrument panel. The trim bezel is mounted to the instrument panel using 2 attaching screws (Fig. 18) and retaining clips. (10) Install the 3 wiring harness connectors on the ignition switch (Fig. 14). (11) Install the vehicle wiring harness connector into the key cylinder halo light (Fig. 13). (12) Install the multi-function switch (Fig. 12) on the tilt head of the steering column assembly. Then install screw (Fig. 12) attaching multi-function switch to tilt head of steering column. (13) Install the vehicle wiring harness connector on the multi-function switch (Fig. 11). Be sure latch on connector is fully engaged with tab on switch. (14) Install the clock spring on the multi-function switch. (15) Install the vehicle wiring harness connector (Fig. 10) on the clock spring assembly. (16) Install the lower steering column shroud on the tilt head of the steering column (Fig. 23). Install and securely tighten the screw attaching the lower shroud to the tilt head.
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REMOVAL AND INSTALLATION (Continued)
(23) Install the 3 bolts (1 in each spoke of the steering wheel) attaching the air bag module to the steering wheel. Tighten the 3 air bag module attaching nuts to a torque of 11 Nm (100 in. lbs.). (24) Install the steering column cover liner (Fig. 4) on the lower instrument panel. Install and securely tighten the 10 bolts (Fig. 4) attaching the steering column cover liner to the instrument panel. (25) Install the park brake pedal release cable on the park brake release lever in the lower steering column cover (Fig. 3). (26) Install the lower steering column trim panel on the lower instrument panel. Install and securely the screws attaching the lower steering column cover to the instrument panel (Fig. 2). (27) Connect negative (ground) cable on the battery terminal.
STEERING
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STEERING
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STEERING
CONTENTS
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POWER STEERING GEAR SERVICE PROCEDURES POWER STEERING PUMP INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS.
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REMOVAL (1) Remove serpentine drive belt. Refer to Group 7, Cooling System, for procedure. (2) Remove power steering pump pulley. Use a hex wrench to secure the power steering shaft while removing the pulley bolt with a box wrench. (Fig. 2)
CAUTION: Do not use an impact wrench to remove the pump pulley this can cause rear pump seal damage. Do not secure power steering shaft with a wrench on the coupling to the A/C compressor this can cause rear pump seal damage. (3) Remove coupling bolts (2) from A/C compressor side of coupling. (4) Loosen A/C compressor bolts and separate compressor from bracket. Do not disconnect A/C hoses. (5) Remove bolts (2) securing the power steering pump to the power steering bracket. (6) Disconnect power steering pump supply hose at the pump and drain fluid. (7) Disconnect power steering pressure hose at the steering gear assembly. (8) Remove power steering pump.
INSTALLATION (1) Install pump on engine. (2) Tighten pump bracket bolts to 47 Nm (35 ft. lbs.).
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. . 36 . . 46 . . 32 . . 35 . . 37 . . . . . . . . . . . . . . . . 36 31 43 42 33 21 38 27
. . 50 . . . . . . . . 51 52 53 51
. . 52 . . 52 . . 51 . . 54 . . 56 . . 64 . . 65 . . 66
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Two planetary gear sets This provides three forward ratios and a reverse ratio. The common sun gear of the planetary gear sets is connected to the front clutch by a driving shell. The drive shell is splined to the sun gear and front clutch retainer. The hydraulic system consists of an oil pump, and a single valve body which contains all of the valves except the governor valves. The transaxle sump and differential sump are both vented through the dipstick. Output torque from the main center line is delivered through helical gears to the transfer shaft. This gear set is a factor of the final drive (axle) ratio. The shaft also carries the governor and parking sprag. An integral helical gear on the transfer shaft drives the differential ring gear. The final drive gearing is completed with one of two gear ratios of 2.98 or 3.19 depending on model and application.
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GENERAL INFORMATION (Continued)
If there is any doubt about its condition, drain out a sample for a double check.
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The throttle valve transmits regulated pressure to the transaxle (dependent on throttle position) to control upshift and downshift.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in these transmissions. Mopar ATF PLUS 3 (Automatic Transmission Fluid- type 7176) should be used to aid in ensuring optimum transmission performance. It is important that the transmission fluid be maintained at the prescribed level using the recommended fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the addition of any fluids to the transmission, other than fluid listed above. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals.
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Diagnosis of these problems should always begin by checking the easily accessible variables; fluid level and condition, gearshift cable adjustment, and throttle pressure cable adjustment. Then perform a road test to determine if the problem has been corrected or that more diagnosis is necessary. If the problem exists after the preliminary tests and corrections are completed, hydraulic pressure tests should be performed
31TH HYDRAULIC TROUBLE CODE CHARTS The following charts should be used to help diagnose hydraulic or mechanical faults in the transaxle .
ROAD TEST
Prior to performing a road test, check the fluid level, and control cable adjustments. During the road test, the transaxle should be operated in each position to check for slipping and any variation in shifting. If vehicle operates at high speeds, but has poor acceleration, the converters overrunning clutch may be slipping. If acceleration is normal, but high throttle opening is needed for high speeds, the stator clutch may have seized. Observe closely for slipping or engine speed flareup. Slipping or flare-up in any gear usually indicates clutch, band, or overrunning clutch problems. If the condition is far advanced, an overhaul will probably be necessary to restore normal operation. In most cases, the clutch or band that is slipping can be determined by noting the transaxle operation in all selector positions. Then comparing which internal units are applied in those positions. The Elements in Use Chart provides a basis for road test analysis . The rear clutch is applied in both the D first gear and 1 first gear positions. Also the overrunning clutch is applied in D first gear and the low/reverse band is applied in 1 first gear position. If the transaxle slips in D range first gear, but does not slip in 1 first gear, the overrunning clutch is slipping. Similarly, if the transaxle slips in any two forward gears, the rear clutch is slipping. Using the same procedure, the rear clutch and front clutch are applied in D third gear. If the transaxle slips in third gear, either the front clutch or the rear clutch is slipping. By selecting another gear which does not use one of those units, the unit which is slipping can be determined. If the transaxle also slips in reverse, the front clutch is slipping. If the transaxle does not slip in reverse, the rear clutch is slipping. The process of eliminating can be used to detect any unit which slips and to confirm proper operation of good units. Road testing can usually diagnose slipping units. Although the actual cause of the problem
GOVERNOR
The governor may be serviced by removing the transaxle oil pan and valve body assembly. The governor may be unbolted from the governor support and removed from the transaxle for reconditioning or replacement. When cleaning or assembling the governor, make sure the governor valves move freely in the bores of the governor body.
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DIAGNOSIS AND TESTING (Continued)
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Diagnosis Guide
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Diagnosis Guide
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DIAGNOSIS AND TESTING (Continued)
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Diagnosis Guide
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Diagnosis Guide
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DIAGNOSIS AND TESTING (Continued)
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Diagnosis Guide
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Diagnosis Guide
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DIAGNOSIS AND TESTING (Continued)
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Diagnosis Guide
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Diagnosis Guide
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DIAGNOSIS AND TESTING (Continued)
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TEST ONE (SELECTOR IN 1) (1) Attach gauges to line and low-reverse ports. (2) Operate engine at 1000 rpm for test. (3) Move selector lever on transaxle all the way rearward (1 position). (4) Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise position to full counterclockwise position. (5) Line pressure should read 52 to 58 psi with throttle lever clockwise. Pressure should gradually increase, as lever is moved counterclockwise, to 80 to 88 psi.
TEST TWO (SELECTOR IN 2) (1) Attach one gauge to line pressure port and tee another gauge into lower cooler line fitting. This will allow lubrication pressure readings to be taken.. (2) Operate engine at 1000 rpm for test. (3) Move selector lever on transaxle one detent forward from full rearward position. This is selector 2 position. (4) Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise position to full counterclockwise position. (5) Line pressure should read 52 to 58 psi with throttle lever clockwise. Pressure should gradually increase, as lever is moved counterclockwise, to 80 to 88 psi. (6) Lubrication pressure should be 10 to 25 psi with lever clockwise and 10 to 35 psi with lever full counterclockwise. (7) This tests pump output, pressure regulation, and condition of rear clutch and lubrication hydraulic circuits. TEST THREE (SELECTOR IN D) (1) Attach gauges to line and kickdown release ports. (2) Operate engine at 1600 rpm for test. (3) Move selector lever on transaxle two detents forward from full rearward position. This is selector D position. (4) Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise position to full counterclockwise position. (5) Line pressure should read 52 to 58 psi with throttle lever clockwise. Pressure should gradually
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DIAGNOSIS AND TESTING (Continued)
(4) Low pressure in R and 1 but correct pressure in 2 indicates rear servo circuit leakage. (5) Low line pressure in all positions indicates a defective pump, a clogged filter, or a stuck pressure regulator valve.
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GOVERNOR PRESSURE Test only if transaxle shifts at wrong vehicle speeds when throttle cable is correctly adjusted. (1) Connect a 0-150 psi pressure gauge to governor pressure take-off point. It is located at lower right side of case, below differential cover. (2) Operate transaxle in third gear to read pressures. The governor pressure should respond smoothly to changes in mph and should return to 0 to 3 psi when vehicle is stopped. High pressure at standstill (above 3 psi) will prevent the transaxle from downshifting. THROTTLE PRESSURE No gauge port is provided for throttle pressure. Incorrect throttle pressure should be suspected if part throttle upshift speeds are either delayed or occur too early in relation to vehicle speeds. Engine runaway on shifts can also be an indicator of low throttle pressure setting, or misadjusted throttle cable. In no case should throttle pressure be adjusted until the transaxle throttle cable adjustment has been verified to be correct.
REAR CLUTCH Apply air pressure to rear clutch apply passage and listen for a dull thud which indicates that rear clutch is operating. Also inspect for excessive oil leaks. If a dull thud cannot be heard in the clutches, place finger tips on clutch housing and again apply air pressure. Movement of piston can be felt as the clutch is applied. KICKDOWN SERVO (FRONT) Direct air pressure into KICKDOWN SERVO ON passage. Operation of servo is indicated by a tightening of front band. Spring tension on servo piston should release the band. LOW AND REVERSE SERVO (REAR) Direct air pressure into LOW-REVERSE SERVO APPLY passage. Operation of servo is indicated by a tightening of rear band. Spring tension on servo piston should release the band. If clutches and servos operate properly, no upshift indicates that a malfunction exists in the valve body.
FRONT CLUTCH Apply air pressure to front clutch apply passage and listen for a dull thud which indicates that front clutch is operating. Hold air pressure on for a few seconds and inspect system for excessive oil leaks.
TORQUE CONVERTER LEAKAGE Possible sources of torque converter leakage are: Torque converter weld leaks at the outside diameter (peripheral) weld. Torque converter hub weld. Torque converter impeller shell cracked adjacent to hub. At drive lug welds.
NOTE: Hub weld is inside and not visible. Do not attempt to repair. Replace torque converter.
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30,000 MILE TRANSAXLE OIL CHANGE When a vehicle attains 30,000 miles on its odometer it is recommended that the transaxle oil be changed. To change the oil, use the procedure that follows: It is recommended that a transaxle fluid exchanger (ATF 2000+ or equivalent) be used to replace the used fluid in the transaxle. If a fluid exchanger is not available use a fluid suction pump (Vacula or equivalent) to draw the fluid out of the dipstick tube. If a fluid suction pump is not available remove the oil pan and drain the fluid.
CAUTION: Chrysler Corporation does not recommend using any fluid exchanger that introduces additives into the transaxle.
TRANSAXLE FLUID EXCHANGER METHOD (1) To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive the vehicle till it reaches full operating temperature. (2) Verify that the fill tank on the transaxle fluid exchanger (ATF 2000+ or equivalent) is clean and dry. (3) Fill the tank to the recommended fill capacity with Mopar ATF Plus 3 Type 7176. (4) Hookup the vehicle to the machine following the manufacturers instructions. Perform the exchange procedure following the instructions provided with the machine. (5) Once machine has completed the fluid exchange. Check the fluid level and condition and fill to proper level with Mopar ATF Plus 3 Type 7176. NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line torque specification is 2 Nm (18 in. lbs.). DIPSTICK TUBE FLUID SUCTION METHOD (1) When performing the fluid suction method, make sure the transaxle is at full operating temperature.
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SERVICE PROCEDURES (Continued)
(2) To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula or equivalent). (3) Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. (4) Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. (5) Remove the suction line from the dipstick tube. (6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176 transaxle fluid. (7) Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. (8) Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 in.) below the ADD mark on the dipstick. (9) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. TRANSAXLE OIL PAN DROP METHOD This procedure involves removing the transaxle oil pan to drain the transaxle fluid. (1) Bring the vehicle up to normal operating temperature. Drive the vehicle a minimum of 10 miles. (2) Raise the vehicle on the hoist. (3) Loosen the transaxle oil pan and drain the fluid into a suitable container. (4) Remove the pan and clean all sealant from the pan and transaxle mating surfaces. Clean the magnet and the inside of the pan. (5) Apply a 1/8 inch bead of Mopar RTV Sealant to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle. Tighten the bolts to 19 Nm (165 in. lbs.). (6) Lower the vehicle and add 4 Quarts of Mopar ATF Plus 3 Type 7176 transaxle fluid. (7) Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. (8) Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 in.) below the ADD mark on the dipstick. (9) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in
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the HOT range. Drive the vehicle a minimum of 10 miles. (10) Raise the vehicle on the hoist. (11) Check for leaks around the transaxle oil pan sealing surfaces. (12) Recheck the fluid level. The level should be in the HOT range.
SEVERE USAGE SERVICE If the vehicle exhibits any of the following symptoms, it is recommended that the transaxle oil and filter be replaced. Transaxle oil discolored Transaxle oil has high mileage Oil feels grimy when rubbed between fingertips Poor shift quality Delayed gear engagement Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT This procedure involves changing the transaxle fluid and filter, driving the vehicle for 10 miles and changing the transaxle fluid a second time. (1) Bring the vehicle up to normal operating temperature. Drive the vehicle a minimum of 10 miles. (2) Raise the vehicle on the hoist. (3) Loosen the transaxle oil pan and drain the fluid into a suitable container. (4) Remove the pan and clean all sealant from the pan and transaxle mating surfaces. Clean the magnet and the inside of the pan. (5) Separate the filter and O-ring from the valve body. Inspect the O-ring for cuts or improper installation. This could lead to delayed garage shifts. (6) Install a new filter. Replace the O-ring as necessary. (7) Apply a 1/8 inch bead of Mopar RTV Sealant to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle. Tighten the bolts to 19 Nm (165 in. lbs.). (8) Lower the vehicle and add 4 Quarts of Mopar ATF Plus 3 Type 7176 transaxle fluid. (9) Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. (10) Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 in.) below the ADD mark on the dipstick. (11) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. Drive the vehicle a minimum of 10 miles. (12) Raise the vehicle on the hoist.
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COOLER FLUSH USING TOOL 6906A (1) Remove cover plate filler plug on Tool 6906A. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. (2) Reinstall filler plug on Tool 6906A. (3) Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. (4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush.
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SERVICE PROCEDURES (Continued)
(5) Connect the BLUE pressure line to the OUTLET (From) cooler line. (6) Connect the CLEAR return line to the INLET (To) cooler line (7) Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. (8) Turn pump OFF. (9) Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. (10) Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. (11) Place CLEAR suction line into a one quart container of Mopar ATF Plus 3 type 7176 automatic transmission fluid. (12) Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. (13) Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines.
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REMOVAL (1) Remove harness connector from sensor. Make sure weatherseal stays on harness connector. (2) Remove bolt securing the sensor in the extension housing. (3) Carefully pull sensor and pinion gear assembly out of extension housing. (4) Remove pinion gear from sensor. INSTALLATION (1) To install, reverse the above procedure. Make sure extension housing and sensor flange are clean prior to installation. Always use a NEW sensor O-ring. (2) Tighten bolt to 7 Nm (60 in. lbs.). Tighten speedometer cable to 4 Nm (35 in. lbs.).
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REMOVAL (1) Disconnect negative battery cable. (2) Remove air cleaner and hoses. (3) Disconnect throttle linkage and shift linkage from transaxle. (4) Unplug torque converter clutch connector, located near the dipstick. Unplug the gear position switch. (5) Remove transaxle dipstick tube. (6) Remove the transaxle cooler lines and plug. (7) Install engine support fixture (Fig. 5) .
INSTALLATION (1) When installing transaxle, reverse the above procedure. (2) If torque converter was removed from transaxle be sure to align pump inner gear pilot flats with torque converter impeller hub flats. (3) Adjust gearshift and throttle cables. (4) Refill transaxle with Mopar ATF PLUS 3 (Automatic Transmission Fluid) Type 7176.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL (1) Screw seal remover Tool C-3981-B into seal (Fig. 7), then tighten screw portion of tool to withdraw the seal.
DISASSEMBLY
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Fig. 18 Loosen Lock Nut and Tighten Kickdown Band Adjusting Screw
Remove Number 6 thrust washer from sun gear driving shell.
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Fig. 31 Sun Gear Driving Shell Components Fig. 28 Front Planetary Gear Snap Ring
Fig. 33 Rear Planetary Gear Assembly Fig. 30 Sun Gear Driving Shell
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Fig. 49 Throttle Valve Lever Assembly Fig. 46 Remove or Install Throttle Shaft E-Clip
Fig. 50 Manual Valve Fig. 47 Throttle Shaft E-Clip, Washer, and Seal
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OIL PUMP-RECONDITION
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DISASSEMBLY
Fig. 60 Front Clutch Waved Snap Ring Fig. 59 Measuring Pump Clearance (Gear to Pocket)
FRONT CLUTCH-RECONDITION
INSPECTION Inspect plates and discs for flatness. They must not be warped or cone shaped. Inspect facing material on all driving discs. Replace discs that are charred, glazed or heavily pitted. Discs should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily. Inspect driving disc splines for wear or other damage. Inspect steel plate surfaces for burning, scoring, or damaged driving lugs. Replace if necessary. Inspect steel plate lug grooves in clutch retainer for smooth surfaces, plates must travel freely in grooves. Inspect band contacting surface on clutch
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Fig. 62 Front Clutch (4-Disc Shown) Fig. 65 Measuring Front Clutch Plate Clearance
REAR CLUTCH-RECONDITION
INSPECTION Inspect facing material on all driving discs. Replace discs that are charred, glazed or heavily pitted. Discs should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily. Inspect driving disc splines for wear or other damage. Inspect steel plate and pressure plate surface for burning, scoring or damaged driving lugs. Re place if necessary. Inspect plates and discs for flatness, they must not be warped or coneshaped. Inspect steel plate lug grooves in clutch retainer for smooth surfaces, plates must travel freely in the grooves. Note ball check in piston; make sure ball moves freely. Inspect seal rings surfaces in clutch retainer for nicks or deep scratches; light scratches will not interfere with sealing of the seals. Inspect neoprene seal rings for deterioration, wear and hardness. Inspect piston spring and waved snap ring for distortion or breakage. Inspect teflon and/or cast iron seal rings on input shaft for wear. Do not remove rings unless conditions warrant. Inspect rear clutch to front clutch No. 2 thrust washer for wear. Washer thickness should be .061 to .063 inch, replace if necessary. DISASSEMBLY Press out input shaft, if required. ASSEMBLY To reassemble, reverse the above procedure.
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Fig. 75 Annulus Gear Support Front Snap Ring Fig. 72 Measuring Rear Clutch Plate Clearance
Fig. 73 Front Planetary Gear Snap Ring and No. 4 Thrust Washer (Always Install a New Snap Ring)
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ASSEMBLY
ACCUMULATOR-RECONDITION
DISASSEMBLY
Fig. 80 Remove Retainer, Spring and Servo Fig. 83 Accumulator Plate and Snap Ring
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Fig. 95 Using Tool L-4406-1 with Adapter L-4406-3, Remove Transfer Shaft Gear Bearing Cone
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Fig. 101 Governor Assembly Fig. 104 Remove or Install Transfer Shaft and Bearing Retainer Assembly Using Tool L-4512
Fig. 102 Transfer Shaft Bearing Snap Ring Fig. 105 Transfer Shaft and Bearing Retainer
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PARKING PAWL
DISASSEMBLY
Fig. 110 Tighten Transfer Shaft Gear Retaining Nut to 271 Nm (200 ft. lbs.)
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Fig. 118 Remove Output Shaft Gear Bearing Cone Fig. 115 Remove Output Shaft Retaining Nut and Washer
Fig. 119 Install Output Shaft Gear Bearing Cone Fig. 116 Remove Output Shaft Gear
Fig. 120 Remove Output Shaft and Rear Annulus Gear Assembly Fig. 117 Output Shaft Gear and (Select) Shim
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Fig. 124 Install Output Shaft into Rear Planetary Annulus Gear
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Fig. 129 Install Output Shaft Assembly Fig. 127 Install Output Shaft Gear Bearing Cup
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DIFFERENTIAL REPAIR
NOTE: The transfer shaft should be removed for differential repair and bearing turning torque checking.
Fig. 133 Tighten Output Shaft Retaining Nut to 271 Nm (200 ft. lbs.)
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Fig. 143 Remove or Install Bearing Retainer Fig. 140 Remove Bearing Retainer Axle Seal
Fig. 144 Differential Bearing Retainer (Typical) Fig. 141 Install Bearing Retainer Axle Seal
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Fig. 145 Extension Bolts Fig. 148 Remove Differential Bearing Cone (Extension Housing Side)
Fig. 146 Remove or Install Extension Housing Fig. 149 Position Bearing Cone Onto Differential
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Fig. 151 Position Button and Collets Onto Differential and Bearing (Ring Gear Side)
Fig. 152 Position Tool 5048 Over Button and Collets at Differential Bearing
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DETERMINING SHIM THICKNESS Shim thickness need be determined only if any of the following parts are replaced: Transaxle case Differential carrier Differential bearing retainer Extension housing Differential bearing cups and cones Refer to Bearing Adjustment Procedure in rear of this section to determine proper shim thickness.
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CLEANING AND INSPECTION (Continued)
Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs, nicks, and scores. Small nicks and scores may be removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The sharpness of these edges is vitally important. It prevents foreign matter from lodging between valve and valve body. This reduces the possibility of sticking. Inspect all valves and plugs for freedom of operation in valve body bores. When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the bores. The valve body bores do not change its dimensions with use. Therefore, a valve body that was functioning properly when vehicle was new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace valve body unless it is damaged in handling.
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ROD ADJUSTMENT PROCEDURE (1) Perform transaxle throttle pressure adjustment while engine is at normal operating temperature. (2) Loosen adjustment swivel lock screw. (3) To insure proper adjustment, swivel must be free to slide along flat end of throttle rod. Disassemble and clean or repair parts to assure free action, if necessary. (4) Hold transaxle throttle lever firmly toward engine, against its internal stop. Tighten swivel lock screw to 11 Nm (100 in. lbs.) (5) The adjustment is finished and linkage backlash was automatically removed by the preload spring. (6) If lubrication is required see Group 0, Lubrication.
BAND ADJUSTMENT
KICKDOWN BAND (FRONT) The kickdown band adjusting screw is located on left side (top front) of the transaxle case. (1) Loosen locknut and back off nut approximately five turns. Test adjusting screw for free turning in the transaxle case. (2) Using wrench, tighten adjusting screw to 8 Nm (72 in. lbs.).
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ADJUSTMENTS (Continued)
(3) Back off adjusting screw the number of turns listed in Specifications. Hold adjusting screw in this position and tighten locknut to 47 Nm (35ft. lbs.) seated bearing cup and cones are subject to low-mileage failure. (2) Bearing cups and cones should be replaced if they show signs of pitting or heat distress. (3) If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced. NOTE: Bearing end play and drag torque specifications must be maintained to avoid premature bearing failures. (4) Used (original) bearing may lose up to 50 percent of the original drag torque after break-in. NOTE: All bearing adjustments must be made with no other component interference or gear intermesh, except the transfer gear bearing. (5) Refer to the conversion chart in specifications to convert inches to millimeter measurements. Refer to bearing shim chart for proper shim thicknesses.
LOW/REVERSE BAND (REAR) To adjust low-reverse band, proceed as follows: (1) Loosen and back off locknut approximately 5 turns. (2) Using an inch-pound torque wrench, tighten adjusting screw to 5 Nm (41 in. lbs.) true torque. (3) Back off adjusting screw the number of turns listed under Specifications. This chart is located at the rear of this section. (4) Tighten locknut to 14 Nm (10 ft. lbs.).
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ADJUSTMENTS (Continued)
hold the shims in place. Install the output shaft gear and bearing assembly. (13) Install the retaining nut and washer and torque to 271 Nm (200 ft. lbs.). (14) Using an inch-pound torque wrench, check the turning torque. The torque should be between 3 and 8 inch-pounds. (15) If the turning torque is too high, install a .05mm (.002 inch) thicker shim. If the turning torque is too low, install a .05 mm (.002 inch) thinner shim. Repeat until the proper turning torque is 3 to 8 inch pounds.
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DIFFERENTIAL BEARING
(1) Position the transaxle assembly vertically on the support stand, differential bearing retainer side up. (2) Install Tool L-4436A into the differential and onto the pinion mate shaft . (3) Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated.
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ADJUSTMENTS (Continued)
NOTE: If the turning torque was too high when measured, install a .05 mm (.002 inch) thinner shim. If the turning torque is was too low, install a .05 mm (.002 inch) thicker shim. Repeat until 5 to 18 inchpounds turning torque is obtained. Oil Baffle is not required when making shim selection. (e) Install the proper shim under the bearing cup. Make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and cup. (f) Install the differential bearing retainer using Tool 5052 and C-4171. Seal the retainer to the housing with MOPAR Adhesive Sealant and torque bolts to 28 Nm (250 in. lbs.). (7) Using Tool L-4436A and an inch-pound torque wrench, recheck the turning torque of the differential. The turning torque should be between 5 and 18 inch-pounds.
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ADJUSTMENTS (Continued)
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NOTE: If end play is too high, install a .05 mm (.002 inch) thinner shim combination. If end play is too low, install a .05 mm (.002 inch) thicker shim combination. Repeat until .05 to .25 mm (.002 to .010 inch) end play is obtained.
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SCHEMATICS AND DIAGRAMS (Continued)
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SCHEMATICS AND DIAGRAMS (Continued)
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SCHEMATICS AND DIAGRAMS (Continued)
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SCHEMATICS AND DIAGRAMS (Continued)
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Tapered Roller Bearing Settings Differential Assembly . . .6 to 12 in. lbs. Output Hub. . . . . . . . . . . .0 to 3 in. lbs. Transfer Shaft . . . . . . . . .0.002 to 0.010 Overall Drag At Output Hub . . . . . . . . . . . . .3 to 16 in. lbs.
Clutch Pack Clearances Front Clutch (Not Adjustable) . . . . . . . .1.27-2.79mm (0.050-0.110 in.) Rear Clutch . . . . . . . . .0.71-1.10mm (0.028-0.043 in.) Band Adjustment Kickdown, Backed Off From 8 Nm (72 in. lbs.) . . . . . . . . . . . . . . . . . . . . . 2 1/4 Turns Low-Reverse, Backed Off From 5 Nm (41 in. lbs.) . . . . . . . . . . . . . . . . . . . . . .3 1/2 Turns
Gear Ratios Transmission Portion First Gear . . . . . . . . . . . Second Gear. . . . . . . . . . Third Gear. . . . . . . . . . . Reverse Gear . . . . . . . . .
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Pump Clearances Outer Gear To Pocket . . . . . . . . . . . . .0.045-0.141mm (0.0018-0.0056 in.) Outer Gear Side Clearance. . . . . . . . .0.020-0.046mm (0.0008-0.0018 in.) Inner Gear Side Clearance . . . . . . . . .0.020-0.046mm (0.0008-0.0018 in.)
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SPECIFICATIONS (Continued)
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TORQUE
12 Nm (106 in. lbs.) 12 Nm (105 in. lbs.) 28 Nm (250 in. lbs.) 28 Nm (250 in. lbs.) 19 Nm (165 in. lbs.) 28 Nm (250 in. lbs.) 95 Nm (70 ft. lbs.) 68 Nm (50 ft. lbs.) 5 Nm (45 in. lbs.) 54 Nm (40 ft. lbs.) 28 Nm (250 in. lbs.) 7 Nm (60 in. lbs.) 47 Nm (35 ft. lbs.) 54 Nm (40 ft. lbs.) 41 Nm (30 ft. lbs.) 28 Nm (250 in. lbs.) 12 Nm (105 i n. lbs.) 19 Nm (165 in. lbs.) 23 Nm (17 ft. lbs.)
DESCRIPTION
Output Shaft Nut Park/Neutral Switch Pressure Check Plug Pump To Case Bolts Reaction Shaft Assembly Bolt Rear Cover To Case Screw Reverse Band Adj. Lock Nut Reverse Band Shaft Plug Ring Gear Screw Speedo. To Ext. Hous. Screw Sprag Ret. To Transfer Case Bolt Starter To Trans. Bell Bolts Throttle Cable To Trans. Case Bolt Throttle Lever To Trans. Shaft Bolts Trans. To Cyl. Block Bolt Transfer Shaft Nut Transfer Gear Strap Bolts Valve Body Assy. To Case Bolts Valve Body Screw
TORQUE
271 Nm (200 ft. lbs.) 34 Nm (25 ft. lbs.) 5 Nm (45 in. lbs.) 31 Nm (275 in. lbs.) 28 Nm (250 in. lbs.) 19 Nm (165 in. lbs.) 14 Nm (125 in. lbs.) 7 Nm (60 in. lbs.) 95 Nm (70 ft. lbs.) 7 Nm (60 in. lbs.) 28 Nm (250 in. lbs.) 54 Nm (40 ft. lbs.) 12 Nm (105 in. lbs.) 12 Nm (105 in. lbs.) 95 Nm (70 ft. lbs.) 271 Nm (200 ft. lbs.) 23 Nm (17 ft. lbs.) 12 Nm (105 in. lbs.) 5 Nm (45 in. lbs.)
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SPECIAL TOOLS (Continued)
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Adapter C-4658
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Adapter C-4996
Adapter L-44063
Puller L-44076
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SPECIAL TOOLS (Continued)
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Installer L-4520
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. . . . . . . . . . . . . . . .
71 72 72 72 73 72 73 74 73 74 73 74 73 74 74 74
. 75 . 77 . . . . . . . . 78 75 75 78 81 79 81 81
TRANSAXLE IDENTIFICATION The 41TE transaxle identification code is printed on a label. The label is located on the transaxle case next to the solenoid assembly (Fig. 1).
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SELECTION OF LUBRICANT
It is important that the proper lubricant be used in the 41TE transaxle. MOPAR ATF PLUS 3 (Automatic Transmission Fluidtype 7176) should be used to aid in assuring optimum transmission performance. Fluids of the type labeled DEXRON II Automatic Transmission Fluid are not recommended. It is important that the transmission fluid be maintained at the prescribed level using the recommended fluids.
SPECIAL ADDITIVES
Chrysler Corporation does not recommend the addition of any fluids to the transaxle, other than the fluid listed above. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals.
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HYDRAULICS
The hydraulics of the transaxle provide: Manual shift lever select function Main line pressure regulation Torque converter and cooler flow control Oil flow to the friction elements is controlled directly by four solenoid valves. The hydraulics also include a unique logic- controlled solenoid torque converter clutch control valve. This valve locks out the 1st gear reaction element with the application of 2nd, direct, or overdrive gear elements. It also redirects the 1st gear solenoid output so that it can control torque converter clutch operation. To regain access to 1st gear, a sequence of commands must be used to move the solenoid TCC control valve. This precludes any application of the 1st gear reaction element with other elements applied. It also allows one solenoid to control two friction elements. Small, high-rate accumulators are provided in each controlled friction element circuit. These serve to absorb the pressure responses, and allow the controls to read and respond to changes that are occurring.
ELECTRONICS
The 41TE Transmission Control Module (TCM) is located underhood in a potted, die-cast aluminum housing. The module used is a new controller called EATX III. The TCM has a sealed, 60-way connector.
ADAPTIVE CONTROLS
These controls function by reading the input and output speeds over 140 times a second and responding to each new reading. This provides the precise and sophisticated friction element control needed to make smooth clutch-to-clutch shifts for all gear changes. The use of overrunning clutches or other shift quality aids are not required. As with most automatic transaxles, all shifts involve releasing one element and applying a different element. In simplified terms, the upshift logic allows the releasing element to slip backwards slightly. This ensures that it does not have excess capacity. The apply element is filled until it begins to make the speed change to the higher gear. The apply pressure is then controlled to maintain the desired rate of speed change. This continues until the shift is made. The key to providing excellent shift quality is precision. For example, the release element for upshifts is allowed to slip backwards slightly. The amount of that slip is typically less than a total of 20 degrees. To achieve that precision, the TCM learns the traits of the transaxle that it is controlling. It learns the release rate of the releasing element and the apply time of the applying element. It also learns the rate at which the apply element builds pressure sufficient to begin making the speed change. This method achieves more precision than would be possible with exacting tolerances. It can also adapt to any changes that occur with age or environment. For kickdown shifts, the control logic allows the releasing element to slip. Then controls the rate at which the input (and engine) accelerate. When the lower gear speed is achieved, the releasing element reapplies to maintain that speed until the apply element is filled. This provides quick response since the engine begins to accelerate immediately. This also provides a smooth torque exchange since the release element can control the rate of torque increase. This control can make any powertrain feel more responsive without increasing harshness. Adaptive controls respond to input speed changes. They compensate for changes in engine or friction element torque and provide good, consistent shift quality for the life of the transaxle.
SOLENOIDS
The solenoid valves perform most control functions, these valves must be extremely durable and tolerant of dirt. For that reason hardened-steel poppet and ball valves are used. These are free from any close operating clearances. The solenoids operate the valves directly without any intermediate element. Direct operation means that these units must have very high output. They must close against the sizeable flow areas and high line pressures. Fast response is also required to meet the control requirements. Two of the solenoids are normally-venting and two are normally-applying; this was done to provide a default mode of operation. With no electrical power, the transmission provides 2nd gear in (OD), (3), or (L) shift lever positions. All other transmission lever positions will operate normally. The choice of 2nd gear was made to provide adequate breakaway performance while still accommodating highway speeds.
SENSORS
There are three pressure switches to identify solenoid application. There are two speed sensors to read input (torque converter turbine) and output (parking sprag) speeds. There is also a transmission range sensor to indicate the manual shift lever position. The pressure switches are incorporated in an assembly with the solenoids. Engine speed, throttle posi-
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TORQUE MANAGEMENT
Most 41TE transaxles utilize torque management. Torque management is a unique function of the Powertrain Control Module (PCM). The PCM receives output signals from the Transmission Control Module (TCM) and many various engine sensors. The PCM evaluates these signals and decides if it is necessary to decrease the output of the engines torque. This reduction in torque does not interfere with the normal operation of the vehicle. This reduction in torque will prolong the life of the drivetrain components. Torque reduction is not noticeable in normal driving functions. The torque reduction function shuts off above 16 MPH.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios.
ON-BOARD DIAGNOSTICS
This vehicle utilizes a diagnostic system called OBDII. The powertrain control module communicates with the Transmission Control Module. Whenever the transaxle sets a fault in the Transmission Control Module (dependent on which fault is set), the powertrain control module will turn on a MIL (Malfunction Indicator Lamp) on the instrument cluster. By reading the code in the powertrain control module it will tell you where the fault occurred. If the fault occurred in the transaxle, the controller will read a CODE 45. For further information regarding OBDII, refer to Group 25, Emission Systems. These controls provide comprehensive, on-board transaxle diagnostics. The information available can aid in transaxle diagnosis. For example, apply element buildup rate indicates solenoid performance. Also included are self diagnostic functions. Self diagnostics allow the technician to test the condition of the electronic controls. The Transmission Control Module continuously monitors its critical functions. It also records any malfunctions, and the number of engine starts since the last malfunction. This allows the technician to use the information in the event of a customer complaint.
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If vehicle operates properly at high speeds, but has poor acceleration, the converters overrunning clutch may be slipping. If acceleration is normal, but high throttle opening is needed for high speeds, the clutch may have seized. Both of these stator defects require replacement of the torque converter. The clutch that is slipping can be determined by noting the transaxle operation in all selector positions. Then comparing which internal units are applied in those positions. The Elements in Use Chart provides a basis for road test analysis. The process of elimination can be used to detect any unit which slips and to confirm proper operation of good units. Road test analysis can usually diagnose slipping units. However, the actual cause of the malfunction may not be detected. Practically any condition can be caused by leaking hydraulic circuits or sticking valves.
ROAD TEST
Prior to performing a road test, check the fluid level. During the road test, the transaxle should be operated in each position to check for slipping and any variation in shifting.
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TEST THREE-OVERDRIVE CLUTCH CHECK (1) Attach gauge to the overdrive clutch tap. (2) Move selector lever to the (Circle D) position. (3) Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 20 mph. (4) Overdrive clutch pressure should read 74 to 95 psi. (5) Move selector lever to the (3) position and increase indicated vehicle speed to 30 mph. (6) The vehicle should be in second gear and overdrive clutch pressure should be less than 5 psi. (7) This test checks the overdrive clutch hydraulic circuit as well as the shift schedule. TEST FOUR-SELECTOR IN CIRCLE DRIVE, OVERDRIVE GEAR (1) Attach gauge to the 2/4 clutch tap. (2) Move selector lever to the (Circle D) position. (3) Allow vehicle front wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph. (4) The 2/4 clutch pressure should read 75 to 95 psi. (5) This test checks the 2/4 clutch hydraulic circuit. TEST FIVE-SELECTOR IN CIRCLE DRIVE, OVERDRIVE (1) Attach gauge to the torque converter clutch off pressure tap. (2) Move selector lever to the (Circle D) position. (3) Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 50 mph.
CAUTION: Both wheels must turn at the same speed. (4) Torque converter clutch off pressure should be less than 5 psi. (5) This test checks the torque converter clutch hydraulic circuit.
TEST SIX-SELECTOR IN REVERSE (1) Attach gauge to the reverse and LR clutch tap. (2) Move selector lever to the reverse position. (3) Read reverse clutch pressure with output stationary (foot on brake) and throttle opened to achieve 1500 rpm.
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DIAGNOSIS AND TESTING (Continued)
(4) Reverse and LR clutch pressure should read 165 to 235 psi. (5) This test checks the reverse clutch hydraulic circuit.
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TEST RESULT INDICATIONS (1) If proper line pressure is found in any one test, the pump and pressure regulator are working properly. (2) Low pressure in all positions indicates a defective pump, a clogged filter, or a stuck pressure regulator valve. (3) Clutch circuit leaks are indicated if pressures do not fall within the specified pressure range. (4) If the overdrive clutch pressure is greater than 5 psi in Step 4 of Test Three, a worn reaction shaft seal ring or a defective solenoid assembly is indicated. (5) If the underdrive clutch pressure is greater than 5 psi in Step 4 of Test 2A, a defective solenoid assembly or TCM is the cause.
OVERDRIVE CLUTCH Apply air pressure to the overdrive clutch apply passage and watch for the push/pull piston to move forward. The piston should return to its starting position when the air pressure is removed.
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UNDERDRIVE CLUTCH Because this clutch piston cannot be seen, its operation is checked by function. Air pressure is applied to the low/reverse and the 2/4 clutches. This locks the output shaft. Use a piece of rubber hose wrapped around the input shaft and a pair of clamp-on pliers to turn the input shaft. Next apply air pressure to the underdrive clutch. The input shaft should not rotate with hand torque. Release the air pressure and confirm that the input shaft will rotate.
TORQUE CONVERTER LEAKAGE Possible sources of torque converter leakage are: Torque converter weld leaks at the outside (peripheral) weld. Torque converter hub weld.
NOTE: Hub weld is inside and not visible. Do not attempt to repair. Replace torque converter.
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DIAGNOSIS AND TESTING (Continued)
If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic manual. To replace the shifter position indicator, refer to Group 8E, Instrument Panel And Gauges. CONDITION ALL PRND3L DISPLAY LIGHTS ON IN P&N GEAR POSITIONS POSSIBLE CAUSE 1.Check wiring and connectors 2. Faulty trans. range sensor 3. Faulty manual lever ALL DISPLAY LIGHTS ON IN ALL GEAR POSITIONS 1. Check wiring & connectors 2. Faulty trans. range sensor 3. Faulty manual lever 4. CCD communication malfunction 5. Check oil level ALL DISPLAY LIGHTS OFF 1. Normal transient condition between P&R and R&N gear positions 2. Check shift lever linkage 3. Body controller malfunction 4. Check wiring and connectors 5. Faulty cluster ALL DISPLAY LIGHTS OFF ACCOMPANIED BY A NO BUS MESSAGE DISPLAY LIGHTS OUT OF SEQUENCE WITH SHIFT LEVER 1. CCD communication malfunction
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30,000 MILE TRANSAXLE OIL CHANGE When a vehicle attains 30,000 miles on its odometer it is recommended that the transaxle oil be changed. To change the oil, use the procedure that follows: It is recommended that a transaxle fluid exchanger (ATF 2000+ or equivalent) be used to replace the used fluid in the transaxle. If a fluid exchanger is not available use a fluid suction pump (Vacula or equivalent) to draw the fluid out of the dipstick tube. If a fluid suction pump is not available remove the oil pan and drain the fluid.
CAUTION: Chrysler Corporation does not recommend using any fluid exchanger that introduces additives into the transaxle. TRANSAXLE FLUID EXCHANGER METHOD (1) To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive the vehicle till it reaches full operating temperature. (2) Verify that the fill tank on the transaxle fluid exchanger (ATF 2000+ or equivalent) is clean and dry. (3) Fill the tank to the recommended fill capacity with Mopar ATF Plus 3 Type 7176. (4) Hookup the vehicle to the machine following the manufacturers instructions. Perform the exchange procedure following the instructions provided with the machine. (5) Once machine has completed the fluid exchange. Check the fluid level and condition and fill to proper level with Mopar ATF Plus 3 Type 7176. NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line torque specification is 2 Nm (18 in. lbs.).
1. Check wiring and connectors 2. Faulty trans. range sensor 3. Faulty manual lever 4. CCD communication malfunction
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SEVERE USAGE SERVICE If the vehicle exhibits any of the following symptoms, it is recommended that the transaxle oil and filter be replaced. Transaxle oil discolored Transaxle oil has high mileage Oil feels grimy when rubbed between fingertips Poor shift quality Delayed gear engagement Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT This procedure involves changing the transaxle fluid and filter, driving the vehicle for 10 miles and changing the transaxle fluid a second time. (1) Bring the vehicle up to normal operating temperature. Drive the vehicle a minimum of 10 miles. (2) Raise the vehicle on the hoist. (3) Loosen the transaxle oil pan and drain the fluid into a suitable container. (4) Remove the pan and clean all sealant from the pan and transaxle mating surfaces. Clean the magnet and the inside of the pan. (5) Separate the filter and O-ring from the valve body. Inspect the O-ring for cuts or improper installation. This could lead to delayed garage shifts. (6) Install a new filter. Replace the O-ring as necessary. (7) Apply a 1/8 inch bead of Mopar RTV Sealant to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle. Tighten the bolts to 19 Nm (165 in. lbs.). (8) Lower the vehicle and add 4 Quarts of Mopar ATF Plus 3 Type 7176 transaxle fluid. (9) Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. (10) Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 in.) below the ADD mark on the dipstick.
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SERVICE PROCEDURES (Continued)
(11) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. Drive the vehicle a minimum of 10 miles. (12) Raise the vehicle on the hoist. (13) Remove the pan and clean all sealant from the pan and transaxle mating surfaces. Clean the magnet and the inside of the pan. (14) Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter O-ring for any damage and replace as necessary. (15) After the transaxle has stopped draining, reinstall the filter and O-ring. (16) Apply a 1/8 inch bead of Mopar RTV Sealant to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle. Tighten the bolts to 19 Nm (165 in. lbs.). (17) Lower the vehicle and add 4 Quarts of Mopar ATF Plus 3 Type 7176 transaxle fluid. (18) Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. (19) Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 in.) below the ADD mark on the dipstick. (20) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range.
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(7) Add sufficient fluid to bring level to 1/8 inch below the ADD mark. CAUTION: Do not overfill transaxle. Do not add oil if level is between: Lower holes for warm oil (100F). Upper holes for hot oil (180F). (8) Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region (Fig. 5).
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COOLER FLUSH USING TOOL 6906A (1) Remove cover plate filler plug on Tool 6906A. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. (2) Reinstall filler plug on Tool 6906A. (3) Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. (4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. (5) Connect the BLUE pressure line to the OUTLET (From) cooler line. (6) Connect the CLEAR return line to the INLET (To) cooler line (7) Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. (8) Turn pump OFF. (9) Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. (10) Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. (11) Place CLEAR suction line into a one quart container of Mopar ATF PLUS 3 Type 7176 automatic transmission fluid. (12) Turn pump ON until all transmission fluid is removed from the one quart container and lines. This
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SERVICE PROCEDURES (Continued)
The shift lever position must stay until prompted to shift to overdrive The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRBIII indicates the procedure is complete The calculated oil temperature must be above 60 and below 200 (1) Plug the DRBIII scan tool into the data link connector. The connector is located under the instrument panel. (2) Go to the Transmission screen. (3) Go to the Miscellaneous screen. (4) Select Quick Learn Procedure. Follow the instructions of the DRBIII to perform the Quick Learn Procedure.
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(5) Using pliers, squeeze ears of cable attachment at mounting bracket then push through hole to remove. (6) Unseat the dash grommet and remove the cable from the vehicle.
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ADJUSTMENT Lift and rotate the gearshift hand lever into the park (P) gate position and remove the ignition key. This confirms the shift lever is in the gated park (P) position. After confirming the park gate position, turn the ignition switch. If the starter will operate, the park gate position is correct. Move the shift lever into the neutral (N) position. If the starter will operate in this position, the linkage is properly adjusted. If the starter fails to operate in either position, linkage adjustment is required. (1) Park the vehicle on level ground and set the parking brake. (2) Place the gearshift lever in park (P) gate position and remove key.
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REMOVAL AND INSTALLATION (Continued)
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SOLENOID ASSEMBLY-REPLACE
REMOVAL (1) Disconnect battery negative cable. (2) Remove engine air cleaner and tube. (3) Remove gearshift cable (Fig. 17). (4) Remove manual valve lever. (5) Disconnect transmission range sensor connector. (6) Hoist vehicle. (7) Carefully remove transaxle oil pan and drain fluid. (8) Remove transaxle oil filter. Let transaxle oil drain fully. (9) Remove valve body retaining bolts. (10) Extract park rod from guide bracket and remove valve body from transaxle. (11) Place valve body on workbench (Fig. 18). (12) Remove TRS retaining screw (Fig. 19).
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SPEED SENSOR-INPUT
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. The input speed sensor is located to the left of the manual shift lever (Fig. 22).
SPEED SENSOR-OUTPUT
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor.
The output speed sensor is located to the right of the manual shift lever (Fig. 23).
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REMOVAL AND INSTALLATION (Continued)
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Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios.
REMOVAL (1) Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig. 24). Then disconnect the 60 way connector on Transmission Control Module.
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VALVE BODY
REMOVAL
Fig. 31 Push Park Rod Rollers from Guide Bracket Fig. 28 Remove Oil Pan
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REMOVAL AND INSTALLATION (Continued)
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The transaxle and torque converter must be removed as an assembly; otherwise, the torque converter drive plate, pump bushing or oil seal may be damaged. The drive plate will not support a load; therefore, none of the weight of the transaxle should be allowed to rest on the drive plate during removal.
REMOVAL (1) Disconnect negative battery cable. (2) Remove air cleaner duct. Disconnect transaxle shift linkage at manual valve lever (Fig. 34).
TRANSAXLE
Transaxle removal does NOT require engine removal. See Group 7, Cooling to drain engine cooling system and remove coolant return extension (3.0 liter engine only).
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REMOVAL AND INSTALLATION (Continued)
(18) Rotate engine clockwise to gain access to torque converter bolts (Fig. 41). Remove torque converter mounting bolts.
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(27) Remove lower bellhousing bolts. (28) Carefully lower the transaxle assembly from vehicle.
INSTALLATION (1) For installation of transaxle, reverse the above procedure. (2) Check and/or adjust gearshift cable. (3) Refill transaxle with MOPAR ATF PLUS 3 (Automatic Transmission Fluid) Type 7176.
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Fig. 48 Transmission Range Sensor Removed Fig. 46 Install Oil Pump Seal
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TRANSAXLE DISASSEMBLE
NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification. CAUTION: Do not intermix clutch discs or plates as the unit might then fail. (1) Remove input and output speed sensors. (2) Remove transaxle solenoid pack (Fig. 59).
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Fig. 99 Remove Low/Reverse Reaction Plate Snap Ring Fig. 96 Remove Tapered Snap Ring
Fig. 100 Remove Low/Reverse Clutch Pack Fig. 97 Remove Low/Reverse Reaction Plate
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Fig. 104 Transfer Shaft Gear Nut and Coned Washer Fig. 101 Remove Rear Cover Bolts
Fig. 105 Remove Transfer Shaft Gear Fig. 102 Remove Rear Cover
Fig. 106 Remove Transfer Shaft Gear and (Select) Shim Fig. 103 Remove Transfer Shaft Gear Nut
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Fig. 108 Remove Transfer Gear Bearing Cone Fig. 111 Remove Transfer Shaft
Fig. 109 Remove Transfer Shaft Bearing Cup Fig. 112 Bearing Cup Removed
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Fig. 137 Remove Piston Retainer Fig. 140 Remove Output Bearing Outer Cup
This concludes the disassemble of the transaxle centerline. To disassemble the input clutch assembly, refer to Input Clutches-Recondition.
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INPUT CLUTCHES-RECONDITION
DISASSEMBLY
Fig. 146 OD/Reverse Pressure Plate Snap Ring Fig. 143 Pry Reverse Clutch Reaction Plate
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Fig. 148 Waved Snap Ring Fig. 151 Overdrive Shaft Assembly
Fig. 149 Remove OD Clutch Pack Fig. 152 Underdrive Shaft Assembly
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Fig. 162 Input Hub Tapered Snap Ring Fig. 159 UD Spring Retainer Snap Ring
Fig. 163 Tap on Input Hub Fig. 160 UD Return Spring and Retainer
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Fig. 183 Install Last UD Clutch Disc Fig. 180 Install UD Spring Retainer and Snap Ring
Fig. 184 OD/UD Reaction Plate Fig. 181 Underdrive Clutch Pack
The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.
Fig. 182 UD Clutch Flat Snap Ring Fig. 185 Tapered Snap Ring
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TRANSAXLE ASSEMBLE
To assemble the transaxle centerline, refer to the following procedures.
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Fig. 219 Install Snap Ring Fig. 216 Install Low/Reverse Piston Return Spring
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(6) Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting. (7) Use Tool 6259 to remove the retaining bolt and washer. To remove the output gear, use Tool L-4407. (8) Remove the gauging shim and install the proper shim (Fig. 224). Use grease to hold the shim in place. Install the output gear and bearing assembly (Fig. 225).
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Fig. 229 Output Gear Retaining Bolt Stirrup (Serration Side Out) Fig. 227 Tighten Output Gear to 271 Nm (200 ft. lbs.)
(10) Using an inch-pound torque wrench, check the turning torque (Fig. 228). The torque should be between 3 and 8 inch-pounds. If the turning torque is too high, install a .04 mm (.0016 inch) thicker shim. If the turning torque is too low, install a .04 mm (.0016 inch) thinner shim. Repeat until the proper turning torque is 3 to 8 inch pounds. NOTE: Install output gear stirrup and strap bolts. All transaxles utilize a stirrup and retaining strap that is attached to the output gear. The stirrup prevents the output gear retaining bolt from turning and backing out of the rear carrier. The strap is used to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out.
Fig. 230 Stirrup Strap (Align Strap Holes With Tapped Gear Holes)
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Fig. 232 Turn Stirrup Clockwise Against Flats Of Output Gear Retaining Bolt
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Fig. 240 Install Bearing Cup Retainer Fig. 237 Install Transfer Shaft
Fig. 241 Install Transfer Gear Bearing Cone Fig. 238 Install Transfer Shaft Bearing Snap Ring
TRANSFER SHAFT BEARING (1) Install a 4.66 mm (.184 inch) gauging shim on the transfer shaft. (2) Install transfer shaft gear and bearing assembly and torque the nut to 271 Nm (200 ft. lbs.). To measure bearing end play: Attach Tool L-4432 to the transfer gear. Mount a steel ball with grease into the end of the transfer shaft. Push and pull the gear while rotating back and forth to insure seating of the bearing rollers. Using a dial indicator, measure transfer shaft end play. (3) Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain the proper bearing setting. (4) Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L-4407.
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Fig. 258 Install 2/4 Clutch Retainer Snap Ring Fig. 261 Install Front Carrier and Rear Annulus Assembly
DETERMINING No. 4 THRUST PLATE THICKNESSINPUT SHAFT END PLAY To determine the proper thickness of the No. 4 thrust plate, select the thinnest No. 4 thrust plate. Using petrolatum (Fig. 263) to hold thrust plate in position, install input clutch assembly. Be sure the input clutch assembly is completely seated (Fig. 264).
CAUTION: If view through input speed sensor hole is not as shown above, the input clutches assembly is not seated properly.
Remove the oil pump O-ring (Fig. 265). You will be able to install and remove the oil pump and gasket very easily to select the proper No. 4 thrust plate.
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Reinstall the input clutches assembly with the selected thrust plate .
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Fig. 272 Install Pump Attaching Bolts Fig. 275 Install Low/Reverse Accumulator Snap Ring
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Fig. 282 Install Oil Pan Fig. 279 Install Valve Body
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Fig. 286 Remove Differential Cover Fig. 284 Install Solenoid Pack
(2) Install input and output speed sensors. This concludes the assembly of the transaxle centerline.
DIFFERENTIAL REPAIR
NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft.
DISASSEMBLE The transfer shaft should be removed for differential repair and bearing turning torque checking. (1) Remove the differential cover and bolts (Fig. 285) (Fig. 286). (2) Remove the differential bearing retainer and bolts (Fig. 287) (Fig. 288).
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Fig. 290 Position Tool 5048 Over Button and Collets at Differential Bearing (Ring Gear Side)
Fig. 289 Position Button and Collets Onto Differential and Bearing (Ring Gear Side)
(6) Using Miller Special Tool L-4518, remove the differential bearing race from the extension housing. (7) Using Miller Special Tool 6062A, remove the differential bearing race from the bearing retainer (Fig. 292) (Fig. 293).
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Fig. 294 Checking Side Gear End Play (Extension Housing Side)
L-4410, C-4171
Diff. Race. On Retainer Side Diff. Race. On Ext. Hous. Side Extension Housing Seal Bearing Retainer Seal
Fig. 295 Checking Side Gear End Play (Bearing Retainer Side)
CHECKING SIDE GEAR END PLAY Check side gear end play whenever the differential is removed for service.
NOTE: Side gear end play must be BETWEEN 0.001 to 0.013 inch.
ASSEMBLE
NOTE: Use Mopar Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case. (1) Using Miller Special Tool L-4410, and C-4171, install differential bearing to differential (extension housing side) (Fig. 296).
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PRELOAD ADJUSTMENT W/O SHIM (1) Remove the bearing cup from the differential bearing retainer using Miller special Tool 6062A. (2) Remove existing shim from under bearing cup. (3) Reinstall the bearing cup into the retainer using Miller Special Tool 6061, and C-4171. NOTE: Oil baffle is not required when making the shim calculation. (4) Install the bearing retainer into the case. Torque bolts to 28 Nm (250 in. lbs.).
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Reverse Clutch (Select Snap Ring) . . . . .0.76-1.24mm (0.030-0.049 in.) Overdrive Clutch (No Selection) . . . . . . . . . . . . . . . . . . .0.96-2.26mm (0.038-0.089 in.) Underdrive Clutch Select Pressure Plate) . . . . . . . . . . . .0.91-1.47mm (0.036-0.058 in.) Transmission End Play . . . . . . . . . . . . .0.12-0.63mm (0.005-0.025 in.)
Gear Ratios
Transmission Portion First Gear . . . . . . . . . . . Second Gear. . . . . . . . . . Direct Gear . . . . . . . . . . Overdrive Gear . . . . . . . Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.84 .1.57 .1.00 .0.69 .2.21
Overall Top Gear Ratio 3.8 Liter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38 3.3 Liter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49 2.4 Liter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.69 Pump Clearances Outer Gear To Pocket . . . . . . . . . . . . .0.045-0.141mm (0.0018-0.0056 in.) Outer Gear Side Clearance. . . . . . . . .0.020-0.046mm (0.0008-0.0018 in.) Inner Gear Side Clearance . . . . . . . . .0.020-0.046mm (0.0008-0.0018 in.) Tapered Roller Bearing Settings Differential Assembly . . .5 to 18 in. lbs. Drag Torque Output Hub. . . . . . . . . . . .3 to 8 in. lbs. Drag Torque Transfer Shaft . . . . . . . . .0.002 to 0.004 in. End Play Overall Drag At Output Hub . . . . . . . .3 to 16 in. lbs. Drag Torque Clutch Pack Clearances Low/Rev Clutch (Select Reaction Plate) . . . . . . . . . . . .0.89-1.04mm (0.035-0.042 in.) Two/Four Clutch (No Selection) . . . . . . . . . . . . . . . . . . .0.76-2.64mm (0.030-0.104 in.)
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Puller C-637
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Adapter C-4996
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SPECIAL TOOLS (Continued)
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Installer L-4520
Remover/Installer 5049-A
Installer 5050A
Installer 5052
Compressor 5058A
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Compressor 5059-A
Installer 6053
Installer 5067
Button 6055
Pliers 6051
Plate 6056
Installer 6052
Disk 6057
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SPECIAL TOOLS (Continued)
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Installer 6061
Installer 6261
Remover 6062-A
Tip 6268
Holder 6259
Remover/Installer 6301
Bolt 6260
Remover/Installer 6302
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Installer 6536-A
Puller 7794-A
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Service of the Power Transfer Unit is limited to: Seals Gaskets One ball bearing Output flange If the ring gear and pinion, any tapered roller bearings, case, covers, or pinion carrier fail the entire unit must be replaced.
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DIAGNOSIS AND TESTING (Continued)
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seal leaks. These holes are located on the bottom side of the assembly (Fig. 6).
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INSTALLATION (1) Install new seal with Seal Installer 5049 (Fig. 32). (2) If the original flange is used, align index marks and press flange onto pinion. If a new flange is used disregard the alignment marks on the pinion and press flange onto the pinion.
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INSTALLATION (1) Clean and inspect seal area. (2) Use special tool No. MD998803 and install seal (Fig. 37). When installing seal the spring side of the seal must face toward the special tool.
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REMOVAL (1) Remove power transfer unit from the vehicle. (2) Remove end cover bolts (Fig. 41). (3) Tap on end cover ears to separate cover from case (Fig. 42). (4) Drive seal out with a hammer and small chisel (Fig. 43).
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REMOVAL (1) Remove power transfer unit from the vehicle. (2) Remove end cover bolts (Fig. 46). (3) Tap on end cover ears to separate end cover from case (Fig. 47). (4) Pry out seal with a pry bar (Fig. 48). INSTALLATION (1) Clean and inspect seal area. (2) Remove input shaft from housing and stand on soft block of wood. Install input shaft end seal with seal installer 5065 and handle C-4171. (3) Lubricate seal lip after installing seal into input shaft. (4) Clean sealing surfaces of the end cover and P.T.U. case. Apply a bead of Mopar Gasket Maker, Loctite Gasket Eliminator No. 518 or equivalent. (5) Place end cover onto P.T.U. case and install bolts. Tighten bolts to 28 Nm (250 in. lbs.) in the sequence shown in (Fig. 49). Retighten first bolt after all others are tight.
CAUTION: When end cover is installed be careful not to damage the P.T.U. Input Shaft Cover Seal.
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REMOVAL (1) Raise vehicle on hoist. (2) Remove right front half shaft from vehicle. (3) Remove output seal with a hammer and chisel (Fig. 52). (4) Remove bearing retaining snap ring (Fig. 53). (5) Use bearing puller MD998346 to remove bearing (Fig. 54).
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SPECIFICATIONS TORQUE
DESCRIPTION TORQUE End Cover . . . . . . . . . . . . . . . . .28 Nm (250 in. lbs.) Fill Plug . . . . . . . . . . . . . . . . . . .27 Nm (240 in. lbs.) Flange Nut . . . . . . . . . . . . . . . .162 Nm (120 ft. lbs.) Inspection Plug . . . . . . . . . . . . .20 Nm (180 in. lbs.) Rear Cover . . . . . . . . . . . . . . . . .28 Nm (250 in. lbs.) Ring Gear . . . . . . . . . . . . . . . . . . .94 Nm (70 ft. lbs.)
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GENERAL INFORMATION A-598 MANUAL TRANSAXLE . . . . . . . . . . . . . . . 2 A-558 MANUAL TRANSAXLERHD VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GEAR RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GEAR RATIOSRHD VEHICLES . . . . . . . . . . . . 3 GEARSHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . 3 GEARSHIFT PATTERNRHD VEHICLES . . . . . . 3 SELECTION OF LUBRICANT . . . . . . . . . . . . . . . . 2 SELECTION OF LUBRICANTRHD VEHICLES . 2 SPECIAL ADDITIVES . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL ADDITIVESRHD VEHICLES . . . . . . . 3 TRANSAXLE IDENTIFICATION INFORMATION . . 2 TRANSAXLE IDENTIFICATION INFORMATIONRHD VEHICLES . . . . . . . . . . 2 DESCRIPTION AND OPERATION AXLE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GEARSHIFT LEVERS . . . . . . . . . . . . . . . . . . . . . . 3 DIAGNOSIS AND TESTING CLUTCH PROBLEMS . . . . . . . . . . . . . . . . . . . . . 4 COMMON PROBLEM CAUSES . . . . . . . . . . . . . . 3 HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . 4 NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4 SLIPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . 4 SERVICE PROCEDURES FLUID DRAIN AND FILL . . . . . . . . . . . . . . . . . . . 4 FLUID DRAIN AND FILLRHD VEHICLES . . . . 4 REMOVAL AND INSTALLATION A-558 TRANSAXLE ASSEMBLYRHD VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 AXLE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BACK-UP LAMP SWITCH . . . . . . . . . . . . . . . . . . 9 CRANKSHAFT POSITION SENSOR 2.5L VM DIESEL . . . . . . . . . . . . . . . . . . . . . . 10 CROSSOVER LEVER . . . . . . . . . . . . . . . . . . . . . 11 GEARSHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . 5
GEARSHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . 5 GEARSHIFT CABLES . . . . . . . . . . . . . . . . . . . . . . 5 GEARSHIFT CABLESRHD VEHICLES . . . . . . . 7 GEARSHIFT KNOB . . . . . . . . . . . . . . . . . . . . . . . 5 GEARSHIFT MECHANISM REPLACEMENT . . . . . 7 GEARSHIFT MECHANISM REPLACEMENT RHD VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . 8 INPUT SHAFT FRONT BEARING RETAINER . . . 15 INPUT SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . 16 SELECTOR LEVER . . . . . . . . . . . . . . . . . . . . . . 11 SHIFT SHAFT SEALS . . . . . . . . . . . . . . . . . . . . 12 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VEHICLE SPEED SENSOR DRIVE GEAR . . . . . . 9 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 39 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 32 INTERMEDIATE SHAFT . . . . . . . . . . . . . . . . . . . 33 SHIFT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . 43 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 TRANSAXLE CASE . . . . . . . . . . . . . . . . . . . . . . 48 CLEANING AND INSPECTION SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . 52 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ADJUSTMENTS BEARING ADJUSTMENT PROCEDURE . . . . . . . 56 GEARSHIFT CROSSOVER CABLE . . . . . . . . . . . 52 GEARSHIFT CROSSOVER CABLE . . . . . . . . . . . 55 INTERMEDIATE SHAFT BEARING PRELOAD . . 57 SPECIFICATIONS A-558 MANUAL TRANSAXLERHD VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 A-598 (T-750) MANUAL TRANSAXLE . . . . . . . 59 SPECIAL TOOLS A-558 MANUAL TRANSAXLERHD VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 A-598 (T-750) MANUAL TRANSAXLE . . . . . . . 60
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SELECTION OF LUBRICANT
The A-598 manual transaxle uses SAE 5W-30 engine oil, meeting SG and/or SG-CD qualifications, as the factory fill lubricant. G5 SAE 10W-40 engine oil is a suitable service fill alternative. Hypoid gear lube, manual transmission fluid, and/or automatic transmission fluid should not be used in this transaxle. Hard shifting effort, bearing, gear, and/or synchronizer failure may occur if incorrect fluid is used.
SPECIAL ADDITIVES
The addition of any fluids to the transaxle, other than the fluid listed above, is not recommended. An exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission
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GENERAL INFORMATION (Continued)
sealers should be avoided, since they may adversely affect seals.
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GEAR RATIOS
Gear ratios for the 2.4L gasoline engine and 2.5L Turbo Diesel MTX are as follows: 1st3.36 2nd1.90 3rd1.28 4th0.92 5th0.71 Reverse3.17 Final drive ratio of 3.88 was selected for maximum performance. All forward gears are synchronized. Gear ratios for the 2.0L GAS MTX are as follows: 1st3.69 2nd2.24 3rd1.45 4th1.03 5th0.81 Reverse3.17 Final drive ratio of 4.08 was selected for maximum performance. All forward gears are synchronized.
GEARSHIFT PATTERN
The A-598 transaxle shift pattern is a Hpattern (Fig. 3). Overdrive fifth and reverse gears are inline and to the right of the first through fourth gear positions.
AXLE SEALS
The axle shaft seals are identical for both sides of the differential and will interchange.
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HARD SHIFTING
Hard shifting may be caused by a misadjusted crossover cable. If hard shifting is accompanied by gear clash, synchronizer clutch and stop rings or gear teeth may be worn or damaged. Misassembled synchronizer components also cause shifting problems. Incorrectly installed synchronizer sleeves, struts, or springs can cause shift problems.
NOISY OPERATION
Transaxle noise is most often a result of worn or damaged components. Chipped, broken gear or synchronizer teeth, and brinnelled, spalled bearings all cause noise. Abnormal wear and damage to the internal components is frequently the end result of insufficient lubricant.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components can cause difficult shifting, gear clash, and noise. A worn or damaged clutch disc, pressure plate, or release bearing can cause hard shifting and gear clash.
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SERVICE PROCEDURES (Continued)
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INSTALLATION (1) For installation, reverse removal procedure, omitting step (2).
GEARSHIFT BOOT
REMOVAL (1) Remove shifter knob. Refer to gearshift knob removal. (2) Pull up on boot until retention clips disengage from the console and remove (Fig. 7).
INSTALLATION (1) For installation, reverse removal procedure, taking care to fully engage the retention clips.
GEARSHIFT BOOT
REMOVAL (1) Remove shifter knob. Refer to gearshift knob removal. (2) Pull up on boot until retention clips disengage from the console and remove (Fig. 8). INSTALLATION (1) For installation, reverse removal procedure, taking care to fully engage the retention clips.
GEARSHIFT CABLES
REMOVAL (1) Disconnect battery negative cable. (2) Remove air cleaner assembly. (3) Disconnect gearshift cable ends from transaxle shift levers (Fig. 9) (Fig. 10).
CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings.
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REMOVAL AND INSTALLATION (Continued)
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(3) Disconnect gearshift cable ends from transaxle shift levers (Fig. 16) (Fig. 17). CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. (4) Remove cable to bracket retaining clips at transaxle (Fig. 18). CAUTION: It is recommended that new cable retaining clips be used for reinstallation. (5) Pull cables up out of engine mount bracket. (6) Remove gearshift knob and boot. Refer to Knob and Boot Removal in this section. (7) Remove console screws (Fig. 19). (8) Remove cable retaining clips at shifter (Fig. 20) (Fig. 21). CAUTION: It is recommended that new cable retaining clips be used for reinstallation. Clips must be installed to span the slotted holes. (9) Disconnect shift cables from shifter. Pry with equal force on both sides of shifter cable isolator bushings to avoid damaging bushings. (10) Lift vehicle on hoist. Cut gearshift cable tie strap at floor pan with diagonal cutters. (11) Remove shift cables from vehicle by grasping cables and grommets one at a time and tugging down through floor pan holes (Fig. 22).
INSTALLATION (1) To install, reverse removal procedure. After cables have been replaced, cable adjustment should be checked. Refer to cable adjustment procedure in this section.
NOTE: High temperature tie straps must be used when replacing cable(s). Locate the new tie strap at the white band on the crossover cable and cinch cables tightly together. CAUTION: Only the crossover cable is adjustable. The selector cable does not have any adjustment capabilities.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) To install, reverse removal procedure. (2) Confirm vehicle speedometer is functioning properly following installation.
REMOVAL (1) From top side of vehicle, remove wiring connector from switch (Fig. 24). (2) Unscrew switch from transaxle.
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REMOVAL AND INSTALLATION (Continued)
REMOVAL (1) Remove electrical connector at crankshaft position sensor (Fig. 25). (2) Remove screw retaining the crankshaft position sensor to the bellhousing. (3) Remove the crankshaft position sensor.
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AXLE SEALS
The axle shaft seals are identical for both sides of the differential and will interchange.
CROSSOVER LEVER
REMOVAL (1) Remove crossover cable. Refer to Gearshift Cable removal. (2) Using a pin punch, remove the crossover roll pin from lever. (3) Pull up and remove the crossover lever from the transaxle crossover shaft. INSTALLATION (1) For installation, reverse removal procedure. Replace the roll pin that was removed with a new one.
SELECTOR LEVER
REMOVAL (1) Remove the selector cable. Refer to Gearshift Cable removal. (2) Using a pin punch, remove the roll pin from the lever. (3) Remove the selector lever from the transaxle selector shaft INSTALLATION (1) For installation, reverse removal procedure. Replace the roll pin with a new one.
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REMOVAL (1) Remove the shift lever from the seal that is to be serviced. Refer to shift lever removal for service procedure. (2) Using a pick tool, pry up on the shift shaft seal and remove seal from bore. INSTALLATION (1) Position new shift shaft seal in bore. (2) Install shift shaft seal into bore using an appropriate size deepwell socket.
TRANSAXLE
The following items can be serviced without removing the transaxle from the vehicle: Gearshift housing 5th speed synchronizer 5th speed gear Roller detents and springs Speedometer pinion Vehicle speed sensor Bearing retainer plate. All external covers Shift shaft seals Axle shaft seals To service any other component of the A-598 transaxle you must remove it from the vehicle.
REMOVAL (1) Disconnect battery negative cable. (2) Remove air intake hose. Disconnect air mass meter connector. (3) Remove intercooler hose.
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REMOVAL AND INSTALLATION (Continued)
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(2) Fill transaxle to the proper level with the specified lubricant. (3) While the vehicle is elevated slightly, run the transaxle through all the forward gears. Apply brakes and shift into reverse. Run the transaxle through reverse gear.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) For installation, reverse removal procedure. Use Mopar Gasket Maker to seal input bearing retainer sleeve to bellhousing.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Position the modular clutch assembly onto the input shaft of the transaxle (Fig. 62). (2) To reinstall transaxle, reverse removal procedure making certain to align the elongated hole in the drive plate with the modular clutch bolt hole that has the white paint mark.
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DISASSEMBLY (1) Remove engine mount bracket (Fig. 64). (2) Remove differential bearing retainer (Fig. 65). (3) Remove extension housing (Fig. 66). (4) Remove differential cover with soft-faced hammer (Fig. 67).
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DISASSEMBLY AND ASSEMBLY (Continued)
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Fig. 68 Differential
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DISASSEMBLY AND ASSEMBLY (Continued)
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Fig. 82 5th Gear Synchronizer Snap Ring Fig. 85 5th Gear Retaining Nut
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DISASSEMBLY AND ASSEMBLY (Continued)
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Fig. 94 Shuttles
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DISASSEMBLY AND ASSEMBLY (Continued)
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Fig. 104 Reverse Shift Rail Fig. 101 5th Gear Shift Rail
(28) Remove reverse shift rail (Fig. 104) (Fig. 105). (29) Move the 12 and 34 shift rail lugs out of the way (Fig. 106). (30) Remove geartrain set (Fig. 107).
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(2) Carefully install 5th gear shift rail (Fig. 109) (Fig. 110).
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DISASSEMBLY AND ASSEMBLY (Continued)
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DISASSEMBLY AND ASSEMBLY (Continued)
(17) Apply a bead of Mopar Gasket Maker or equivalent onto end cover. Install 5th gear/synchro end cover. Tighten bolts to 28 Nm (250 in. lbs.). (18) Move 34 shift lug into position. Install 34 roll pin at 34 shift lug (Fig. 121).
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INPUT SHAFT
The input shaft is serviced as an assembly. The only serviceable component of the input shaft is the rear bearing.
DISASSEMBLY (1) Install the bearing splitter 1130 under the rear bearing. (2) Position the input shaft into a shop press (Fig. 128). (3) Remove the rear bearing (Fig. 129).
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DISASSEMBLY AND ASSEMBLY (Continued)
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INTERMEDIATE SHAFT
DISASSEMBLY (1) Install intermediate shaft into shop press. (2) Install bearing splitter 1130 under the 4th speed gear clutch teeth (Fig. 132). (3) Remove intermediate shaft rear bearing snap ring (Fig. 133). (4) Position Special Tool 67921 over intermediate shaft.
CAUTION: To prevent damaging the intermediate shaft, grasp the bottom of the shaft when doing shop press procedures. (5) Using Special Tool 67921 as a driver, press off and remove 4th speed gear (Fig. 134). (6) Remove intermediate shaft from shop press. (7) Install Special Tool 6938 onto front intermediate bearing for protection. (8) Remove 34 synchro snap ring (Fig. 135) (Fig. 136).
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DISASSEMBLY AND ASSEMBLY (Continued)
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Fig. 142 12 Synchro Snap Ring Fig. 144 12 Dual Cone Synchro
(16) Install Special Tool 1130 bearing splitter under the plastic intermediate shaft front bearing (17) Position shaft into shop press. (18) Position Special Tool MD99880201 over the intermediate shaft. (19) Remove the intermediate shaft front bearing (Fig. 145).
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DISASSEMBLY AND ASSEMBLY (Continued)
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DISASSEMBLY AND ASSEMBLY (Continued)
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DIFFERENTIAL
NOTE: The differential is typically serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you should replace the differential assembly.
DIFFERENTIAL BEARINGS Differential bearings are usually serviced as pairs. If one differential bearing fails, you should replace both bearing cups and cones
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.
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DISASSEMBLY AND ASSEMBLY (Continued)
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Fig. 161 Insert (Select) Shim and Differential Bearing Retainer Cup
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Fig. 166 Remove or Install Ring Gear Bolts and Ring Gear
DIFFERENTIAL GEARS
REMOVAL (1) Remove pinion shaft retaining pin (Fig. 167) (Fig. 168). (2) Remove pinion shaft (Fig. 169). (3) Rotate side gears to opening in differential (Fig. 170). (4) Remove differential gears (Fig. 171).
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DISASSEMBLY AND ASSEMBLY (Continued)
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Fig. 170 Remove Pinion Gears, Side Gears, and Thrust Washers by Rotating Side Gears to Opening in Case
INSTALLATION (1) Assemble the differential side gears, pinion gears and pinion gears with the pinion gear washers. (2) Install pinion shaft retaining pin (Fig. 172). (3) Stake pinion shaft retaining pin with a suitable chisel (Fig. 173). (4) Rotate the assembly two full revolutions both clockwise and counterclockwise. Set up dial indicator as shown and record end play (Fig. 174) (Fig. 175). Rotate side gear 90 degrees and record another end play. Again, rotate side gear 90 degrees and record a final end play.
SYNCHRONIZER
The 12 synchronizer is a dual-cone synchronizer (Fig. 176). The disassembly and assembly procedures are the same as the 34 synchronizer (Fig. 177)
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DISASSEMBLY AND ASSEMBLY (Continued)
(3) Install the synchro springs into the synchro struts. (4) Line up stop ring tang over the struts in the hub. Install stop rings. Center the struts by pushing on both stop rings. (5) Install the outer cones (dual-cone synchronizer) into the synchronizer stop rings. (6) Install the inner cones (dual-cone synchronizer) into the outer cones.
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SHIFT COVER
The gearshift cover can be disassembled and worn parts can be replaced individually (Fig. 178).
DISASSEMBLY (1) Remove gearshift housing roll pin at shift lever (Fig. 179). (2) Remove shift selector shaft dust boot (Fig. 180). (3) Remove selector shaft oil seal (Fig. 181). (4) Remove shifter housing vent cap at crossover lever (Fig. 182).
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DISASSEMBLY AND ASSEMBLY (Continued)
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ASSEMBLY (1) Install selector shaft components and selector shaft into shift housing. (2) Install selector shaft roll pin flush with selector. (3) Install outer selector shaft C-clip. (4) Install inner selector shaft C-clip. (5) Install crossover shaft.
NOTE: Proper torque of the 5-R blocker bolts is very important. (6) Install the 5th/reverse gear blocker bolts (Fig. 191).
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TRANSAXLE CASE
INTERMEDIATE SHAFT FRONT BEARING CUP
REMOVAL (1) Insert Special Tool 6787 into the intermediate shaft front bearing cup (Fig. 193). (2) Tighten the special tool so that the tool fingers spread out and seat underneath the bearing cup.
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DISASSEMBLY AND ASSEMBLY (Continued)
(2) Verify the oil feeder is centered within the bearing bore. (3) Position the bearing cup into the bearing bore. (4) Position Special Tool 6939 and Special Tool C-4171 into the intermediate shaft bearing cup. (5) Press new bearing cup into the case (Fig. 196).
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DISASSEMBLY AND ASSEMBLY (Continued)
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SYNCHRONIZER
Fig. 208 Slide Hammer 3752
CLEAN Do not attempt to clean the blocking rings in solvent. The friction material will become contaminated. Place synchronizer components in a suitable holder and clean with solvent. Air dry. INSPECT Proper inspection of components involve: Teeth, for wear, scuffed, nicked, burred, or broken teeth Struts, for wear or distortion Springs, for distortion, cracks, or wear If any of these conditions exist in these components, replace as necessary.
ADJUSTMENTS
Fig. 209 Shift Rail Bushing Removal
REVERSE SHIFT LEVER
REMOVAL (1) Remove reverse shift lever E-clip. (2) Remove the flat and wave washers. (3) Remove the reverse shift lever from the mounting stud. INSTALLATION (1) Position the reverse shift lever onto the mounting stud. (2) Install the washers onto the mounting stud. (3) Install the E-clip.
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ADJUSTMENTS (Continued)
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ADJUSTMENTS (Continued)
CAUTION: Proper torque to the crossover cable adjusting screw is very important.
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ADJUSTMENTS (Continued)
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ADJUSTMENTS (Continued)
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ADJUSTMENTS (Continued)
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(3) Bearing preload and drag torque specifications must be maintained to avoid premature bearing failures. Used (original) bearings may lose up to 50% of their original drag torque after break in. All bearing adjustments must be made with no other component interference or gear intermesh. (4) Replace bearings as a pair: If one differential bearing is defective, replace both differential bearings. (5) Bearing cones must not be reused if removed. (6) Turning torque readings should be obtained while smoothly rotating in either direction.
Fig. 226 End Cover Removed Fig. 225 Auxiliary Vent Installation
been replaced, you must perform the differential bearing preload shim adjustment. If the transaxle case has been replaced, you must perform both procedures. (2) Remove 5th shift fork roll pin (Fig. 227). (3) Use Special Tool 6252 to hold 5th gear. Remove input shaft 5th gear nut (Fig. 228). (4) Remove 5th gear synchro snap ring (Fig. 229). (5) Remove 5th gear synchro, synchro plate, and fork. (6) Remove 5th drive gear off of the input shaft (Fig. 230). (7) Remove bearing retainer plate (Fig. 231). (8) Remove bearing preload shim (Fig. 232). (9) Bolt down the bearing support plate in two places (verify dowels are in place). (10) Seat the intermediate bearing cup against the bearing. (11) Measure depth of intermediate bearing cup with dial depth gauge (Fig. 233).
GENERAL RULES ON SERVICING BEARINGS (1) Use extreme care when removing and installing bearing cups and cones. Burrs or nicks on the bearing seat will give a false end play reading while gauging for proper shims. Improperly seated bearing cups and cones are subject to lowmileage failure. (2) Bearing cups and cones should be replaced if they show signs of pitting or heat distress. If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.
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ADJUSTMENTS (Continued)
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ADJUSTMENTS (Continued)
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SPECIAL TOOLS
A-558 MANUAL TRANSAXLE FLUID FILL
The fluid level should be within 3.175mm (1/8 inch) from the bottom of the transaxle fill hole (vehicle must be level when checking). Fill transaxle to proper level with SAE 5W-30 engine oil, meeting SG and/or SG-CD qualifications. G5 SAE 10W-40 engine oil is a suitable service fill alternative. TRANSAXLE A-558 METRIC MEASURE 1.9-2.2 Liters
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SPECIAL TOOLS (Continued)
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Adapters C-293-45
Handle C-4171
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Adapter C-4996
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22 - 1
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TIRES
INDEX
page DESCRIPTION AND OPERATION RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . . REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . SPARE TIRE (TEMPORARY) . . . . . . . . . . . . . . TIRE INFLATION PRESSURES . . . . . . . . . . . . TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . TIRE PRESSURE FOR HIGH-SPEED DRIVING DIAGNOSIS AND TESTING LEAD CORRECTION CHART . . . . . . . . . . . . . . PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . TIRE NOISE OR VIBRATION . . . . . . . . . . . . . . TIRE WEAR PATTERNS . . . . . . . . . . . . TREAD WEAR INDICATORS . . . . . . . . SERVICE PROCEDURES REPAIRING TIRE LEAKS . . . . . . . . . . . TIRE AND WHEEL MATCH MOUNTING TIRE AND WHEEL ROTATION (NONDIRECTIONAL THREAD PATTERN) . . CLEANING AND INSPECTION CLEANING TIRES . . . . . . . . . . . . . . . . SPECIFICATIONS TIRE SPECIFICATIONS . . . . . . . . . . . . page ........ 4 ........ 3 ........ 6 ........ 6 ........ 6 ........ 7 ........ 8
. . . . . .
. . . . . .
2 3 2 2 1 3
.. 4 .. 3 .. 4
TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code (Fig. 1). Performance tires will have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. The letter S indicates that the tire is speed rated up to 112 mph. Q up to 100 mph T up to 118 mph U up to 124 mph H up to 130 mph V up to 149 mph Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or MS (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS This vehicle was designed to allow the use of a specified type of snow chain on the tires. Only compact snow chains or other traction aidsmeeting SAE type Class S specifications may be used. Any style
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RADIAL-PLY TIRES
Radial-ply tires improve handling, tread life, ride quality and decrease rolling resistance. Radial-ply tires must always be used in sets of four and under no circumstances should they be used on the front only. They may be mixed with a temporary spare tire when necessary. A maximum speed of 50 MPH is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. It is recommended that tires from different manufactures NOT be mixed. The proper tire pressure should be maintained on all four tires. For proper tire pressure refer to the Tire Inflation Pressure Placard located in the glove box.
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DESCRIPTION AND OPERATION (Continued)
Improper inflation can cause: Uneven wear patterns Reduced tread life Reduced fuel economy Unsatisfactory ride The vehicle to drift. Proper tire air inflation pressure specifications can be found on the Vehicle Tire Placard provided with the vehicle. See owners manual. Tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. Tire inflation pressures specified on the placard are always cold inflation pressure. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure build-up.
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Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires not listed in the specification charts may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE.
REPLACEMENT TIRES
The original equipment tires provide a proper balance of many characteristics such as: Ride Noise Handling Durability Tread life Traction Rolling resistance Speed capability It is recommend that tires equivalent to the original equipment tires be used when replacement is needed.
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To find out if tires are causing the noise or vibration, drive the vehicle over a smooth road at varying speeds. Note the noise level during acceleration and deceleration. The engine, differential and exhaust noises will change as speed varies, while the tire noise will usually remain constant.
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DIAGNOSIS AND TESTING (Continued)
LEAD CORRECTION CHART
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Deflate tire completely before dismounting tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten all 5 wheel nuts to a torque of 135 Nm (100 ft. lbs.).
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SERVICE PROCEDURES (Continued)
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If the high spot is within 102 mm (4.0 in.) of the first spot and is still excessive, replace the tire. If the high spot is within 102 mm (4.0 in.) of the first spot on the wheel, the wheel may be out of specifications. Refer to Wheel and Tire Runout. If the high spot is NOT within 102 mm (4.0 in.) of either high spot, draw an arrow on the tread from second high spot to first. Break down the tire and remount it 90 degrees on rim in that direction (Fig. 10). This procedure will normally reduce the runout to an acceptable amount.
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WHEELS
INDEX
page DESCRIPTION AND OPERATION WHEEL INFORMATION . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . 10 WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 9 page SERVICE PROCEDURES TIRE AND WHEEL BALANCE . . . . . . . . . . . . . . . 11 WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . 11 SPECIFICATIONS WHEEL SPECIFICATIONS . . . . . . . . . . . . . . . . . 12 All aluminum wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Vehicles that are equipped with bolt-on wheel covers use large nose wheel nuts. The wheel nuts used on a vehicle equipped with bolt-on wheel covers are externally threaded so that the wheel covers can be attached to the wheel nuts. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. WARNING: INSTALLING WHEELS WITHOUT GOOD METAL-TO-METAL CONTACT COULD CAUSE LOOSENING OF WHEEL LUG NUTS. THIS COULD ADVERSELY AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE.
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METHOD 1 (RELOCATE WHEEL ON HUB) Check accuracy of the wheel mounting surface; adjust wheel bearings. Drive vehicle a short distance to eliminate tire flat spotting from a parked position. Verify all wheel nuts are properly torqued (Fig. 2).
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DIAGNOSIS AND TESTING (Continued)
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For static balancing, find the location of heavy spot on tire/wheel causing the imbalance. Counter balance wheel directly opposite the heavy spot. Determine weight required to counterbalance the area of imbalance. Place half of this weight on the inner rim flange and the other half on the outer rim flange (Fig. 8). For dynamic balancing, the balancing equipment is designed to indicate the location and amount of weight to be applied to both the inner and outer rim flanges (Fig. 9).
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BODY
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BODY
CONTENTS
page page
Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces. Damage to finish or color can result. Do not hammer or pound on plastic trim panel when servicing interior trim. Plastic panels can break. Chrysler Corporation uses many different types of push-in fasteners to secure the interior and exterior trim to the body. Most of these fasteners can be reused to assemble the trim during various repair procedures. At times, a push-in fastener cannot be removed without damaging the fastener or the component it is holding. If it is not possible to remove a fastener without damaging a component or body, cut or break the fastener and use a new one when installing the component. Never pry or pound on a plastic or pressed-board trim component. Using a suitable fork-type prying device, pry the fastener from the retaining hole behind the component being removed. When installing, verify fastener alignment with the retaining hole by hand. Push directly on or over the fastener until it seats. Apply a low-force pull to the panel to verify that it is secure. When it is necessary to remove components to service another, it should not be necessary to apply excessive force or bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured edges holding the component in place.
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BODY
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PAINT
INDEX
page GENERAL INFORMATION AFTERMARKET PAINT REPAIR PRODUCTS . . . . 3 BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . . 2 page PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . 2 WET SANDING, BUFFING, AND POLISHING . . . . 2
TOUCH-UP PROCEDURE (1) Scrape loose paint and corrosion from inside scratch or chip. (2) Clean affected area with Mopar Tar/Road Oil Remover, and allow to dry. (3) Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the defect without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. (4) Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. (5) On vehicles without clear coat, the touch-up color can be lightly wet sanded (1500 grit) and polished with rubbing compound. (6) On vehicles with clear coat, apply clear top coat to touch-up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, Step 5 can be performed on clear top coat.
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GENERAL INFORMATION (Continued)
BODY
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TCN VMT
27038 28071
B9736 B9842
CHA97TCN CHA98VMT
SG8
47439
26078
B9609
5106
CHA95SG8
*Herberts Standox and Spies Hecker use the Chrysler paint code as listed on the Body Code Plate.
INTERIOR COLORS
INTERIOR COLOR Camel Mist Gray Silver Fern CHRY CODE K5 C3 JK PPG 27731/21584 35799/21576 35798/21577 BASF 26120 25065 25066 DuPONT C9603 C9507 C9509 S-W ACME M-S 51541 50508 50510 AKZO NOBEL SIKKENS CHARJ5I CHARC3I CHARJKI
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BODY
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STATIONARY GLASS
INDEX
page DESCRIPTION AND OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 4 REMOVAL AND INSTALLATION BODY SIDE/SLIDING DOOR STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 page REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . 7 WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the moldings are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and moldings from the parts supplier.
WINDSHIELD REMOVAL EXTERIOR METHOD (1) Remove inside rear view mirror. (2) Remove windshield wiper arms. (3) Remove cowl cover. (4) Remove A-pillar trim panels. (5) Disconnect wire connectors to windshield defroster grid. (6) Place protective covers over instrument panel and hood. (7) Remove windshield molding (Fig. 1). Using pliers, pull outward on molding at the bottom of A-pillars. (8) Using a sharp cold knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences (Fig. 2). A power cutting device can be used if available. (9) Remove windshield from vehicle.
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REMOVAL AND INSTALLATION (Continued)
BODY
23 - 5
shape of the replacement windshield. The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening. (1) Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. (2) Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass. (3) Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation (Fig. 3). (4) Remove replacement windshield from windshield opening. (5) Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 4). WARNING: CLEANER APPLYING ADHESION DO NOT USE SOLVENT BASED GLASS TO CLEAN WINDSHIELD BEFORE GLASS PREP AND PRIMER. POOR CAN RESULT.
(6) Clean inside of windshield with ammonia based glass cleaner and lint-free cloth. (7) Install molding to perimeter of windshield. (8) Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible. (9) Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time. (10) Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence. (11) Apply pinch weld primer 15 mm (.75 in.) wide around the windshield fence. Allow at least three minutes drying time. (12) If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening (Fig. 5). (13) Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence. (14) With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers. (15) Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward until molding is flush to roof line and A-pillars (Fig. 5).
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BODY
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REMOVAL AND INSTALLATION (Continued)
NOTE: Tighten nuts to 3.4 Nm (30 in. lbs.) torque in the sequence indicated. Do not over torque, or glass breakage may result (Fig. 6). (4) Install interior trim.
BODY
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REAR WINDOW
Refer to the Safety Precautions in this section for description of tools and adhesive systems that are recommended for use in this procedure.
REAR WINDOW REMOVAL EXTERIOR METHOD (1) Remove rear window wiper arm, if equipped. (2) Remove screws holding moldings to liftgate at the sides of the rear window (Fig. 7). (3) Using pliers, pull outward on molding at the top and bottom of liftgate. (4) Using a sharp cold knife, cut urethane adhesive holding the rear window to the liftgate. A power cutting device can be used if available (Fig. 2). (5) Remove rear window from vehicle. REAR WINDOW REMOVAL INTERIOR METHOD (1) Remove rear window wiper arm, if equipped. (2) Remove screws holding moldings to liftgate at the sides of the rear window (Fig. 7). (3) Remove liftgate inside lamps and trim covers. (4) Remove center high mounted stop lamp. (5) Using a reciprocating or oscillating power knife, cut urethane adhesive holding the rear window to the liftgate. Refer to instructions provided with the equipment being used. (6) Remove rear window from vehicle.
(6) Clean inside of rear window with ammonia based glass cleaner and lint-free cloth. (7) Apply molding to top and bottom of rear window. (8) Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of rear window and wipe with clean/dry lint-free cloth until no streaks are visible. (9) Apply Glass Primer 25 mm (1 in.) wide around perimeter of rear window. Allow at least three minutes drying time. (10) Apply Pinchweld Primer 15 mm (.75 in.) wide around the rear window fence. Allow at least three minutes drying time. (11) If a low viscosity urethane adhesive is used, install compression spacers on the fence around the rear window opening (Fig. 8). (12) Apply a 10 mm (0.4 in.) bead of urethane along center line of rear window fence.
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BODY
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BODY
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SEATS
INDEX
page REMOVAL AND INSTALLATION ARM REST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 BENCH SEAT BACK COVER . . . . . . . . . . . . . . . . 9 BENCH SEAT BACK HINGE COVERS . . . . . . . . 10 BENCH SEAT BACK HINGE . . . . . . . . . . . . . . . . . 9 BENCH SEAT RISER FIRST REAR . . . . . . . . . 11 BENCH SEAT RISER SECOND REAR . . . . . . . 11 BENCH SEAT TRACK SECOND REAR . . . . . . 11 BUCKET SEAT BACK ASSIST STRAP . . . . . . . . 12 BUCKET SEAT BACK . . . . . . . . . . . . . . . . . . . . . 12 BUCKET SEAT CUSHION PAN . . . . . . . . . . . . . . 12 BUCKET SEAT CUSHION SIDE COVER . . . . . . . 13 BUCKET SEAT RECLINER MANUAL . . . . . . . . 13 BUCKET SEAT RECLINER POWER . . . . . . . . . 14 BUCKET SEAT RISER MANUAL TRACK . . . . . 14 BUCKET SEAT TRACK FRONT COVER POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 BUCKET SEAT TRACK REAR COVER POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET SEAT TRACK MANUAL . . . . . . . . . BUCKET SEAT TRACK POWER . . . . . . . . . CHILD RESTRAINT SEAT MODULE . . . . . . . . HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . HEAD RESTRAINT BENCH SEAT . . . . . . . . HEAD RESTRAINT BUCKET SEAT . . . . . . . HEATED SEAT HEATING ELEMENT . . . . . . . . HEATED SEAT MODULE . . . . . . . . . . . . . . . . HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . MECHANICAL LUMBAR HANDLE ASSEMBLY PLASTIC GROCERY BAG RETAINER . . . . . . . POWER SEAT SWITCH . . . . . . . . . . . . . . . . . RECLINER HANDLE MANUAL . . . . . . . . . . . UNDER SEAT STORAGE BIN GUIDE . . . . . . . UNDER SEAT STORAGE BIN LOCK/LATCH . . UNDER SEAT STORAGE BIN . . . . . . . . . . . . . page
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15 14 14 16 18 16 17 18 18 19 19 19 20 20 21 21 20
REMOVAL (1) Remove bench seat back hinge covers. (2) Remove shoulder bolts holding seat back hinge to seat back frame (Fig. 3). (3) Remove bolts holding seat back hinge to seat cushion frame.
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INSTALLATION (1) Place hinge in position on seat. (2) Engage synchronizing cable end into (clip on left side) hinge latch release arm. (3) Engage synchronizing cable housing into seat back hinge. (4) Place seat back hinge in position on seat. (5) Install bolts to hold seat back hinge to seat cushion frame. (6) Install shoulder bolts to hold seat back hinge to seat back frame (Fig. 3). (7) Install bench seat back hinge covers. (8) Verify seat back hinge operation. SYNCHRONIZING CABLE ADJUSTMENT If the seat back hinges do not release at the same time the synchronizing cable must be adjusted. (1) Remove seat from vehicle. Refer to Owners Manual for proper procedures (Fig. 4). (2) Using a awl, pry synchronizing cable end from clip on left seat back hinge. (3) Pull cable out of housing until cable is tight. (4) Push retaining clip on hinge latch release arm rearward to take up play in hinge mechanism. (5) Engage cable end into retaining clip on hinge.
INSTALLATION (1) Place upper cover in position on seat back hinge. (2) Install screws to hold upper hinge cover to seat back hinge. (3) Place lower cover in position on hinge. (4) Install screws to hold lower cover to seat back hinge (Fig. 5). (5) If necessary, install seat in vehicle.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Place seat back mounting stud into recliner. (2) Install pivot bolts to hold seat back frame to seat track. (3) Install nut to hold recliner to seat back frame (Fig. 9). (4) Install seat cushion pan.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Place seat cushion pan in position in seat cover and pad. (2) Engage J-strip retainers to hold seat cover to cushion pan. (3) Place seat cushion pan in position on seat. (4) Install bolts to hold seat cushion pan to seat track. (5) If equipped, install stowage bin. (6) If equipped, install power seat track front and rear cover. (7) Install seat cushion side covers. (8) Install bucket seat in vehicle.
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Fig. 11 Bucket Seat Cushion Side Cover Fig. 13 Bucket Seat Recliner Manual
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REMOVAL (1) Remove (2) Remove (3) Remove frame. (4) Remove track. (5) Remove
seat from vehicle. seat cushion pan. nut holding recliner to seat back bolts holding seat back frame to seat stud on seat back frame from recliner.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION If power seat track is being replaced, transfer power recliner, wire harness and trim covers to replacement seat track. (1) Insert stud on seat back frame into recliner. (2) Install bolts to hold seat back frame to seat track. (3) Install nut to hold recliner to seat back frame. (4) Install seat cushion pan. (5) Install seat in vehicle.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL (1) Remove four bolts attaching seat to the floor pan. Tip seat forward to access the heated seat module. (2) Disconnect wire connectors from heated seat module. (3) Pry power seat switch knobs straight off switch. (4) Remove screws attaching module to the seat pan. (5) Remove heated seat module.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Place heated seat module in position on seat pan. (2) Install module attaching screws. (3) Connect module wire connectors. (4) Install seat.
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REMOVAL (1) Remove inboard side cover (Fig. 31) and (Fig. 32). (2) Disconnect wire connector from heated seat switch. (3) Carefully depress locking legs on switch and push switch free of cover. INSTALLATION (1) Place heated seat switch in position on side cover. (2) Press switch into locked position. (3) Connect wire connector into heated seat switch. (4) Install inboard side cover.
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REMOVAL (1) Remove seat cushion side cover. (2) Disconnect wire connector from power seat switch. (3) Pry power seat switch knobs straight off switch (Fig. 35). (4) Remove screws holding power seat switch to side cover (Fig. 36). (5) Remove power seat switch from side cover. INSTALLATION (1) Place power seat switch in position on side cover. (2) Install screws to hold power seat switch to side cover (Fig. 36). (3) Push power seat switch knobs straight on switch (Fig. 35). (4) Connect wire connector into power seat switch. (5) Install seat cushion side cover.
INSTALLATION (1) Place recliner handle in position on spline shaft. (2) Install screw to hold recliner handle to recliner spline shaft (Fig. 37).
INSTALLATION (1) Engage storage bin tracks into guides on each side of seat riser. (2) Push storage bin inward until lock tabs snap past retaining ridge on tracks (3) Verify storage bin latch operation.
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REMOVAL AND INSTALLATION (Continued)
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23 24 24 25 25 25 25 26 28 28 29 30 29 30 31 32 31 32 33 33 34 34 34 36 36 36 27 37 37 38 38 38 39 39 39 41 42 41 42 42 40 43 43 44 47 47
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SHOULDER BELT HEIGHT ADJUSTER KNOB . SHOULDER BELT HEIGHT ADJUSTER B OR C-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . SLIDING DOOR CENTER HINGE . . . . . . . . . . . SLIDING DOOR CENTER STOP TRIM COVER . SLIDING DOOR CENTER STRIKER ASSEMBLY SLIDING DOOR HOLD OPEN LATCH STRIKER SLIDING DOOR HOLD OPEN LATCH . . . . . . . . SLIDING DOOR INSIDE LATCH HANDLE BELLCRANK . . . . . . . . . . . . . . . . . . . . . . . . . SLIDING DOOR INSIDE LATCH HANDLE . . . . . SLIDING DOOR INSIDE LATCH RELEASE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . SLIDING DOOR LATCH STRIKER . . . . . . . . . . SLIDING DOOR LATCH/LOCK CONTROL . . . . SLIDING DOOR LOWER ROLLER ARM BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDING DOOR LOWER ROLLER ARM . . . . . . . 64 . . . . . . . 64 64 66 66 67 67 67
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. 68 . 68 . 69 . 69 . 70 . 71 . 71
SLIDING DOOR OUTSIDE LATCH RELEASE HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDING DOOR REAR LATCH . . . . . . . . . . . SLIDING DOOR SILL PLATE . . . . . . . . . . . . SLIDING DOOR STABILIZER SOCKET . . . . . SLIDING DOOR STABILIZER . . . . . . . . . . . . SLIDING DOOR STOP BUMPER . . . . . . . . . SLIDING DOOR TRIM PANEL . . . . . . . . . . . . SLIDING DOOR UPPER ROLLER . . . . . . . . . SLIDING DOOR WEATHER-STRIP . . . . . . . . SLIDING DOOR . . . . . . . . . . . . . . . . . . . . . . STICK-ON BODY SIDE MOLDING . . . . . . . . SUN VISOR SUPPORT . . . . . . . . . . . . . . . . SUN VISOR . . . . . . . . . . . . . . . . . . . . . . . . . UPPER B-PILLAR TRIM COVER . . . . . . . . . . UPPER C-PILLAR TRIM . . . . . . . . . . . . . . . . ADJUSTMENTS SLIDING DOOR ADJUSTMENTS . . . . . . . . .
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72 73 73 74 73 74 74 75 75 64 75 78 76 78 80
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When the conditions causing a water leak have been determined, simulate the conditions as closely as possible. If a leak occurs with the vehicle parked in a steady light rain, flood the leak area with an openended garden hose. If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a reasonable velocity stream or fan spray of water. Direct the spray in a direction comparable to actual conditions. If a leak occurs when the vehicle is parked on an incline, hoist the end or side of the vehicle to simulate this condition. This method can be used when the leak occurs when the vehicle accelerates, stops or turns. If the leak occurs on acceleration, hoist the front of the vehicle. If the leak occurs when braking, hoist the back of the vehicle. If the leak occurs on left turns, hoist the left side of the vehicle. If the leak occurs on right turns, hoist the right side of the vehicle. For hoisting recommendations refer to Group 0, Lubrication and Maintenance, General Information section.
VISUAL INSPECTION BEFORE WATER LEAK TESTS Verify that floor and body plugs are in place, body drains are clear, and body components are properly aligned and sealed. If component alignment or sealing is necessary, refer to the appropriate section of this group for proper procedures. WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS OR TOOLS IN WATER TEST AREA. PERSONAL INJURY CAN RESULT.
WATER LEAK DETECTION To detect a water leak point-of-entry, do a water test and watch for water tracks or droplets forming on the inside of the vehicle. If necessary, remove interior trim covers or panels to gain visual access to the leak area. If the hose cannot be positioned without being held, have someone help do the water test.
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VISUAL INSPECTION BEFORE TESTS Verify that floor and body plugs are in place and body components are aligned and sealed. If component alignment or sealing is necessary, refer to the appropriate section of this group for proper procedures.
ROAD TESTING WIND NOISE (1) Drive the vehicle to verify the general location of the wind noise. (2) Apply 50 mm (2 in.) masking tape in 150 mm (6 in.) lengths along weatherstrips, weld seams or moldings. After each length is applied, drive the vehicle. If noise goes away after a piece of tape is applied, remove tape, locate, and repair defect. POSSIBLE CAUSE OF WIND NOISE Moldings standing away from body surface can catch wind and whistle. Gaps in sealed areas behind overhanging body flanges can cause wind-rushing sounds. Misaligned movable components. Missing or improperly installed plugs in pillars. Weld burn through holes.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body component alignment, body seam porosity, or missing plugs in the engine compartment or door hinge pillar areas. All body sealing points should be airtight in normal driving conditions. Moving sealing surfaces will not always seal airtight under all conditions. At times, side glass or door seals will allow wind noise to be noticed in the passenger compartment during high
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SERVICE PROCEDURES (Continued)
may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. (4) Allow the repaired area to cool and verify the repair. (5) Install trim panel.
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COWL COVER
WARNING: No fingers or tools should be put under the cowl cover while the wiper motor is operating.
REMOVAL (1) Remove wiper arms. Refer to Group 8K, Windshield Wipers and Washers for proper procedures. (2) Remove screws holding lower area of cowl cover to wiper module (Fig. 3). (3) Disengage quarter turn fasteners holding outer ends of cowl cover to wiper module. (4) Release hood latch and open hood. (5) Remove wing nuts holding front of cowl cover to wiper module. (6) Close hood. Do not latch. Remove outboard screws. (Fig. 4). (7) Lift cowl cover upward enough to gain access to right washer hose. (8) Disconnect washer hose from right washer nozzle. (9) Close hood. Do not latch. (10) Remove cowl cover from vehicle. INSTALLATION For installation, reverse the above procedures.
COWL TRIM
REMOVAL (1) Remove door sill plate. (2) Disengage hidden clips holding cowl trim to cowl panel (Fig. 5). (3) Remove cowl trim from vehicle.
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FLOOR CARPET
REMOVAL (1) Remove front seats. (2) Remove front center console. (3) Remove first rear seat. (4) Remove second rear seat. (5) Remove front cowl panels and sill plates. (6) Remove sliding door sill plates. (7) Remove rear door sill plate. (8) Remove lower B-pillar trim covers. (9) Remove D-pillar trim covers. (10) Remove Quarter trim panels.
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REMOVAL AND INSTALLATION (Continued)
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(3) Disengage clips holding door harness wire connector to inner fender brace. (4) Disconnect positive lock slide on the side of the wire connectors (Fig. 8). (5) Depress lock tab holding wire connector halves together. (6) Disconnect door harness from body wiring harness. (7) Remove bolts holding door check strap to A-pillar (Fig. 9). (8) Support door on suitable lifting device. (9) Remove bolts holding lower hinge to door end frame (Fig. 10). (10) Steady door on lifting device and remove bolts holding upper hinge to door end frame. (11) Remove door from vehicle.
FRONT DOOR
CAUTION: If the hinge pin must be removed from the hinge, do not reuse the original pin. The structural integrity of the hinge would be reduced. Verify availability prior to proceeding if hinge pins are to be removed. NOTE: The retaining clips used on the door hinge pins are not to be re-used. Verify availability prior to proceeding if clips are to be removed.
REMOVAL (1) Open front door. (2) Remove front wheelhouse splash shield.
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REMOVAL (1) Remove front door trim panel. (2) Remove door speaker, if equipped. (3) Remove bolts attaching door check strap to A-pillar (Fig. 9). (4) Remove nuts attaching check strap to door end frame (Fig. 12). (5) Remove check strap from door through speaker hole.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION A-PILLAR, HEADER, OR B-PILLAR (1) Position closeout molding in window frame. (2) Insert closeout molding into window frame channel starting at the corners and working inward. (3) Verify door glass operation.
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REMOVAL AND INSTALLATION (Continued)
NOTE: If both hinges on one door are to be replaced, remove and install one hinge completely prior to beginning the second hinge.
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REMOVAL (1) Release front door latch and open door. (2) Support door on suitable lifting device. (3) Remove bolts holding front door to door hinge. (4) Remove bolts holding hinge to pillar. (5) Remove door hinge from vehicle. INSTALLATION
CAUTION: When installing a new hinge, make sure that the head of each hinge pin is fully seated into the door hinge. Also, remove the plastic shipping clip and replace it with the correct metal retaining clip once the hinge pin is seated. (1) Paint hinge prior to installation, if necessary. (2) Position door hinge on vehicle. (3) Install bolts to hold hinge to pillar. (4) Install bolts to hold front door to door hinge. (5) Align door to achieve equal spacing to surrounding body panels. Panels should be flush across all gaps. (6) Verify door alignment and operation. Adjust as necessary.
INSTALLATION (1) Place inner belt molding in position on door. (2) Push inner belt molding downward to engage retaining channel onto door panel flange. (3) Install upper corner seals in proper location. (4) Install door trim panel.
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INSTALLATION (1) Position latch striker and any shims retrieved on vehicle. (2) Loosely install screws to hold latch striker to B-pillar. (3) Align latch striker to outline on B-pillar made previously. (4) Tighten all fasteners. (5) Verify door fit and operation. Adjust latch striker as necessary.
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Engage clip into outside handle to hold lock cylinder. (2) With link arm toward rear of vehicle, push lock cylinder into door handle until clip snaps into place (Fig. 21). (3) Insert lock linkage into door latch. (4) Engage clip to hold door lock linkage to latch. (5) Insert latch linkage into door latch. (6) Engage clip to hold door latch linkage to latch. (7) Install push-in fasteners to hold VTSS switch harness to inner door reinforcement bar, if equipped. (8) Connect VTSS switch connector into door harness, if equipped. (9) Verify door latch operation. (10) Install water shield and door trim panel.
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INSTALLATION (1) Place sill plate in position on vehicle. (2) Align locating pins on backside of trim plate to mating holes in door sill. (3) Engage hidden clips to hold door sill plate to door sill.
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REMOVAL AND INSTALLATION (Continued)
(15) Tilt top of trim panel away from door to gain access to latch linkage. (16) Disengage clip attaching linkage rod to inside latch release handle (Fig. 29). (17) Separate linkage rod from latch handle. (18) Remove front door trim panel from vehicle.
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REMOVAL AND INSTALLATION (Continued)
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FRONT SEAT
REMOVAL (1) From under vehicle, remove nuts attaching front seat risers to the floor. (2) Remove seat and riser from floor (Fig. 34). (3) Tip seat rearward and disconnect wire connectors from body harness, if equipped. (4) Remove seat from vehicle. INSTALLATION For installation, reverse the above procedures.
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REMOVAL AND INSTALLATION (Continued)
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GRILLE
REMOVAL (1) Remove front fascia. Refer to Group 13, Frame and Bumpers, for proper procedures. (2) Disengage clips holding grille to front fascia (Fig. 41). (3) Remove plastic rivets holding grille to fascia. (4) Remove grille from fascia. INSTALLATION (1) Position grille on fascia. (2) Install plastic rivets to hold grille to fascia. (3) Install clips to hold grille to fascia along bottom of grille. (4) Install front fascia. Refer to Group 13, Frame and Bumpers, for proper procedure.
HEADLINING
REMOVAL (1) Remove sun (2) Remove sun (3) If equipped, (4) If equipped,
visors and vanity mirrors. visor center supports. remove coat hooks. remove roof rail modules.
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Fig. 41 Grille
(5) Remove A-pillar trim covers. (6) Remove B-pillar upper trim covers. (7) Remove C-pillar upper trim covers. (8) Remove D-pillar upper trim covers. (9) Remove rear door opening header trim. (10) If equipped, remove overhead console. (11) If equipped, remove reading lamp. (12) Remove dome lamp. (13) Remove push-in locking fasteners holding headlining to rear roof header (Fig. 42) or (Fig. 43). (14) Remove headlining from roof. (15) Extract headlining through rear door opening.
HOOD
REMOVAL (1) Raise hood to full up position. (2) Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to provide reference marks for installation. (3) Remove the top bolts holding hood to hinge and loosen the bottom bolts until they can be removed by hand (Fig. 44). (4) With assistance from a helper at the opposite side of the vehicle to support the hood, remove bottom bolts holding hood to hinge. (5) Remove the hood from the vehicle. INSTALLATION (1) Place hood in position on vehicle. With assistance from a helper at the opposite side of the vehicle
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REMOVAL AND INSTALLATION (Continued)
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Fig. 44 Hood
to support the hood, install bottom bolts to hold hood to hinge finger tight. (2) Install top bolts to hold hood to hinge finger tight. (3) Position bolts at marks and tighten bolts. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. (4) Verify hood operation and alignment.
HOOD LATCH
REMOVAL (1) Release hood latch and open hood. (2) Remove bolts holding hood latch to radiator closure panel crossmember (Fig. 46). (3) Remove hood latch from crossmember. (4) Disconnect hood release cable from hood latch (Fig. 47). (5) Remove hood latch from vehicle.
HOOD HINGE
REMOVAL (1) Remove hood. (2) Remove wiper unit. Refer to Group 8K, Windshield Wipers and Washers, for procedure. (3) Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to provide reference marks for installation. (4) Remove bolts attaching body half of hood hinge to front fender flange and remove hinge from vehicle (Fig. 45). INSTALLATION (1) If necessary, paint new hinge before installation. (2) Place body half of hood hinge in position on vehicle. (3) Install bolts to hold hood hinge to front fender flange. (4) Install wiper unit. Refer to Group 8K, Windshield Wipers and Washers, for proper procedures. (5) Install hood. (6) Align all marks and secure bolts. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. Shims can be added or removed under hood hinge to achieve proper hood height.
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REMOVAL AND INSTALLATION (Continued)
SHORT WHEEL BASE
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REMOVAL (1) Open quarter panel bin storage cover. (2) Lift upward and rearward on jack storage cover retaining latch to disengage (Fig. 51). (3) Remove jack storage cover from vehicle.
INSTALLATION (1) Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle. (2) Position D-pillar trim panel on vehicle.
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REMOVAL AND INSTALLATION (Continued)
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Fig. 53 Left Quarter and D-Pillar Trim Panels LWB Four Door
(18) Pass front seat belt and turning loop through slot in quarter trim panel on three door vehicle. (19) Pass first rear seat belt through slot in quarter trim panel. (20) Pass second rear seat belt, if equipped, through slot in quarter trim panel on long wheel base vehicle. (21) Remove quarter trim panel from vehicle. (9) Install screws to hold rear edge of quarter trim to attaching bracket or inner quarter panel. (10) Install screws to hold quarter trim to inner quarter panel in bolster area. (11) Install screws to hold quarter trim to inner quarter panel in B-pillar area on three door vehicle. (12) Install left front seat belt opening bezel into quarter trim on three door vehicle. (13) Install second rear seat belts anchor on long wheel base vehicle. Tighten all seat belt bolts to 39 Nm (28 in. lbs.) torque. (14) Install first rear seat belt anchor. (15) Install left D-pillar trim panel. (16) Install C-pillar trim panel. (17) Install upper left B-pillar trim on three door vehicle. (18) Install left quarter trim bolster. (19) Install front door sill plate on three door vehicle. (20) Install sliding door sill plate on four door vehicle. (21) Install second rear seat, if equipped. (22) Install first rear seat. (23) Connect the battery negative cable.
INSTALLATION (1) Position quarter trim panel on vehicle. (2) Pass second rear seat belt, if equipped, through slot in quarter trim panel on long wheel base vehicle. (3) Pass first rear seat belt through slot in quarter trim panel. (4) Pass front seat belt through slot in quarter trim panel on three door vehicle. (5) Connect wire connector into accessory power outlet, if equipped. (6) Align locating pins on backside of trim panel to mating holes in inner panels. (7) Position quarter trim panel on inner quarter panel. (8) Install screws to hold top of trim panel to inner sheet metal between B-pillar and C-pillar on three door vehicle.
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LIFTGATE
REMOVAL (1) Release liftgate latch and open liftgate. (2) Remove screws holding liftgate wire connector to rear header. (3) Disconnect liftgate wire harness from body wire harness. (4) Remove liftgate upper frame molding. (5) Disconnect rear window washer hose from spray nozzle. (6) Support liftgate on a suitable lifting device. (7) Remove screws holding support cylinders to liftgate. (8) Remove bolts holding liftgate hinge to roof header (Fig. 55). (9) With assistance, remove liftgate from vehicle. INSTALLATION (1) With assistance, place liftgate in position on vehicle. (2) Install bolts to hold liftgate hinge to roof header. (3) Install screws to hold support cylinders to liftgate. (4) Remove lifting device from under liftgate.
Fig. 55 Liftgate
(5) Connect liftgate wire harness into body wire harness. (6) Install screws to holding wire connector to rear header. (7) Connect rear window washer hose onto spray nozzle. (8) Install liftgate upper frame molding.
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REMOVAL AND INSTALLATION (Continued)
(9) Verify liftgate alignment. The liftgate should have a gap to adjacent panels and fit flush across the gaps. The gap is; 7 mm (0.280 in.) to the fascia, 6 mm (0.240 in.) to the roof, 4 mm (0.160 in.) to the aperture.
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(6) Install bolts to hold liftgate hinge to roof header. (7) Remove duct tape from roof and liftgate. (8) Support liftgate on a suitable lifting device. (9) Verify liftgate alignment. Refer to Liftgate Remove and Installation for proper gap measurements.
LIFTGATE HINGE
REMOVAL (1) Release liftgate latch and open liftgate. (2) Support liftgate on a suitable lifting device. (3) Apply several layers of duct tape on the outside of to roof across the gap to the lift gate to hold the liftgate in position. (4) Remove bolts holding liftgate hinge to roof header. (5) Remove bolts holding hinge to liftgate (Fig. 56). (6) Remove hinge from vehicle.
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INSTALLATION (1) Install lock cylinder clip into liftgate handle. (2) Push lock cylinder into handle until clip engages groove in lock cylinder with an audible click (Fig. 60). (3) Install outside liftgate handle. (4) Verify lock cylinder operation.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
(2) Engage hidden clips to hold molding to liftgate upper frame (Fig. 66).
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OVERHEAD GRAB-HANDLES
REMOVAL (1) Using a trim stick (C-4755), remove screw access covers from grab-handle. (2) Remove screws holding grab-handle to roof rail. (3) Remove grab-handle from vehicle. INSTALLATION (1) Place grab-handle in position on vehicle. (2) Install screws to hold grab-handle to roof rail. (3) Install screw access covers into grab-handle.
QUARTER GLASS
REMOVAL (1) Remove C-pillar trim. (2) Open quarter glass to vent position. (3) Remove screw attaching quarter window retainer to vent motor arm. (4) Disengage quarter window retainer from vent motor arm.
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REMOVAL AND INSTALLATION (Continued)
(5) Remove nuts holding quarter glass to C-pillar (Fig. 72). (6) Remove quarter glass from vehicle.
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Fig. 74 Left Quarter Trim Bolster SWB and LWB Three Door
(3) Remove radiator sight shield. (4) Remove engine air inlet resonator. (5) Remove bolt holding air cleaner housing to crossmember. (6) Remove screw holding coolant recovery bottle to crossmember. (7) Remove bolts holding radiator isolators to crossmember. (8) Remove bolts holding ends of crossmember to radiator closure panel (Fig. 75). (9) Lift crossmember upward and away from radiator closure panel. (10) Remove crossmember from vehicle.
REMOVAL (1) Disengage hidden clips holding trim bolster to quarter trim panel (Fig. 73) and (Fig. 74). (2) Disengage hook retainer holding front of trim bolster to quarter trim panel, if applicable (Fig. 73). (3) Remove quarter trim bolster from vehicle. INSTALLATION (1) Place quarter trim bolster in position on vehicle. (2) Engage hook retainer to hold front of trim bolster to quarter trim panel, if applicable. (3) Engage hidden clips to hold trim bolster to quarter trim panel.
INSTALLATION (1) Place radiator closure panel crossmember in position on vehicle. (2) Insert ends of crossmember between layered metal sections of radiator closure panel at each side of radiator.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Position D-pillar trim on vehicle. (2) Pass second rear seat belt, if equipped, through slot in trim panel on short wheel base vehicle. (3) Connect speaker wire connector to speaker, if equipped. (4) Align locating pins on backside of trim panel to mating holes in D-pillar. (5) Engage hidden clips to hold trim to D-pillar. (6) Install screws to hold trim panel to attaching bracket on short wheel base vehicle. (7) Install quarter trim bolster on short wheel base vehicle. (8) Install bolt to attach second rear seat belt, if equipped, anchor to quarter on short wheel base vehicle. Tighten all seat belt bolts to 39 Nm (29 in. lbs.) torque. (9) Install second rear seat belt turning loop on long wheel base vehicle. (10) Install liftgate sill plate. (11) Install rear header trim cover.
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(14) Pass second rear seat belt through slot in trim panel on long wheel base vehicle. (15) Pass first rear seat belt through slot in trim panel. (16) Remove quarter trim panel from vehicle.
INSTALLATION (1) Position quarter trim panel on vehicle. (2) Pass first rear seat belt through slot in trim panel. (3) Pass second rear seat belt through access hole in trim panel on long wheel base vehicle. (4) Connect wire connector into accessory power outlet, if equipped. (5) Align locating pins on backside of trim panel to mating holes in inner quarter panel. (6) Engage hidden clips to hold front of quarter trim to quarter panel rearward of sliding door opening. (7) Install screws to hold rear edge of quarter trim to attaching bracket. (8) Install screws to hold quarter trim to inner quarter panel in bolster area. (9) Install second rear seat belt anchor on long wheel base vehicle. Tighten all seat belt bolts to 39 Nm (29 in. lbs.) torque.
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REMOVAL AND INSTALLATION (Continued)
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Fig. 81 Right Quarter and D-Pillar Trim Panels LWB without Rear A\C
(10) (11) (12) (13) (14) (15) (16) (17) Install first rear seat belt anchor. Install D-pillar trim panel. Install C-pillar trim panel. Install quarter trim bolster. Install sliding door sill trim panel. Install second rear seat, if equipped. Install first rear seat. Connect the battery negative cable.
REMOVAL (1) Warm the affected stick-on molding and body metal to approximately 38 C (100 F) using a suitable heat lamp or heat gun. (2) Pull stick-on molding from painted surface. (3) Remove adhesive tape residue from painted surface of vehicle. Use a 3M Scotch-Brite Molding Adhesive and Stripe Removal Discs, or equivalent, to clean adhesive residue from painted surfaces. The adhesive removal discs are available from automotive paint suppliers. Refer to instructions supplied with the discs for proper usage.
INSTALLATION (1) If molding is to be reused; (a) Remove tape residue from molding. (b) Clean back of molding with Mopar Super Kleen solvent, or equivalent. (c) Wipe molding dry with lint free cloth. (d) Apply new body side molding (two sided adhesive) tape to back of molding. (2) Clean body surface with Mopar Super Kleen solvent, or equivalent. Wipe surface dry with lint free cloth. (3) Remove protective cover from tape on back of molding. (4) Apply molding to body from front of vehicle to rear. (5) Using a roller tool, roll molding onto body panel with enough force to assure adhesion and not bend roof panels.
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Fig. 82 Right Quarter and D-Pillar Trim Panels LWB with Rear A\C
(4) Remove buckle from vehicle.
INSTALLATION For installation, reverse the above procedures. Tighten seat belt anchor bolts to 39 Nm (29 ft. lbs.) torque.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION (1) Place seat belt buckle in position on seat. (2) Install bolt to attach seat belt buckle to seat rear frame rail. Tighten all seat belt bolts to 39 Nm (29 ft. lbs.) torque.
INSTALLATION For installation, reverse the above procedures. Tighten all seat belt anchor bolts to 39 Nm (29 ft. lbs.) torque.
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REMOVAL AND INSTALLATION (Continued)
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(13) Remove bolt holding seat belt retractor to quarter panel. (14) Lift retractor upward and disengage arrow head retainer holding retractor to quarter panel (Fig. 88). (15) Remove seat belt from vehicle.
Fig. 88 Seat Belt Left First Rear Outboard SWB Three Door
INSTALLATION For installation, reverse the above procedures. Tighten all seat belt anchor bolts to 39 Nm (29 ft. lbs.) torque.
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REMOVAL AND INSTALLATION (Continued)
(6) Remove bolt attaching turning loop to extension bracket above quarter glass. (7) Remove turning loop from extension bracket. (8) Remove D-pillar trim panel. (9) Remove quarter trim bolster. (10) Remove quarter trim panel as necessary to gain access to HVAC unit. (11) Route seat belt webbing and turning loop through access hole in quarter trim. (12) Loosen HVAC unit enough to gain access to seat belt retractor fasteners. (a) Remove bracket around HVAC unit (Fig. 91). (b) Remove air duct (Fig. 92). (c) Remove fasteners holding HVAC unit to inner quarter panel (Fig. 93). (d) Remove screws attaching upper evaporator housing to lower evaporator housing. (e) Remove coolant line retaining bracket holddown bolt. (13) Remove bolts attaching seat belt guide loop to inner quarter panel. (14) Pull outward on HVAC unit and remove bolt holding retractor to inner quarter panel. (15) Remove screw attaching retractor to inner quarter panel. (16) Remove second rear seat belt retractor from vehicle.
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INSTALLATION (1) Place shoulder belt height adjuster knob in position on height adjuster. (2) Push knob on until retainers engage.
SLIDING DOOR
CAUTION: Apply several layers of masking tape to the body around the rear end of the upper roller channel and the forward edge of the quarter panel, to avoid damaging the paint.
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REMOVAL AND INSTALLATION (Continued)
REMOVAL (1) Apply masking tape to outside surface of quarter panel below the center roller channel, rearward of the door opening. (2) Release sliding door latch and open door. (3) Apply masking tape to door jamb area, rearward of the upper roller channel. (4) Remove screw holding upper roller arm stop bumper to upper roller arm (Fig. 97). (5) Remove stop bumper from upper roller arm. (6) Remove center stop bumper trim cover from sliding door (Fig. 98). (7) Remove center stop from sliding door. (8) Remove sliding door sill plate. (9) Remove hold open latch striker (Fig. 99). (10) Open quarter glass. (11) Remove center roller channel end cover (Fig. 100). (12) Support sliding door on a suitable lifting device with a padded upper surface. The door must be moveable with lifting device in place.
CAUTION: Do not allow the center hinge roller to contact the quarter glass. Glass can break. (13) Roll door rearward until lower rollers disengage from lower channel. (14) Roll the door rearward until the upper (Fig. 101) and center hinge rollers exit the upper and center channels (Fig. 102). (15) Remove sliding door from vehicle.
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INSTALLATION
NOTE: Center hinge has an adjustable bolt for up/down alignment. Refer to Siding Door Center Hinge Adjustment. (1) Place center hinge in position on vehicle. (2) Roll center hinge forward in roller channel. (3) Place center hinge in position on sliding door and align marks. (4) Install bolts to hold center hinge to sliding door. (5) Verify sliding door alignment and operation.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION (1) Position bellcrank on vehicle. (2) Install screw holding bellcrank to inner door panel. (3) Position cable from bellcrank. (4) Engage clip to hold release handle latch cable to bellcrank. (5) Position bellcrank link on latch/lock control. (6) Engage clip to hold inside release bellcrank link to latch/lock control. (7) Install latch/lock control cover. (8) Install watershield. (9) Install sliding door trim panel.
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INSTALLATION (1) Position latch/lock locking lever in unlocked position. (2) Engage rigging cam (Fig. 114). (3) Place latch/lock in position on vehicle. (4) If equipped, engage wire connector into power door lock motor. (5) Insert bolt heads into slots in sliding door inner panel. (6) Tighten bolts to hold latch/lock control to sliding door.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION Refer to (Fig. 129), (Fig. 130), (Fig. 131), (Fig. 132) or (Fig. 133) for proper location of fasteners to hold the molding to the wheelhouse lip and rocker panels. (1) If molding is to be reused; (a) Remove tape residue from molding. (b) Clean back of molding with Mopar Super Kleen, or equivalent. (c) Wipe molding dry with lint free cloth. (d) Apply a single coat of Mopar TPO Molding Prep to tape side of molding and allow to dry thoroughly. (e) Apply new body side molding (two sided adhesive) tape to back of molding. (2) Clean body surface with Mopar Super Kleen, or equivalent. Wipe surface dry with lint free cloth.
SUN VISOR
All vehicles with driver and passenger side airbags must have a colored coded five Bullet point airbag warning label applied to the sun visor, verify label availability and ensure the label is installed.
REMOVAL (1) Disengage sun visor from center support. (2) Remove screws attaching sun visor to roof header (Fig. 134). (3) Remove sun visor from roof. (4) If equipped, disconnect illuminated vanity mirror wire connector from body harness. (5) Remove sun visor from vehicle.
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REMOVAL AND INSTALLATION (Continued)
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REMOVAL AND INSTALLATION (Continued)
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UP/DOWN ADJUSTMENT (1) Visually inspect the sliding door for fitting low at the rear of the door by checking the alignment of the belt line of the door to quarter panel. (2) Fully open the sliding door. (3) Verify that all center hinge bolts are tight. (4) Adjust the rear of the sliding door up by turning the center hinge bolt clockwise (Fig. 137). (5) Close the door and check the sliding door alignment. (6) Readjust the center hinge if necessary to obtain alignment between the belt line of the sliding door and quarter panel. (7) Fully open door and apply thread lock nut onto the center hinge bolt. Tighten nut until till it butts up against the welded nut on the center hinge. Tighten nut to 15 Nm (130 in. lbs.). It may be necessary to hold the center hinge bolt to prevent it from turning while tightening nut. (8) Verify alignment. Re-adjust as necessary.
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ADJUSTMENTS (Continued)
(b) Mark outline of center hinge on sliding door to assist in making adjustments. (c) Loosen center hinge bolts (Fig. 137). (d) Move hinge fore or aft to position the sliding door into the correct location. (e) Tighten center hinge bolts. (f) Verify alignment. Re-adjust as necessary. (3) If the sliding door is low at the B-post; (a) Remove access plug in the sliding door trim panel. (b) Open the door to mid-point of travel. (c) Mark outline of lower roller arm bracket on sliding door to assist in making adjustments. (d) Loosen lower roller arm bracket bolts (Fig. 138). (e) Move hinge downward to raise the door. (f) Tighten lower roller arm bracket bolts. (g) Verify alignment. Re-adjust as necessary.
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(e) Move hinge upward to raise the door. (f) Tighten lower roller arm bracket bolts. (g) Verify alignment. Re-adjust as necessary.
SEAL COMPRESSION (1) Check seal compression at top and bottom of B-post seal. (2) Adjust seal compression at the top of the B-post seal; (a) Open door to mid-point of travel. (b) Mark outline of upper roller arm on bracket to assist in making adjustments. (c) Loosen bolts holding upper roller arm to bracket (Fig. 139) (d) Decrease the length of the upper roller arm to increase seal compression. (e) Increase the length of the upper roller arm to decrease seal compression. (f) Tighten all upper roller arm bolts. (g) Verify door alignment. Re-adjust as necessary.
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ADJUSTMENTS (Continued)
NOTE: Adjusting seal compression at the B-post can affect door flushness the C-post.
STABILIZER ADJUSTMENT (1) Open sliding door. (2) Loosen bolts holding stabilizers to sliding door enough that the stabilizers can move with some effort. (3) Close and then reopen sliding door. (4) Tighten all bolts.
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CONTENTS
page page
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SEATS
INDEX
page REMOVAL AND INSTALLATION BENCH SEAT BACK COVER . . . . . . . . . . . . . . . . 2 HEAD RESTRAINT ESCUTCHEON . . . . . . . . . . . 1 page HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . . . . 2 HEAD RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . 1
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. . . 17 . . . 18 . . . 16 . . . 19 . . . 19 . . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 20 20 21 21 22 23 23 25 26 27 28 28 29 30 31 32 32 34 33 33
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INHALED. SEEK MEDICAL ATTENTION IMMEDIATELY IF SWALLOWED OR INHALED. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN AND PETS. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT RUNNING TEMPERATURE. PERSONAL INJURY CAN RESULT. CAUTION: The engine cooling system is designed to develop internal pressure of 97 to 123 kPa (14 to 18 psi). Allow the vehicle to cool a minimum of 15 minutes before opening the cooling system. Refer to Group 7, Cooling System.
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DESCRIPTION AND OPERATION (Continued)
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The high pressure relief valve vents only a small amount of refrigerant necessary to reduce system pressure and then reseats itself. The majority of the refrigerant is conserved in the system. The valve is calibrated to vent at a pressure of 3450 to 4140 kPa (500 to 600 psi). If a valve has vented a small amount of refrigerant, it does not necessarily mean the valve is defective. The High Pressure Relief Valve is located on the compressor manifold at the discharge passage. NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor.
CONDENSATE DRAIN
Condensation from the evaporator housing is drained through the dash panel and on to the ground. This drain must be kept open to prevent water from collecting in the bottom of the housing. If the drain is blocked condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensate drainage below the vehicle.
EVAPORATOR PROBE
The Evaporator probe is located on the HVAC. The probe prevents evaporator freeze-up by signaling the Powertrain Control Module to cycle the compressor ON and OFF. The probe monitors the temperature of the refrigerant after expansion. The evaporator probe is inserted into the evaporator between the coils. The probe is a sealed unit and cannot be adjusted or repaired. It must be replaced if found defective.
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SYSTEM AIRFLOW
The system pulls outside (ambient) air through the cowl opening at the base of the windshield. Then it goes into the plenum chamber above the heaterA/C
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DESCRIPTION AND OPERATION (Continued)
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NOTE: The oil used in the compressor is ND8 PAG R134a refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use. Tightly cap afterwards to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with. Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak.
REFRIGERANT OIL LEVEL CHECK When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filterdrier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz) of oil, and system capacity may be 220 ml (7.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz).
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Dual ml 220 ml 30 ml 30 ml 60 ml 60 ml
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol).
ACTUATOR CALIBRATION Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the actuators, HVAC control module and its linkages. Invehicle calibration can be entered from the controls front panel. If the REAR WIPE and INTERMITTENT LEDs flash simultaneously when Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a failure occurred (Fig. 6) and (Fig. 7). Diagnostics will always occur during Calibration Diagnostic and Cooldown test.
SERVICING REFRIGERANT OIL LEVEL (1) Using a refrigerant recovery machine, remove refrigerant from the A/C system. (2) Remove refrigerant lines from A/C compressor. (3) Remove compressor from vehicle. (4) From suction port on top of compressor, drain refrigerant oil from compressor. (5) Add system capacity minus the capacity of components that have not been replaced through suction port on compressor. Refer to the Refrigerant Oil Capacity Chart. (6) Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system.
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DIAGNOSIS AND TESTING (Continued)
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CALIBRATION/COOLDOWN LED DISPLAY CODES See table for definition of flashing LEDs. If no problems are found, the control functions normally. CALIBRATION/COOLDOWN LED DISPLAY CODES
CORRECTIVE ACTION NONE
LEDS NO LEDS FLASHINGNORMAL OPERATION REAR WIPER AND INTERMITTENT LEDS FLASH SIMULTANEOUSLY
PASS/FAIL PASSED CALIBRATION, DIAGNOSTICS AND COOLDOWN FAILED CALIBRATION DIAGNOSTICS FAILED COOLDOWN FAILED CALIBRATION, DIAGNOSTICS AND FAILED COOLDOWN TEST
Fig. 7 Radio Bezel and HVAC Control, Rear Blower Motor Switch and Zone Control
DIAGNOSTICS During the Actuator calibration, diagnostics are performed on the actuators and evaporator temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT LEDs will flash to indicate either a successful calibration or the appropriate fail code(s). At this time manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LEDs will flash simultaneously showing that a failure has occurred. The control will not indicate the fail code, but only that a failure had occurred during the last diagnostics test. The only way to clear the failure codes is repeat the Calibration Diagnostic and Cooldown test, after all repairs are completed. COOLDOWN TEST This test has been designed for performance testing of the A/C system at the manufacturing facility. If the HVAC control module is replaced, the Cooldown test will occur during Calibration test. Cooldown will not occur on Heater Only units. During the Cooldown test the control will monitor the temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature down a predetermined minimum amount in less than 2 minutes.
A/C AND RECIRC LEDS FLASH SIMULTANEOUSLY REAR WIPER AND INTERMITTENT LEDS ARE FLASHING SIMULTANEOUSLY A/C AND RECIRC LEDS ARE FLASHING SIMULTANEOUSLY
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CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT Test can be aborted by doing one of the following: Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons. Cycling Ignition OFF and then ON. Control will automatically abort after 15 minutes from the time Calibration Diagnostics and Cooldown was entered. The HVAC control module will return to normal operation or may indicate unsuccessful Calibration Diagnostics or Cooldown test by LEDs flashing simultaneously. EEPROM DATA Calibration Diagnostics, Cooldown Status and evaporator temperature Fin Sensor values are stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control module uses this information: To determine if Cooldown needs to run For proper position of the Heater-A/C unit assembly doors ACTUATOR CALIBRATION AND DIAGNOSTICS.
NOTE: Do not run actuators unless they are properly mounted on the HVAC control module. Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and INTERMITTENT LEDs will flash alternately during the test. The control will cycle the Blend actuator(s) to the Heat stop
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DIAGNOSIS AND TESTING (Continued)
FAIL CODES/LEVEL DISPLAY Fail Codes/Level are displayed using the REAR WIPER and INTERMITTENT LEDs flashing in the sequence indicated below. The REAR WIPER LED represents the Level and the INTERMITTENT LED represents the Value. After Calibration/Diagnostics is completed, the control will begin flashing Level 1 codes. Depressing the WASH button will cycle to Level 2, depressing WASH again will cycle to Level 3. Each time the WASH button is depressed will cycle to the next level. After Level 5 is reached, you will cycle back to Level 1. If the Control is a Heater Only you will only cycle from Levels 1 to 3. WIPE BUTTON LED
LEVEL DISPLAY
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individual test the INTERMITTENT LED flash rate will change as the Temperature or Mode potentiometer is moved from one end to the other, see Potentiometer vs. Position and Flash Rate table.
1 2 3 4 5
FAIL CODES MODE POTENTIOMETER TEST BLEND/PASS. POTENTIOMETER TEST EVAPORATOR PROBE (A/C AND ZONE UNITS ONLY) DRIVER POTENTIOMETER (ZONE UNITS ONLY)
EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: Set Blower motor to any speed other than OFF Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. Run Diagnostics (Depress REAR WIPER and REAR WASH) When Diagnostics is complete, Cycle to Level 4. Display Sequence is as follows: REAR WIPER LED will display the Level INTERMITTENT LED will display tens digit Short Pause INTERMITTENT LED will display the ones digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cooldown test is exited.
TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS The Temperature and Mode Potentiometer can be tested after calibration is complete by pressing the WASH button and cycling to Levels 2, 3 or 5 as displayed by the REAR WIPER LED. On Heater Only units you can only cycle to Levels 2 and 3. In each
After calibration, Rear Wiper LED flashing once, Intermittent LED not flashing. The system has passed calibration. Press the Rear Wiper button to exit calibration.
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After calibration, Rear Wiper LED flashing once, Intermittent LED flashing four times. The main temperature actuator/passenger temperature actuator on a zone system did not reach hot stop. (1) Check if the correct HVAC control module was used. (2) Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from hot to cold position and check Pin 5 voltage it should change from 3.5 -4.5 volts 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (3) Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary. (4) Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. (5) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing five times. The evaporator probe is open. (1) Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If not OK, if greater than 4.75 volts check for loose or corroded connector, open circuit and repair as necessary. (2) Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (3) If ground and power circuit are OK, replace Evaporator Probe. (4) Once repairs are completed, press the intermittent button about 5 seconds until all LEDs light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
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DIAGNOSIS AND TESTING (Continued)
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing six times. The evaporator probe is shorted. (1) Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If less than 0.1 volts, check for loose or corroded connector, open or shorted circuit and repair as necessary. (2) Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for shorted circuit and repair as necessary. (3) If ground and power circuit are OK, replace Evaporator Probe (4) Once repairs are completed, press the intermittent button about 5 seconds until all LEDs light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing seven times. The Drivers temperature actuator on a zone system did not reach cold stop. (1) Check if the correct HVAC control module was used. (2) Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from cold to the hot position, check Pin 4 voltage it should change from 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (3) Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary. (4) Check for binding doors, if door are binding repair as necessary. If gears and door are OK, replace actuator. (5) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing eight times. The Drivers temperature actuator on a zone system did not reach hot stop. (1) Check if the correct HVAC control module was used. (2) Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from hot to cold position, Pin 4 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary.
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(3) Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary. (4) Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. (5) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing nine times. The HVAC control module, has a internal failure. (1) Replace the HVAC control module. (2) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration and testing the A/C and RECIRC LED flashing simultaneously. Failed Cooldown test. (1) Determine if the refrigerant system is operating correctly: Check the outlet air temperature Feel the compressor suction plumbing, is it hot? (2) If not OK, go to Step 3. If OK, repeat the Calibration Diagnostic and Cooldown test. (3) If system does not seem to be operating correctly, perform diagnostics for poor performance: Low refrigerant charge No charge Compressor not operating Verify that the test was done with the evaporator at room temperature. The test consists of starting the compressor and measuring the time it takes for the evaporator temperature to fall 7C (20F). If the compressor has been running, the evaporator is cold already and will not be capable of falling 7C (20F). If the test was run with a cold evaporator, turn A/C off and turn the blower motor switch to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the Calibration Diagnostic and Cooldown test. If refrigerant system is performing properly and the system will not pass test. Repeat the Calibration Diagnostic and Cooldown test to determine if the evaporator temperature FIN sensor has developed an open or a short circuit. If the HVAC control module still passes Calibration test, verify Cooldown test manually with a pocket thermometer. The outlet air temperature must drop at least 7C (20F) within two minutes. If the vehicle passes with the manual thermometer, take HVAC control to level 4 (evaporator probe temperature readout) and repeat the Cooldown test. Ensure the evaporator is at room temperature before starting test. Check if evaporator
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PERFORMANCE TEST PROCEDURE Review Safety Precautions and Warnings in this group before proceeding with this procedure. Air temperature in test room and on vehicle must be 21 C (70F) minimum for this test.
NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. (1) Connect a tachometer and manifold gauge set. (2) Set control to A/C, RECIRC, and PANEL, temperature lever on full cool and blower on high. (3) Start engine and hold at 1000 rpm with A/C clutch engaged.
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DIAGNOSIS AND TESTING (Continued)
A/C PRESSURE TRANSDUCER VOLTAGE
VOLTAGE 0 CONDITION TRANSDUCER FAULTY OR NO VOLTAGE FROM PCM TRANSDUCER GOOD/LOW PRESSURE CUTOUT CONDITION NORMAL OPERATING CONDITION TRANSDUCER GOOD/HIGH PRESSURE CUTOUT CONDITION TRANSDUCER FAULTY
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.150 TO .450
If the compressor clutch does not engage verify refrigerant charge. If the compressor clutch still does not engage check for battery voltage at the pressure transducer located on the liquid line. If voltage is not detected, refer to: Group 8W, Wiring diagrams. Powertrain Diagnostic Procedures manual for diagnostic information. If voltage is detected at the pressure transducer, connect pressure transducer and check for battery voltage between the compressor clutch connector terminals. If voltage is detected, perform A/C Clutch Coil Tests.
TESTS (1) Verify battery state of charge. (Test indicator in battery should be green). (2) Connect an ampmeter (0-10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0-20 volt scale) with clip leads measuring voltage across the battery and A/C clutch. (3) With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle. (4) The A/C clutch should engage immediately and the clutch voltage should be within two volts of the battery voltage. If the A/C clutch does not engage, test the fuse. (5) The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch coil. This is with the work area temperature at 21C (70F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. (6) If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4 amperes or more, the coil is shorted and should be replaced. If the coil voltage is not within two volts of the battery voltage, test clutch coil feed circuit for excessive voltage drop.
EXPANSION VALVE
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor.
TESTS
NOTE: Expansion valve tests should be performed after compressor tests. Review Safety Precautions and Warnings in this group. The work area and vehicle temperature must
COMPRESSOR CLUTCH/COIL
The air conditioning compressor clutch electrical circuit is controlled by the Powertrain Control Module. It is located in the engine compartment outboard of the battery.
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DIAGNOSIS AND TESTING (Continued)
be 21C to 27C (70F to 85F). To test the expansion valve: NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply facilities. CO2 is also available from companies which service and sell fire extinguishers. (1) Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. (2) Close all doors, windows and vents to the passenger compartment. (3) Set heater A/C control to A/C, full heat, FLOOR, and high blower. (4) Start the engine and allow to idle (1000 rpm). After the engine has reached running temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. (5) If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 1655 kPa (140 to 240 psi). Suction (low pressure) gauge should read 140 kPa to 207 kPa (20 psi to 30 psig). If system cannot achieve proper pressure readings, replace the expansion valve. If pressure is correct, proceed with test. WARNING: PROTECT SKIN AND EYES FROM CONTACTING CO2 PERSONAL INJURY CAN RESULT. (6) If suction side low pressure is within specified range, freeze the expansion valve control head for 30 seconds. Use a super cold substance (liquid CO2). Do not spray R-134a or R-12 Refrigerant on the expansion valve for this test. Suction side low pressure should drop by 10 psi. If not, replace expansion valve. (7) Allow expansion valve to thaw. The low pressure gauge reading should stabilize at 140 kPa to 240 kPa (20 psi to 30 psig). If not, replace expansion valve. (8) When expansion valve test is complete, test A/C overall performance. Remove all test equipment before returning vehicle to use.
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WARNING: DO NOT REMOVE RADIATOR CAP WHEN ENGINE IS HOT, PERSONAL INJURY CAN RESULT. If vehicle has been run recently, wait 15 minutes before removing cap. Place a rag over the cap and turn it to the first safety stop. Allow pressure to escape through the overflow tube. When the system stabilizes, remove the cap completely.
MAXIMUM HEATER OUTPUT: TEST AND ACTION Engine coolant is provided to the heater system by two 16 mm (5/8 inch inside diameter) heater hoses. With engine idling at normal running temperature, set the control to maximum heat, floor, and high blower setting. Using a test thermometer, check the air temperature coming from the floor outlets, refer to Temperature Reference Table. TEMPERATURE REFERENCE TABLE
AMBIENT TEMPERATURE CELSIUS 15.5 21.1 26.6 32.2 FAHRENHEIT 60 70 80 90 MINIMUM FLOOR OUTLET TEMPERATURE CELSIUS 62.2 63.8 65.5 67.2 FAHRENHEIT 144 147 150 153
If the floor outlet air temperature is insufficient, refer to Group 7, Cooling Systems for specifications. Both heater hoses should be HOT to the touch (coolant return hose should be slightly cooler than the supply hose). If coolant return hose is much cooler than the supply hose, locate and repair engine coolant flow obstruction in heater system.
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW (1) Pinched or kinked heater hoses. (2) Improper heater hose routing. (3) Plugged heater hoses or supply and return ports at cooling system connections, refer to Group 7, Cooling System. (4) Plugged heater core. (5) Air locked heater core. (6) If coolant flow is verified and outlet temperature is insufficient, a mechanical problem may exist. POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT (1) Obstructed cowl air intake. (2) Obstructed heater system outlets. (3) Blend-air door not functioning properly.
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SERVICE PROCEDURES (Continued)
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REFRIGERANT CAPACITIES Without Rear A/C = .96 kg (34 oz. or 2.13lb.) With Rear A/C = 1.36 kg (48 oz. or 3.00 lb.) (3) Open the suction and discharge valves. Open the charge valve to allow the heated refrigerant to flow into the system. When the transfer of refrigerant has stopped, close the suction and discharge valve. (4) If all of the charge did not transfer from the dispensing device, run engine at a high idle (1400 rpm). Set the A/C control to A/C, low blower speed, and open windows. If the A/C compressor does not engage, test the compressor clutch control circuit and correct any failure. Refer to Group 8W, Wiring Diagrams. (5) Open the suction valve to allow the remaining refrigerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH-PRESSURE) VALVE AT THIS TIME.
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SERVICE PROCEDURES (Continued)
eliminate all moisture in system. When the suction gauge reads -88 kPa (- 26 in. Hg) vacuum or greater for 45 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. (3) Close all valves. Turn off and disconnect the vacuum pump. (4) The refrigerant system is prepared to be charged with refrigerant.
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PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a. This is accomplished by performing a system Charge Level-Check or Fill. If while performing this test A/C liquid line pressure is less than 207 kPa (30 psi) proceed to Empty Refrigerant System Leak Test. If liquid line pressure is greater than 207 kPa (30 psi) proceed to low refrigerant level leak test. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the symptoms. WARNING: AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE.
THERMOCOUPLE PROBE
To diagnose the A/C system, a temperature probe is required to measure liquid line temperature. The clamp-on type K probe shown in this manual is available through the Chrysler Professional Service Equipment (PSE) program. This probe is compatible with temperature-measuring instruments that accept Type K Thermocouples and have a miniature connector input. Other temperature probes are available through aftermarket sources. All references in this manual will reflect the use of the probe made available through the Professional Service Equipment program. In order to use the temperature probe, a digital thermometer will be required. If a digital thermometer is not available, an adapter is available through the Professional Service Equipment program. It can convert any standard digital multimeter into a thermometer. This adapter is designed to accept any standard K-type thermocouple. If a digital multimeter is not available, it to can be ordered through Professional Service Equipment program.
EMPTY REFRIGERANT SYSTEM LEAK TEST (1) Evacuate the refrigerant system to the lowest degree of vacuum possible (about 28 in Hg.). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed with this procedure. (2) Prepare a .284 Kg. (10 oz.) refrigerant charge to be injected into the system. (3) Connect and dispense .284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system. (4) Proceed to step two of Low Refrigerant Level Leak Test. LOW REFRIGERANT LEVEL LEAK TEST (1) Determine if there is any (R-134a) refrigerant in the system. Use the scan tool (DRB) under the menu Systems SensorsA/C Pressure test or pressure gauge liquid line temperature partial charge check. See system charge level check or fill for procedure. (2) Position the vehicle in a wind free work area. This will aid in detecting small leaks. (3) Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run for five minutes with the system set to the following:
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CAUTION: A leak detector designed for R-12 refrigerant will not detect leaks in a R-134a refrigerant system. (4) Shut off the vehicle and wait 2 to 7 minutes. Then use an Electronic Leak Detector that is designed to detect R-134a type refrigerant and search for leaks. Fittings, lines, or components that appear to be oily usually indicates a refrigerant leak. To inspect the evaporator core for leaks, insert the leak detector probe into the recirculating air door opening or a heat duct. If a thorough leak check has been completed without indication of a leak, proceed to System Charge Level-Check or Fill.
REMOVAL (1) Disconnect the battery negative cable. (2) Recover A/C system refrigerant. (3) Unscrew the High Side service port from the liquid line. (4) Remove O-ring INSTALLATION For installation, reverse the above procedures. Install new O-ring. Evacuate and recharge A/C system.
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION For installation, reverse the above procedures. Make sure the TOP lettering is on the top of the resistor. The coils on the Resistor Block should not be contacting one another. Before installation, gently separate the coils (with fingers only) if one coil is contacting another.
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REMOVAL AND INSTALLATION (Continued)
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COMPRESSOR
REMOVAL
WARNING: REFER TO REFRIGERANT SERVICE PROCEDURES FOR INFORMATION REGARDING PROPER RECOVERY OF THE REFRIGERANT BEFORE ATTEMPTING TO REMOVE THE COMPRESSOR. (1) Disconnect negative battery cable. (2) Pinch off coolant lines to rear Heat unit (if equipped). Drain engine coolant. (3) Remove upper radiator hose. (4) Remove drive belt (refer to Group 7, Cooling System). Disconnect compressor clutch wire lead. (5) Remove refrigerant lines from compressor (Fig. 21) and (Fig. 22).
COMPRESSOR CLUTCH/COIL
Fig. 22 Discharge line
(6) Remove compressor nuts and bolts (Fig. 23). (7) Remove compressor (Fig. 24).
REMOVAL (1) Remove the compressor shaft bolt (Fig. 25). A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal.
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REMOVAL AND INSTALLATION (Continued)
CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing operation. No attempt should be made to separately replace either part. This will result in clutch slippage due to insufficient contact area.
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INSTALLATION (1) Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten with the wire clip screw. (2) Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing outward. Also both snap ring eyelets must be to the right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the groove.
CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. (3) Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface (Fig. 29). CAUTION: Do not mar the pulley frictional surface.
used. If not, place a trial stack of shims, 1 mm (0.040 in.) thick, on the shaft against the shoulder. (6) Install front plate assembly onto shaft. (7) With the front plate assembly tight against the shim(s), measure the air gap between front plate and pulley face with feeler gauges. The air gap should be between 0.5 and 0.9 mm (.020 and .035 inch) If proper air gap is not obtained, add or subtract shims until desired air gap is obtained. (8) Install compressor shaft bolt. Tighten to 17.5 2 Nm (155 20 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN After a new clutch has been installed, check the voltage and amperage to the clutch (determine it to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability.
CONDENSER ASSEMBLY
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL (1) Recover A/C system refrigerant. (2) Remove liquid line at filter-drier (Fig. 30). (3) Remove (2) bolts attaching filter-drier to radiator module (Fig. 31). (4) Remove upper radiator crossmember. (5) Tilt radiator rearward. (6) Remove upper discharge line at condenser (Fig. 32). (7) Through fascia, remove lower liquid line from filter-drier. (8) Remove (2) lower condenser mounting bolts. (9) Remove (2) upper mounting bolts. (10) Remove condenser from vehicle (Fig. 33).
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Fig. 31 Filter-Drier
INSTALLATION
NOTE: Inspect Cooling Module for presence of seals. Verify seals are available for re-installation. (1) Before installation, replace all O-rings and gaskets, coat all sealing surfaces with approved wax-free refrigerant oil. Then, reverse the above procedures. (2) Torque the following components to specifications:
DISCHARGE LINE
REMOVAL (1) Recover A/C system refrigerant. (2) Remove discharge line mounting nut at compressor (Fig. 34). (3) Remove discharge line at the top fitting on the condenser (Fig. 35).
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REMOVAL AND INSTALLATION (Continued)
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EVAPORATOR PROBE
REMOVAL (1) Remove the glove box. Refer to Group 8E, Instrument Panel and Systems. (2) Disconnect the evaporator probe connector (Fig. 36). (3) Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing (Fig. 37). (4) Remove evaporator probe from evaporator (Fig. 38).
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EXPANSION VALVE
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION.
REMOVAL (1) Disconnect the battery negative cable. (2) Recover A/C system refrigerant. (3) Remove the accessory drive belt. (4) Remove upper generator bracket. (5) Disconnect generator field wire connector. (6) Push generator forward. (7) Remove ground wire at dash panel. (8) Remove the nut retaining the refrigerant line sealing plate to the expansion valve (Fig. 39). (9) Remove the stud from the expansion valve (Fig. 40). (10) Carefully pull the refrigerant line sealing plate assembly from expansion valve towards the front of the vehicle. Use care not to scratch the expansion valve sealing surfaces with pilot tubes. (11) Cover the openings to prevent contamination. (12) Remove two screws securing the expansion valve to the evaporator sealing plate (Fig. 40). (13) Carefully remove expansion valve (Fig. 41). (14) Remove the old O-rings.
FILTER-DRIER ASSEMBLY
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. (1) Recover A/C system refrigerant.
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REMOVAL AND INSTALLATION (Continued)
(2) Remove liquid line at filter-drier (Fig. 42).
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INSTALLATION (1) Before installation, replace both refrigerant line O-rings. Then reverse the above procedures. Torque filter/drier mounting bolts to 45 in. lbs. 10. (2) Evacuate and recharge system.
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INSTALLATION (1) For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing inlets (2) Evacuate and recharge the A/C system. (3) Perform HVAC control Calibration Diagnostic and Cooldown test.
HEATER CORE
REMOVAL (1) Drain coolant system. (2) Remove left side lower column cover. (3) Remove steering column assembly. Refer to Group 19, Steering for service procedure. (4) Remove ABS module, bracket and wiring (Fig. 47). (5) Remove I/P to body harness interconnect and bracket (Fig. 48). (6) Remove lower silencer boot at base of steering shaft (Fig. 49) (7) Pinch off heater lines under the hood. (8) Remove heater core cover. Insert a small amount of towels under the heater core tubes. Remove heater core plate and tubes (Fig. 50). (9) Depress heater core retaining clips (Fig. 51). (10) Pull up on accelerator pedal and slide heater core past (Fig. 52).
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REMOVAL AND INSTALLATION (Continued)
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HEATER HOSES
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation. (1) Drain engine cooling system. Refer to Group 7, Engine Cooling. (2) Loosen clamps at each end of heater hose to be removed (Fig. 54) and (Fig. 55).
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LIQUID LINE
Fig. 56 ABS Control Module
REMOVAL (1) Disconnect the battery negative cable. (2) Recover A/C system refrigerant. (3) Remove the accessory drive belt. (4) Remove upper generator bracket. (5) Remove ground wire at dash panel. (6) Remove the nut retaining the refrigerant line sealing plate to the expansion valve (Fig. 39). (7) Remove the stud from the expansion valve (Fig. 40). (8) Remove liquid line from expansion valve. (9) Cover the openings to prevent contamination. (10) Disconnect wire connector at pressure transducer. (11) Remove liquid line mounting bracket at right frame rail. (12) Using access slot between radiator crossmember and grille, loosen liquid line mounting plate at filter-drier. Remove liquid line from filter-drier. It may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece assembly. (13) Remove the old O-rings.
(3) Remove mode actuator connector (Fig. 57).
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REMOVAL AND INSTALLATION (Continued)
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SUCTION LINE
REMOVAL (1) Disconnect the battery negative cable. (2) Recover A/C system refrigerant. (3) Remove the accessory drive belt. (4) Remove upper generator bracket. (5) Remove ground wire at dash panel. (6) Remove the nut retaining the refrigerant line sealing plate to the expansion valve (Fig. 39). (7) Remove the stud from the expansion valve (Fig. 40). (8) Remove suction line from expansion valve. (9) Remove suction line mounting nut at compressor (Fig. 61). (10) Remove suction line mounting bracket. (11) Remove suction line.
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INSTALLATION (1) For installation, reverse the above procedures. (2) Perform the HVAC control Calibration Diagnostic and Cooldown test.
DISASSEMBLYEVAPORATOR HOUSING (1) Place HVAC unit assembly on workbench. (2) Remove distribution housing mounting screws (Fig. 63). (3) Remove blower motor cover (Fig. 64). (4) Remove blower motor wiring grommet and feed wiring through blower housing (Fig. 65). (5) Remove blower motor screws. Remove blower motor from housing (Fig. 66) and (Fig. 67). (6) Remove recirculation door cover (Fig. 68).
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DISASSEMBLY AND ASSEMBLY (Continued)
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ASSEMBLYEVAPORATOR HOUSING (1) For reassembly of the evaporator housing, reverse the above procedures. (2) Perform the HVAC control Calibration Diagnostic and Cooldown test. DISASSEMBLYDISTRIBUTION HOUSING (1) Place distribution housing on workbench (Fig. 72). (2) Remove heater core cover (Fig. 73). (3) Remove heater core tube plate (Fig. 74) and (Fig. 75). (4) Remove heater core tubes (Fig. 76).
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Fig. 71 Evaporator
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DISASSEMBLY AND ASSEMBLY (Continued)
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DISASSEMBLY AND ASSEMBLY (Continued)
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ASSEMBLYDISTRIBUTION HOUSING For reassembly of the distribution housing, reverse the above procedures. To reassemble the distribution housing actuator gears an assembly procedure of the gears and cam is necessary.
ACTUATOR GEARS ALIGNMENT PROCEDURE (1) Install lower FLOOR door actuator gear to housing. Match master spline of FLOOR door actuator gear to master spline on door. (2) Install cam wheel. Align cam wheel track to FLOOR door actuator gear. (3) Align cam wheel slot with the post on the distribution housing marked 1. (4) Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master spline on PANEL door. Position actuator gear within cam wheel track. (5) Install DEFROST door actuator gear to housing. Match master spline of DEFROST door actuator to master spline on DEFROST door. Position actuator gear within cam wheel track. (6) Reinstall housing in vehicle. (7) Perform the HVAC control Calibration Diagnostic and Cooldown test.
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. . . . . . 41 . . . . . . 41 . . . . . . 41 . . . . . . 41 . . . . . . 43 . . . . . . 43 . . . . . . 43 . . . . . . 44
. 46
block ensure that the area around it is clean of any contaminations that can get in to the system (Fig. 1), (Fig. 2), (Fig. 4), (Fig. 3) and (Fig. 5).
SYSTEM OPERATION
The auxiliary rear heating-air/conditioning unit is located in the right rear quarter panel. The rear heater A/C control operates in conjunction with the front heater A/C control. A four position two speed blower (override) switch is located on the front Heater A/C control panel (Fig. 6). The operator can use the rear heater A/C blower switch to operate the blower, regardless of the rear control setting. In the OFF position, the rear control will not function. In the ON (RR) position, the rear control will function normally providing three speeds (Fig. 7). The mode setting is controlled by the front A/C control panel.
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DESCRIPTION AND OPERATION (Continued)
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REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. (1) Remove right quarter trim panel and D-pillar trim. Refer to Group 23, Body. (2) Remove fan A/C distribution duct. (3) Remove rear A/C unit. (4) Remove blower scroll. (5) Remove evaporator cover (Fig. 12). (6) Remove the nut that mounts the refrigerant plumbing block to the expansion valve (Fig. 13). (7) Carefully pull the evaporator and expansion valve straight out of unit (Fig. 14). Do not scratch the sealing surfaces with the plumbing extension tube pilots. (8) Remove and discard the O-rings between the plumbing extension and the expansion valve. (9) Cover the plumbing extension sealing surface to prevent contamination. (10) Bring evaporator and expansion valve to a clean work space. (11) Remove two 1/4-20 Torx Head screws. (12) Remove expansion valve. (13) Measure and record the amount of residual oil from the removed evaporator.
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REMOVAL AND INSTALLATION (Continued)
CAUTION: Do not damage the evaporator insulation liner during installation. (3) Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. (4) Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system. (5) Carefully align the expansion valve onto the pilot tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 23 3 Nm (200 30 inch pounds) torque. (6) Install evaporator cover and blower scroll. (7) Install quarter trim panel, evacuate/charge system, and perform the performance test.
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condenser is mounted on the primary condenser in front of the radiator. Both condenser must be removed as an assembly and then separated. WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. The condenser assembly must first be removed from vehicle. Refer to CONDENSER ASSEMBLY removal and installation in this section for service procedures.
REMOVAL (1) Hoist vehicle (2) Remove compression fittings to the suction and liquid lines located on the right, outboard side of the underbody, rearward of the front crossmember. (Fig. 2) (3) remove (1) bolt securing a/c lines to block located on the right, outboard side of the underbody, rearward of the rear wheel and tire. (Fig. 5) (4) Remove (3) straps securing underbody lines. (Fig. 1) (5) Separate and remove a/c lines from vehicle. INSTALLATION (1) Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved waxfree refrigerant oil. Then, reverse the above procedures. (2) Evacuate and recharge system.
REMOVAL (1) After condenser assembly removal, place on bench for disassembly. (2) Remove (1) bolt to liquid line on auxiliary condenser. (3) Remove (4) attaching bolts and separate auxiliary from primary condenser. (Fig. 15) INSTALLATION (1) Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved waxfree refrigerant oil. Then, reverse the above procedures. (2) Evacuate and recharge system.
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REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH REAR A/C, THE REFRIGERANT SYSTEM MUST BE EMPTIED BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. (1) Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C plumbing from rear heater A/C unit. (2) Hoist vehicle. (3) Remove A/C lines at lower floor pan flange (Fig. 17).
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION For installation, reverse the above procedures. Install new O-rings at refrigerant lines. Evacuate and charge the refrigerant system. Fill the heater core (Fig. 26). Test for leaks and overall performance.
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INSTALLATION For installation, reverse the above procedures. Prefill the heater core (Fig. 26). Test for leaks and overall performance.
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REMOVAL AND INSTALLATION (Continued)
NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled completely, the following procedure can be used: Vehicle at room temperature. Engine is brought up to operating temperature. Front unit is OFF, temperature slides are at full HEAT position. Engine is at idle. With rear blower motor ON HIGH Discharge air temperature, measured at the dual register located on the C-pillar base, is between 57C to 62C (135 and 145 F).
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(5) Remove (3) straps securing underbody lines. (Fig. 1) (6) Separate and remove rear heater lines from vehicle.
MODE DOOR
REMOVAL (1) Remove A/C unit. (2) Place unit on bench. (3) Remove heater core. (4) Remove blower scroll. (5) Remove evaporator cover. (6) Remove A/C line to expansion valve mounting nut. (7) Carefully pull evaporator out of housing. (8) Remove mode door actuator and gear extension. (9) Remove Heater-A/C housing clips and screws. (10) Separate housing halves. (11) Remove mode door. INSTALLATION For installation, reverse the above procedures.
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GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PRECAUTIONS AND WARNINGS . . . . DESCRIPTION AND OPERATION A/C PRESSURE TRANSDUCER . . . . . . . . . . . . A/C SERVICE PORTS . . . . . . . . . . . . . . . . . . . . AIR DISTRIBUTION DUCTS . . . . . . . . . . . . . . . COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR HIGH-PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . ENGINE COOLING SYSTEM REQUIREMENTS . EVAPORATOR PROBE . . . . . . . . . . . . . . . . . . . HANDLING TUBING AND FITTINGS . . . . . . . . HVAC CONTROL MODULE . . . . . . . . . . . . . . . . SIDE DOOR HEATER A/C OUTLETS . . . . . . . . SIDE WINDOW DEMISTER . . . . . . . . . . . . . . . SYSTEM AIRFLOW . . . . . . . . . . . . . . . . . . . . . SYSTEM OIL LEVEL . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING A/C PERFORMANCE TEST . . . . . . . . . . . . . . . A/C PRESSURE TRANSDUCER . . . . . . . . . . . ACTUATOR CALIBRATION/DIAGNOSTICS AND COOLDOWN TEST . . . . . . . . . . . . . . . . . . . . . BLOWER MOTOR AND WHEEL ASSEMBLY . COMPRESSOR CLUTCH/COIL . . . . . . . . . . . . COMPRESSOR NOISE DIAGNOSIS . . . . . . . . EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . HEATER PERFORMANCE TEST . . . . . . . . . . . HVAC CONTROL DIAGNOSTIC CONDITIONS . SYSTEM CHARGE LEVEL TEST . . . . . . . . . . . GENERAL INFORMATION INTRODUCTION
1 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 11 11 5 12 12 12 14 14 9 15
SERVICE PROCEDURES CHARGING REFRIGERANT SYSTEM . . . . . . . EVACUATING REFRIGERANT SYSTEM . . . . . R-134a REFRIGERANT . . . . . . . . . . . . . . . . . . STICKING HVAC CONTROL MODULE PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM LEAK CHECKING . . . . . . . . . . . . . . . THERMOCOUPLE PROBE . . . . . . . . . . . . . . . REMOVAL AND INSTALLATION A/C PRESSURE TRANSDUCER . . . . . . . . . . . A/C SERVICE PORTS . . . . . . . . . . . . . . . . . . . BLEND-AIR DOOR ACTUATOR . . . . . . . . . . . BLOWER MOTOR AND WHEEL ASSEMBLY . BLOWER MOTOR RESISTOR BLOCK . . . . . . BLOWER MOTOR WHEEL . . . . . . . . . . . . . . . COMPRESSOR (2.5L TURBO DIESEL) . . . . . CONDENSER ASSEMBLY . . . . . . . . . . . . . . . . DISCHARGE LINE . . . . . . . . . . . . . . . . . . . . . EVAPORATOR PROBE . . . . . . . . . . . . . . . . . . EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . FILTER-DRIER ASSEMBLY . . . . . . . . . . . . . . . HEATER A/C UNIT HOUSING . . . . . . . . . . . . . HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . HEATER HOSES . . . . . . . . . . . . . . . . . . . . . . . LIQUID LINE . . . . . . . . . . . . . . . . . . . . . . . . . MODE DOOR ACTUATOR . . . . . . . . . . . . . . . . RECIRC DOOR ACTUATOR . . . . . . . . . . . . . . SIDE WINDOW DEMISTER DUCTS . . . . . . . . SUCTION LINE . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY AND ASSEMBLY HEATER A/C UNIT RECONDITION . . . . . . . . .
17 17 16 18 19 18 19 19 20 20 21 22 22 23 23 24 25 26 26 26 28 28 29 30 29 29 30
The Heater, or Heater and Air Conditioning systems share many of the same components. This group will deal with both systems together when component function is common, and separately when they are not. For proper operation of the instrument panel controls, refer to the Owners Manual provided with the vehicle.
All vehicles are equipped with a common Heater A/C unit housing assembly. When the vehicle has only a heater system, the evaporator and recirculating air door are omitted. An optional zone control HVAC unit is available. This unit has dual blend-air doors that can be regulated independently of each other. The temperature setting can be different from drivers side to passenger side.
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not serviceable in vehicle. The procedures for service of these ducts are covered in Group 8E, Instrument Panel and Gauges. The only ducts that are serviceable in the vehicle are the side window demister ducts and the ducts that feed the front door outlets for the first rear passenger(s) seating. To service the door ducts refer to Group 23, Body.
COMPRESSOR
The A/C compressor for the 2.5L Turbo Diesel, is located on the front side of the engine block. It is mounted to the engine block by four bolts. The com-
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DESCRIPTION AND OPERATION (Continued)
pressor is driven off the back of the power steering pump. A rubber flex coupling transfers the power from the power steering pump to the compressor clutch.
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CONDENSATE DRAIN
Condensation from the evaporator housing is drained through the dash panel and on to the ground. This drain must be kept open to prevent water from collecting in the bottom of the housing. If the drain is blocked condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensate drainage below the vehicle.
EVAPORATOR PROBE
The Evaporator probe is located on the HVAC. The probe prevents evaporator freeze-up by signaling the Powertrain Control Module to cycle the compressor ON and OFF. The probe monitors the temperature of the refrigerant after expansion. The evaporator probe is inserted into the evaporator between the coils. The probe is a sealed unit and cannot be adjusted or repaired. It must be replaced if found defective.
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SYSTEM AIRFLOW
The system pulls outside (ambient) air through the cowl opening at the base of the windshield. Then it goes into the plenum chamber above the heaterA/C unit housing. On air conditioned vehicles, the air passes through the evaporator. At this point the air flow can be directed either through or around the heater core. This is done by adjusting the blend- air door with the TEMP control on the control head. An optional zone control HVAC control module is available. This unit has dual blend-air doors that can be regulated independently of each other. The temperature setting can be different from drivers side to passenger side. After the air passes the blend-air door(s), the air flow can then be directed from the Panel, Floor, and Defrost outlets. Air flow velocity can be adjusted with the blower speed selector switch on the control head. Ambient air intake can be shut off by closing the recirculating air door. This will recirculate the air that is already inside the vehicle. This is done by depressing the Recirc. button on the control head. On air conditioned vehicles, moving the control to Mix or Defrost depresses the A/C button and will engage the compressor. This will send refrigerant through the evaporator, and remove heat and humidity from the air before it goes through the heater core. CAUTION: In cold weather, use of the Recirculation mode may lead to excessive window fogging. The Recirculation mode is automatically deactivated in Mix and Defrost modes to improve window clearing operation.
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DESCRIPTION AND OPERATION (Continued)
capacity of the system and consequently result in higher discharge air temperatures. NOTE: The oil used in the Denso 2.5L Turbo Diesel and the Denso 2.0L gasoline engine compressors is ND-8 PAG R134a refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use. Tightly cap afterwards to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with. Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak.
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REFRIGERANT OIL LEVEL CHECK When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filterdrier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The compressor is drained through the suction port or by removing the sump bolt on top of the compressor, refer to Compressor Removal and Installation procedures. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Example: The evaporator retains 50 ml (1.7 oz.). The condenser retains 30 ml (1 oz) of oil, and system capacity may be 220 ml (7.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz.).
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for the Denso 2.5L Turbo Diesel and Denso 2.0L gasoline engine compressors is ND-8 PAG compressor oil. For gasoline vehicles still using R-12 refrigerant, use ND8 PAG compressor oil.
SERVICING REFRIGERANT OIL LEVEL (1) Using a refrigerant recovery machine, remove refrigerant from the A/C system. (2) Remove refrigerant lines from A/C compressor. (3) Remove compressor from vehicle. (4) From suction port on top of compressor, drain refrigerant oil from compressor. (5) Add system capacity minus the capacity of components that have not been replaced through suction port on compressor. Refer to the Refrigerant Oil Capacity Chart. (6) Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system.
ACTUATOR CALIBRATION Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the
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DIAGNOSTICS During the Actuator calibration, diagnostics are performed on the actuators and evaporator temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT LEDs will flash to indicate either a successful calibration or the appropriate fail code(s). At this time manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LEDs will flash simultaneously showing that a failure has occurred. The control will not indicate the fail code, but only that a failure had occurred during the last diagnostics test. The only way to clear the failure codes is repeat the Calibration Diagnostic and Cooldown test, after all repairs are completed. COOLDOWN TEST This test has been designed for performance testing of the A/C system at the manufacturing facility. If the HVAC control module is replaced, the Cooldown test will occur during Calibration test. Cooldown will not occur on Heater Only units. During the Cooldown test the control will monitor the temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature down a predetermined minimum amount in less than 2 minutes.
CALIBRATION/COOLDOWN LED DISPLAY CODES See chart for definition of flashing LEDs. If no problems are found, the control functions normally. CALIBRATION/DIAGNOSTICS TEST ENTRY
TO INITIATE TESTS: Set Blower motor ON HIGH Set Mode position to Panel Open all A/C outlets Set Temperature to Cold (Both slide pots if equipped) Depress WASH and REAR WIPER button simultaneously for 5 Seconds (Until all LEDs light) RESULTS: All LEDs will turn on for 5 Seconds Calibration Test is running when REAR WIPER and INTERMITTENT are alternately flashing. Cooldown test is running if A/C and RECIRC are alternately flashing. Acceptable results is REAR WIPER LED is the only LED flashing. Push Rear Wiper to exit. After all tests have passed, Calibration Diagnostics and Cooldown can be run separately.
Fig. 6 Radio Bezel and HVAC Control, Rear Blower Motor Switch and Zone Control
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DIAGNOSIS AND TESTING (Continued)
LEDS NO LEDS FLASHINGNORMAL OPERATION PASS/FAIL CORRECTIVE ACTION
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Cycling Ignition OFF and then ON. Control will automatically abort after 15 minutes from the time Calibration Diagnostics and Cooldown was entered. The HVAC control module will return to normal operation or may indicate unsuccessful Calibration Diagnostics or Cooldown test by LEDs flashing simultaneously.
FAILED RUN REAR WIPER AND CALIBRATION CALIBRATION DIAGNOSTICS TEST INTERMITTENT LEDS FLASH SIMULTANEOUSLY A/C AND RECIRC FAILED LEDS FLASH COOLDOWN SIMULTANEOUSLY REAR WIPER AND INTERMITTENT LEDS ARE FLASHING SIMULTANEOUSLY A/C AND RECIRC LEDS ARE FLASHING SIMULTANEOUSLY RUN COOLDOWN TEST
RUN FAILED CALIBRATION, CALIBRATION DIAGNOSTICS TEST AND FAILED COOLDOWN TEST
EEPROM DATA Calibration Diagnostics, Cooldown Status and evaporator temperature Fin Sensor values are stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control module uses this information: To determine if Cooldown needs to run For proper position of the Heater-A/C unit assembly doors ACTUATOR CALIBRATION AND DIAGNOSTICS.
NOTE: Do not run actuators unless they are properly mounted on the HVAC control module. Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and INTERMITTENT LEDs will flash alternately during the test. The control will cycle the Blend actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as actuator travel falling within their minimum and maximum limits. BLEND/PASSENGER ACTUATOR BACKGROUND The Blend/Passenger Actuator can move the temperature door in two directions. When the voltage at Pin 12 of the control module is high, about 11.5 volts, and the voltage at Pin 17 is low, about 1.5 volts, the door will move towards the Heat position. When Pin 17 is High and Pin 12 is Low the door will move towards the Cold position. When both Pins are high or both Pins are low, the actuator will not move. The Blend/Passenger feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Blend/Passenger actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door. DRIVER ACTUATOR BACKGROUND The Driver Actuator can move the temperature door in two directions. When the voltage at Pin 15 of the control module is high, about 11.5 volts, and the voltage at Pin 13 is low, about 1.5 volts the door will
CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT Test can be aborted by doing one of the following: Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons.
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FAIL CODES/LEVEL DISPLAY Fail Codes/Level are displayed using the REAR WIPER and INTERMITTENT LEDs flashing in the sequence indicated below. The REAR WIPER LED represents the Level and the INTERMITTENT LED represents the Value. After Calibration/Diagnostics is completed, the control will begin flashing Level 1 codes. Depressing the WASH button will cycle to Level 2, depressing WASH again will cycle to Level 3. Each time the WASH button is depressed will cycle to the next level. After Level 5 is reached, you will cycle back to Level 1. If the Control is a Heater Only you will only cycle from Levels 1 to 3. WIPE BUTTON LED
LEVEL 1 2 3 4 5 FAIL CODES MODE POTENTIOMETER TEST BLEND/PASS. POTENTIOMETER TEST EVAPORATOR PROBE (A/C AND ZONE UNITS ONLY) DRIVER POTENTIOMETER (ZONE UNITS ONLY) DISPLAY
TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS The Temperature and Mode Potentiometer can be tested after calibration is complete by pressing the WASH button and cycling to Levels 2, 3 or 5 as displayed by the REAR WIPER LED. On Heater Only units you can only cycle to Levels 2 and 3. In each individual test the INTERMITTENT LED flash rate will change as the Temperature or Mode potentiometer is moved from one end to the other, see Potentiometer vs. Position and Flash Rate table. POTENTIOMETER VS. POSITION AND FLASH RATE
INTERMITTENT INTERMITTENT LED FASTER LED SLOWER FLASH RATE FLASH RATE PANEL HOT HOT DEFROST COLD COLD
EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: Set Blower motor to any speed other than OFF
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DIAGNOSIS AND TESTING (Continued)
Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. Run Diagnostics (Depress REAR WIPER and REAR WASH) When Diagnostics is complete, Cycle to Level 4. Display Sequence is as follows: REAR WIPER LED will display the Level INTERMITTENT LED will display tens digit Short Pause INTERMITTENT LED will display the ones digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cooldown test is exited.
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Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (2) Remove actuator, and check if the gear pins are in the correct cam track or binding. If OK, go to Step 3. If not OK, repair as necessary. (3) Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. (4) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED not flashing. The system has passed calibration. Press the Rear Wiper button to exit calibration. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing once. The mode actuator did not reach defrost position. (1) Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from the defrost to panel position, and check Pin 6 voltage it should change from 0.5 - 1 volts to 3.5 - 4.5 volts. If voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (2) Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 3. If not OK, repair as necessary. (3) Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. (4) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing twice. The mode actuator did not reach panel position. (1) Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from panel to defrost position, and check Pin 6 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1 volts. If voltage is OK, go to
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing three times. The main temperature actuator/passenger temperature actuator on a zone system did not reach cold stop. (1) Check if the correct HVAC control module was used. (2) Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from the cold to hot position, and check Pin 5 voltage it should change from 0.5 - 4 volts to 3.5 - 4.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (3) Remove actuator, and check if gear pins are in the correct cam track or binding. If OK, go to Step 4. If not OK, repair as necessary. (4) Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. (5) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing four times. The main temperature actuator/passenger temperature actuator on a zone system did not reach hot stop. (1) Check if the correct HVAC control module was used. (2) Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from hot to cold position and check Pin 5 voltage it should change from 3.5 -4.5 volts 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (3) Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary.
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After calibration, Rear Wiper LED flashing once, Intermittent LED flashing five times. The evaporator probe is open. (1) Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If not OK, if greater than 4.75 volts check for loose or corroded connector, open circuit and repair as necessary. (2) Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (3) If ground and power circuit are OK, replace Evaporator Probe. (4) Once repairs are completed, press the intermittent button about 5 seconds until all LEDs light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing six times. The evaporator probe is shorted. (1) Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If less than 0.1 volts, check for loose or corroded connector, open or shorted circuit and repair as necessary. (2) Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for shorted circuit and repair as necessary. (3) If ground and power circuit are OK, replace Evaporator Probe (4) Once repairs are completed, press the intermittent button about 5 seconds until all LEDs light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing seven times. The Drivers temperature actuator on a zone system did not reach cold stop. (1) Check if the correct HVAC control module was used. (2) Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from cold to the hot position, check Pin 4 voltage it should change from 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage is OK, go
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing eight times. The Drivers temperature actuator on a zone system did not reach hot stop. (1) Check if the correct HVAC control module was used. (2) Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from hot to cold position, Pin 4 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. (3) Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary. (4) Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. (5) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing nine times. The HVAC control module, has a internal failure. (1) Replace the HVAC control module. (2) Once repairs are completed repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes. After calibration and testing the A/C and RECIRC LED flashing simultaneously. Failed Cooldown test. (1) Determine if the refrigerant system is operating correctly: Check the outlet air temperature Feel the compressor suction plumbing, is it hot? (2) If not OK, go to Step 3. If OK, repeat the Calibration Diagnostic and Cooldown test. (3) If system does not seem to be operating correctly, perform diagnostics for poor performance: Low refrigerant charge
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DIAGNOSIS AND TESTING (Continued)
No charge Compressor not operating Verify that the test was done with the evaporator at room temperature. The test consists of starting the compressor and measuring the time it takes for the evaporator temperature to fall 7C (20F). If the compressor has been running, the evaporator is cold already and will not be capable of falling 7C (20F). If the test was run with a cold evaporator, turn A/C off and turn the blower motor switch to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the Calibration Diagnostic and Cooldown test. If refrigerant system is performing properly and the system will not pass test. Repeat the Calibration Diagnostic and Cooldown test to determine if the evaporator temperature FIN sensor has developed an open or a short circuit. If the HVAC control module still passes Calibration test, verify Cooldown test manually with a pocket thermometer. The outlet air temperature must drop at least 7C (20F) within two minutes. If the vehicle passes with the manual thermometer, take HVAC control to level 4 (evaporator probe temperature readout) and repeat the Cooldown test. Ensure the evaporator is at room temperature before starting test. Check if evaporator probe will drop the temperature 7C (20F) in two minutes. If the Evaporator Probe is found to be faulty, check that the sensor is positioned in the evaporator fins properly. If not, correct and repeat test. If OK, replace the evaporator probe. Once the repairs are completed, repeat the Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
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PERFORMANCE TEST PROCEDURE Review Safety Precautions and Warnings in this group before proceeding with this procedure. Air temperature in test room and on vehicle must be 21 C (70F) minimum for this test.
NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. (1) Connect a tachometer and manifold gauge set. (2) Set control to A/C, RECIRC, and PANEL, temperature lever on full cool and blower on high. (3) Start engine and hold at 1000 rpm with A/C clutch engaged. (4) Engine should be warmed up with doors and windows closed. (5) Insert a thermometer in the left center A/C outlet and operate the engine for five minutes. The A/C clutch may cycle depending on ambient conditions. (6) With the A/C clutch engaged, compare the discharge air temperature to the A/C Performance Temperatures chart (Fig. 7). (7) If the discharge air temperature fails to meet the specifications in the performance temperature chart. Refer to the Refrigerant Service Procedures for further diagnosis.
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COMPRESSOR CLUTCH/COIL
The air conditioning compressor clutch electrical circuit is controlled by the Powertrain Control Mod-
TESTS (1) Verify battery state of charge. (Test indicator in battery should be green). (2) Connect an ampmeter (0-10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0-20 volt scale) with clip leads measuring voltage across the battery and A/C clutch. (3) With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle. (4) The A/C clutch should engage immediately and the clutch voltage should be within two volts of the battery voltage. If the A/C clutch does not engage, test the fuse. (5) The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch coil. This is with the work area temperature at 21C (70F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts.
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DIAGNOSIS AND TESTING (Continued)
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TESTS
NOTE: Expansion valve tests should be performed after compressor tests. Review Safety Precautions and Warnings in this group. The work area and vehicle temperature must be 21C to 27C (70F to 85F). To test the expansion valve: NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply facilities. CO2 is also available from companies which service and sell fire extinguishers. (1) Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. (2) Close all doors, windows and vents to the passenger compartment. (3) Set heater A/C control to A/C, full heat, FLOOR, and high blower. (4) Start the engine and allow to idle (1000 rpm). After the engine has reached running temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. (5) If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 1655 kPa (140 to 240 psi). Suction (low pressure) gauge should read 140 kPa to 207 kPa (20 psi to 30 psig). If system cannot achieve proper pressure readings, replace the expansion valve. If pressure is correct, proceed with test. WARNING: PROTECT SKIN AND EYES FROM CONTACTING CO2 PERSONAL INJURY CAN RESULT. (6) If suction side low pressure is within specified range, freeze the expansion valve control head for 30 seconds. Use a super cold substance (liquid CO2). Do not spray R-134a Refrigerant on the expansion valve for this test. Suction side low pressure should drop by 10 psi. If not, replace expansion valve.
PRE-DIAGNOSTIC PREPARATIONS Review Safety Precautions and Warnings in this group before performing the following procedures. Check the coolant level, drive belt tension, vacuum line connections, radiator air flow and fan operation. Start engine and allow to warm up to normal temperature.
WARNING: DO NOT REMOVE RADIATOR CAP WHEN ENGINE IS HOT, PERSONAL INJURY CAN RESULT. If vehicle has been run recently, wait 15 minutes before removing cap. Place a rag over the cap and turn it to the first safety stop. Allow pressure to escape through the overflow tube. When the system stabilizes, remove the cap completely.
MAXIMUM HEATER OUTPUT: TEST AND ACTION Engine coolant is provided to the heater system by two 16 mm (5/8 inch inside diameter) heater hoses. With engine idling at normal running temperature, set the control to maximum heat, floor, and high blower setting. Using a test thermometer, check the air temperature coming from the floor outlets, refer to Temperature Reference chart. TEMPERATURE REFERENCE CHART
AMBIENT TEMP. CELSIUS FAHRENHEIT 15.5 21.1 26.6 32.2 60 70 80 90 MINIMUM FLOOR OUTLET TEMP. CELSIUS FAHRENHEIT 62.2 63.8 65.5 67.2 144 147 150 153
If the floor outlet air temperature is insufficient, refer to Group 7, Cooling Systems for specifications. Both heater hoses should be HOT to the touch (coolant return hose should be slightly cooler than the supply hose). If coolant return hose is much cooler than the supply hose, locate and repair engine coolant flow obstruction in heater system.
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DIAGNOSIS AND TESTING (Continued)
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW (1) Pinched or kinked heater hoses. (2) Improper heater hose routing. (3) Plugged heater hoses or supply and return ports at cooling system connections, refer to Group 7, Cooling System. (4) Plugged heater core. (5) Air locked heater core. (6) If coolant flow is verified and outlet temperature is insufficient, a mechanical problem may exist. POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT (1) Obstructed cowl air intake. (2) Obstructed heater system outlets. (3) Blend-air door not functioning properly. TEMPERATURE CONTROL If temperature cannot be adjusted with the TEMP lever on the control panel, the following could require service: (1) Blend-air door binding. (2) Faulty blend-air door motor. (3) Improper engine coolant temperature. (4) Faulty Instrument Panel Control.
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REQUIREMENTS TO DISCHARGE R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. (1) Establish your preferred method of measuring liquid line pressure. Use a manifold gauge set or a DRB scan tool. (2) Attach a clamp-on thermocouple (Professional Service Equipment 66-324-0014 or 80PK-1A) or equivalent to the liquid line. It must be placed as close to the A/C Pressure Transducer as possible to observe liquid line temperature. Refer to Thermocouple Probe in this section for more information on probe. (3) The vehicle must be in the following modes: Transaxle in Park Engine Idling at 700 rpm A/C Controls Set to Outside Air Panel Mode Full Cool High Blower motor, (vehicle equipped with rear A/C turn rear blower motor ON HIGH) A/C Button in the ON position Vehicle Windows Open. Recirc. button turned OFF (4) Operate system for a couple of minutes to allow the system to stabilize. (5) Set system pressure to about 1793 kPa (260 psi) by placing a piece of cardboard over part of the front side of the condenser. To place cardboard properly, remove the upper radiator-condenser cover. Insert cardboard between condenser and radiator front. This will maintain a constant pressure. (6) Observe Liquid Line pressure and Liquid line temperature. Using the Charge Determination Chart determine where the system is currently operating. If the system is in the undercharged region, ADD 0.057 Kg. (2 oz.) to the system and recheck readings. If the system is in the overcharged region, RECLAIM 0.057 Kg. (2 oz.) from the system and recheck readings. Continue this process until the system readings are in the proper charge area on the Charge Determination Chart. (7) The same procedure can be performed using the scan tool (DRB). To determine liquid line pressure, attach the scan tool, go to System MonitorsA/C Pressure. Observe liquid line pressure from A/C Pressure Transducer on digital display and digital thermometer. Refer to Charge Determination Chart and determine where the system is operating.
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SERVICE PROCEDURES (Continued)
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correct any failure. Refer to Group 8W, Wiring Diagrams. (5) Open the suction valve to allow the remaining refrigerant to transfer to the system. WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH-PRESSURE) VALVE AT THIS TIME. (6) Close all valves and test the A/C system performance. (7) Disconnect the charging station or manifold gauge set. Install the service port caps.
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Fig. 10 Refrigerant Lines and Port Locations (2.5L Turbo Diesel engine)
(3) Close all valves. Turn off and disconnect the vacuum pump. (4) The refrigerant system is prepared to be charged with refrigerant. meter is not available, an adapter is available through the Professional Service Equipment program. It can convert any standard digital multimeter into a thermometer. This adapter is designed to accept any standard K-type thermocouple. If a digital multimeter is not available, it to can be ordered through Professional Service Equipment program.
THERMOCOUPLE PROBE
To diagnose the A/C system, a temperature probe is required to measure liquid line temperature. The clamp-on type K probe shown in this manual is available through the Chrysler Professional Service Equipment (PSE) program. This probe is compatible with temperature-measuring instruments that accept Type K Thermocouples and have a miniature connector input. Other temperature probes are available through aftermarket sources. All references in this manual will reflect the use of the probe made available through the Professional Service Equipment program. In order to use the temperature probe, a digital thermometer will be required. If a digital thermo-
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SERVICE PROCEDURES (Continued)
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gauge liquid line temperature partial charge check. See system charge level check or fill for procedure. (2) Position the vehicle in a wind free work area. This will aid in detecting small leaks. (3) Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run for five minutes with the system set to the following: Transaxle in Park Engine Idling at 700 rpm A/C Controls Set in 100 percent outside air Full Panel Mode Blower motor ON HIGH A/C in the ON position Front Windows Open. Rear Air Off (If Equipped) CAUTION: A leak detector designed for R-12 refrigerant will not detect leaks in a R-134a refrigerant system. (4) Shut off the vehicle and wait 2 to 7 minutes. Then use an Electronic Leak Detector that is designed to detect R-134a type refrigerant and search for leaks. Fittings, lines, or components that appear to be oily usually indicates a refrigerant leak. To inspect the evaporator core for leaks, insert the leak detector probe into the recirculating air door opening or a heat duct. If a thorough leak check has been completed without indication of a leak, proceed to System Charge Level-Check or Fill.
EMPTY REFRIGERANT SYSTEM LEAK TEST (1) Evacuate the refrigerant system to the lowest degree of vacuum possible (about 28 in Hg.). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed with this procedure. (2) Prepare a .284 Kg. (10 oz.) refrigerant charge to be injected into the system. (3) Connect and dispense .284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system. (4) Proceed to step two of Low Refrigerant Level Leak Test. LOW REFRIGERANT LEVEL LEAK TEST (1) Determine if there is any (R-134a) refrigerant in the system. Use the scan tool (DRB) under the menu Systems SensorsA/C Pressure test or pressure
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REMOVAL AND INSTALLATION (Continued)
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INSTALLATION For installation, reverse the above procedures. Make sure the TOP lettering is on the top of the resistor. The coils on the Resistor Block should not be contacting one another. Before installation, gently separate the coils (with fingers only) if one coil is contacting another.
INSTALLATION (1) Transfer mounting spacer/bushings onto the new compressor. (2) Lift compressor into place and start compressor mounting bolts. Do not tighten bolts at this time. The compressor may have to be moved slightly to align the flex drive bolts. (3) Align compressor clutch with flex drive. Then start both flex drive bolts. Tighten the bolts after both flex drive bolts have been installed. (4) Tighten compressor mounting bolts. (5) Lower vehicle and install refrigerant lines. Always replace O-rings and gaskets. (6) Evacuate refrigerant system. Charge system with the correct amount of R-134a refrigerant. The refrigerant capacity is .91 kg. 7 gm. (32 oz. 2.0 oz.).
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REMOVAL AND INSTALLATION (Continued)
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CONDENSER ASSEMBLY
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor.
INSTALLATION
NOTE: Inspect Cooling Module for presence of seals. Verify seals are available for re-installation. (1) Before installation, replace all O-rings and gaskets, coat all sealing surfaces with approved wax-free refrigerant oil. Then reverse the above procedures. (2) Evacuate and charge system.
DISCHARGE LINE
REMOVAL (1) Recover A/C system refrigerant. (2) Remove discharge line mounting nut at compressor (Fig. 10). (3) Remove discharge line at the top fitting on the condenser (Fig. 23). INSTALLATION (1) For installation, reverse the above procedures. Replace all O-rings. (2) Evacuate and recharge A/C system. (3) Perform the HVAC Control Calibration Diagnostic and Cooldown test.
REMOVAL (1) Recover A/C system refrigerant. (2) Remove liquid line at filter-drier (Fig. 21). (3) Remove (2) nuts attaching filter-drier to radiator module. (4) Remove upper radiator crossmember. (5) Tilt radiator rearward. (6) Remove upper discharge line at condenser (Fig. 10). (7) Through fascia, remove lower liquid line from filter-drier. (8) Remove (2) lower condenser mounting bolts. (9) Remove (2) upper mounting bolts. (10) Remove condenser from vehicle (Fig. 22).
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EVAPORATOR PROBE
REMOVAL (1) Remove the glove box. Refer to Group 8E, Instrument Panel and Systems. (2) Disconnect the evaporator probe connector (Fig. 24).
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REMOVAL AND INSTALLATION (Continued)
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EXPANSION VALVE
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION.
REMOVAL (1) Disconnect the battery negative cable. (2) Recover A/C system refrigerant. (3) Remove the accessory drive belt. (4) Remove upper generator bracket. (5) Disconnect generator field wire connector. (6) Push generator forward. (7) Remove ground wire at dash panel. (8) Remove the nut retaining the refrigerant line sealing plate to the expansion valve (Fig. 27). (9) Remove the stud from the expansion valve (Fig. 28). (10) Carefully pull the refrigerant line sealing plate assembly from expansion valve towards the front of the vehicle. Use care not to scratch the expansion valve sealing surfaces with pilot tubes. (11) Cover the openings to prevent contamination. (12) Remove two screws securing the expansion valve to the evaporator sealing plate (Fig. 28). (13) Carefully remove expansion valve (Fig. 29). (14) Remove the old O-rings.
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FILTER-DRIER ASSEMBLY
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. (1) Recover A/C system refrigerant. (2) Remove liquid line at filter-drier (Fig. 21). (3) Remove the (2) bolts holding filter-drier bracket to radiator fan module bracket. (4) Remove the lower liquid line at condenser. (5) Remove the upper radiator crossmember. (6) Pull up on radiator and slide filter-drier from the mounting location.
INSTALLATION (1) Before installation, replace both refrigerant line O-rings. Then reverse the above procedures. (2) Evacuate and recharge system.
INSTALLATION (1) For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing inlets (2) Evacuate and recharge the A/C system. (3) Perform HVAC control Calibration Diagnostic and Cooldown test.
HEATER CORE
REMOVAL (1) Drain coolant system. (2) Remove left side lower column cover. (3) Remove steering column assembly. Refer to Group 19, Steering for service procedure. (4) Remove ABS module, bracket and wiring (Fig. 31). (5) Remove I/P to body harness interconnect and bracket (Fig. 32). (6) Remove lower silencer boot at base of steering shaft (Fig. 33) (7) Pinch off heater lines under the hood.
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REMOVAL AND INSTALLATION (Continued)
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HEATER HOSES
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation. (1) Drain engine cooling system. Refer to Group 7, Engine Cooling. (2) Loosen clamps at each end of heater hose to be removed (Fig. 38) and (Fig. 39).
LIQUID LINE
REMOVAL (1) Disconnect the battery negative cable. (2) Recover A/C system refrigerant. (3) Remove ground wire at dash panel. (4) Remove the nut retaining the refrigerant line sealing plate to the expansion valve (Fig. 27). (5) Remove the stud from the expansion valve (Fig. 28). (6) Remove liquid line from expansion valve. (7) Cover the openings to prevent contamination. (8) Disconnect wire connector at pressure transducer. (9) Remove liquid line mounting clip at right strut tower. (10) Using access slot between radiator crossmember and grille, loosen liquid line mounting plate at filter-drier. Remove liquid line from filter-drier. (11) Remove the old O-rings. INSTALLATION For installation, reverse the above procedures. Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque. Install new O-rings. Install two-piece line in place of original part. Assemble line halves after it is installed on vehicle. Evacuate and recharge A/C system.
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REMOVAL AND INSTALLATION (Continued)
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SUCTION LINE
REMOVAL (1) Disconnect the battery negative cable. (2) Recover A/C system refrigerant. (3) Remove ground wire at dash panel. (4) Remove the nut retaining the refrigerant line sealing plate to the expansion valve (Fig. 27). (5) Remove the stud from the expansion valve (Fig. 28). (6) Remove suction line from expansion valve.
INSTALLATION (1) For installation, reverse the above procedures. (2) Perform the HVAC control Calibration Diagnostic and Cooldown test.
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INSTALLATION (1) For installation, reverse the above procedures. (2) Perform the HVAC control Calibration Diagnostic and Cooldown test.
DISASSEMBLYEVAPORATOR HOUSING (1) Place HVAC unit assembly on workbench. (2) Remove distribution housing mounting screws (Fig. 46).
INSTALLATION For installation, reverse the above procedures. Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque. Install new O-rings. Install two-piece line in place of original part. Assemble line halves after it is installed on vehicle. Evacuate and recharge A/C system.
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DISASSEMBLY AND ASSEMBLY (Continued)
(4) Remove blower motor wiring grommet and feed wiring through blower housing (Fig. 48).
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(6) Remove recirculation door cover (Fig. 51). (7) Remove Recirc. door (Fig. 52).
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Fig. 54 Evaporator
ASSEMBLYEVAPORATOR HOUSING (1) For reassembly of the evaporator housing, reverse the above procedures. (2) Perform the HVAC control Calibration Diagnostic and Cooldown test. DISASSEMBLYDISTRIBUTION HOUSING (1) Place distribution housing on workbench (Fig. 55).
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DISASSEMBLY AND ASSEMBLY (Continued)
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DISASSEMBLY AND ASSEMBLY (Continued)
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DISASSEMBLY AND ASSEMBLY (Continued)
(4) Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master spline on PANEL door. Position actuator gear within cam wheel track. (5) Install DEFROST door actuator gear to housing. Match master spline of DEFROST door actuator
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to master spline on DEFROST door. Position actuator gear within cam wheel track. (6) Reinstall housing in vehicle. (7) Perform the HVAC control Calibration Diagnostic and Cooldown test.
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ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . 1
ON-BOARD DIAGNOSTICS
INDEX
page GENERAL INFORMATION SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . 1 DESCRIPTION AND OPERATION CIRCUIT ACTUATION TEST MODE . . . . . . . . . . . 3 COMPONENT MONITORS . . . . . . . . . . . . . . . . . 10 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . 3 HIGH AND LOW LIMITS . . . . . . . . . . . . . . . . . . . 11 page LOAD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 MALFUNCTION INDICATOR LAMP (MIL) . . . . . . . 1 MONITORED SYSTEMS . . . . . . . . . . . . . . . . . . . . 8 NON-MONITORED CIRCUITS . . . . . . . . . . . . . . . 11 STATE DISPLAY TEST MODE . . . . . . . . . . . . . . . 2 TRIP DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . 10
output circuit shorts to ground when engine operates above 2400 RPM (resulting in 0 volt input to the PCM). Because the condition happens at an engine speed above the maximum threshold (2000 rpm), the PCM will not store a DTC. There are several operating conditions for which the PCM monitors and sets DTCs. Refer to Monitored Systems, Components, and Non-Monitored Circuits in this section. NOTE: Various diagnostic procedures may actually cause a diagnostic monitor to set a DTC. For instance, pulling a spark plug wire to perform a spark test may set the misfire code. When a repair is completed and verified, use the DRB scan tool to erase all DTCs and extinguish the MIL. Technicians can display stored DTCs by using the DRB scan tool. Refer to Diagnostic Trouble Codes in this section. For DTC information, refer to charts in this section.
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DESCRIPTION AND OPERATION (Continued)
Adaptive Fuel Factor Barometric Pressure Engine Speed Module Spark Advance Speed Control Target Intake Air Temp Degrees Intake Air Temp Volts Charging System Goal Theft Alarm Status Map Sensor Voltage Vehicle Speed Throttle Opening (percentage) TPS Calculated Cam Timing Position Target Idle Time From Start To Run Run Time At Stall Injector Pulse-width Upstream O2S Volts Downstream O2S Volts Closed Loop Timer Short Term Adaptive Current Adaptive Cell Adaptive Memory Cell 0 Adaptive Memory Cell 1 Adaptive Memory Cell 2 Adaptive Memory Cell 3 Adaptive Memory Cell 4 Adaptive Memory Cell 5 Adaptive Memory Cell 6 Adaptive Memory Cell 7 Adaptive Memory Cell 8 Adaptive Memory Cell 9 Adaptive Memory Cell 10 Adaptive Memory Cell 11 Adaptive Memory Cell 12 Adaptive Memory Cell 13 Adaptive Memory Cell 14 Adaptive Memory Cell 15 Purge Free Idle Cell Purge Free Cell 2 (corresponds to memory cell 2) Purge Free Cell 3 (corresponds to memory cell 5) Target IAC Steps Retard Cylinder (1) Retard Cylinder (2) Retard Cylinder (3) Retard Cylinder (4) Retard Cylinder (5) Retard Cylinder (6)
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BULB CHECK Each time the ignition key is turned to the ON position, the malfunction indicator (check engine) lamp on the instrument panel should illuminate for approximately 2 seconds then go out. This is done for a bulb check. OBTAINING DTCS USING DRB SCAN TOOL (1) Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column. (2) Turn the ignition switch on and access the Read Fault screen. (3) Record all the DTCs and freeze frame information shown on the DRB scan tool. (4) To erase DTCs, use the Erase Trouble Code data screen on the DRB scan tool. Do not erase any DTCs until problems have been investigated and repairs have been performed.
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HEX CODE 01 02 05
DRB SCAN TOOL DISPLAY No Cam Signal at PCM Internal Controller Failure Charging System Voltage Too Low
DESCRIPTION OF DIAGNOSTIC TROUBLE CODE No camshaft signal detected during engine cranking. PCM Internal fault condition detected. Battery voltage sense input below target charging during engine operation. Also, no significant change detected in battery voltage during active test of generator output circuit. Battery voltage sense input above target charging voltage during engine operation. An open or shorted condition detected in the auto shutdown relay circuit. An open or shorted condition detected in the generator field control circuit. An open or shorted condition detected in the torque converter part throttle unlock solenoid control circuit (3 speed auto RH trans. only). An open or shorted condition detected in the low speed radiator fan relay control circuit. An open or shorted condition detected in the Speed Control vacuum or vent solenoid circuits. An open or shorted condition detected in the A/C clutch relay circuit. An open or shorted condition detected in the EGR transducer solenoid circuit. An open or shorted condition detected in the duty cycle purge solenoid circuit. Injector #3 output driver does not respond properly to the control signal. Injector #2 output driver does not respond properly to the control signal. Injector #1 output driver does not respond properly to the control signal. A shorted or open condition detected in one or more of the idle air control motor circuits. Throttle position sensor input below the minimum acceptable voltage Throttle position sensor input above the maximum acceptable voltage. Engine coolant temperature sensor input below minimum acceptable voltage. Engine coolant temperature sensor input above maximum acceptable voltage.
06 0A* 0B 0C P0743
Charging System Voltage Too High Auto Shutdown Relay Control Circuit Generator Field Not Switching Properly Torque Converter Clutch Soleniod/ Trans Relay Circuits Rad Fan Control Relay Circuit Speed Control Solenoid Circuits A/C Clutch Relay Circuit P0403 P0443 P0203 P0202 P0201 P0505 P0122 P0123 P0117 P0118 EGR Solenoid Circuit EVAP Purge Solenoid Circuit Injector #3 Control Circuit Injector #2 Control Circuit Injector #1 Control Circuit Idle Air Control Motor Circuits Throttle Position Sensor Voltage Low Throttle Position Sensor Voltage High ECT Sensor Voltage Too Low ECT Sensor Voltage Too High
0E 0F* 10* 11 12 13 14 15 19 1A 1B 1E 1F
P1491
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DESCRIPTION AND OPERATION (Continued)
HEX CODE 20 21* 23 24 25 27 P0500 P0107 P0108 P1297 GENERIC SCAN TOOL CODE P0134 DRB SCAN TOOL DISPLAY Right Rear (or just) Upstream O2S Stays at Center Engine Is Cold Too Long No Vehicle Speed Sensor Signal MAP Sensor Voltage Too Low MAP Sensor Voltage Too High No Change in MAP From Start to Run No Crank Reference Signal at PCM P0353 P0352 P0351 Ignition Coil #3 Primary Circuit Ignition Coil #2 Primary Circuit Ignition Coil #1 Primary Circuit No ASD Relay Output Voltage at PCM P0401 P1697 P1698 P0112 P0113 P0106 P0204 P0132 P0600 P0205 P0206 EGR System Failure PCM Failure SRI Miles Not Stored PCM Failure EEPROM Write Denied Intake Air Temp Sensor Voltage Low Intake Air Temp Sensor Voltage High Barometric Pressure Out Of Range Injector #4 Control Circuit Right Rear (or just) Upstream O2S Shorted to Voltage PCM Failure SPI Communications Injector #5 Control Circuit Injector #6 Control Circuit
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DESCRIPTION OF DIAGNOSTIC TROUBLE CODE Neither rich or lean condition detected from the oxygen sensor. Engine did not reach operating temperature within acceptable limits. No vehicle speed sensor signal detected during road load conditions. MAP sensor input below minimum acceptable voltage. MAP sensor input above maximum acceptable voltage. No difference recognized between the engine MAP reading and the barometric (atmospheric) pressure reading from start-up. No crank reference signal detected during engine cranking. Peak primary circuit current not achieved with maximum dwell time. Peak primary circuit current not achieved with maximum dwell time. Peak primary circuit current not achieved with maximum dwell time. An Open condition Detected In The ASD Relay Output Circuit. Required change in air/fuel ratio not detected during diagnostic test. Unsuccessful attempt to update EMR mileage in the PCM EEPROM. Unsuccessful attempt to write to an EEPROM location by the PCM. Intake air temperature sensor input below the maximum acceptable voltage. Intake air temperature sensor input above the minimum acceptable voltage. MAP sensor has a baro reading below an acceptable value. Injector #4 output driver does not respond properly to the control signal. Oxygen sensor input voltage maintained above the normal operating range. PCM Internal fault condition detected. Injector #5 output driver does not respond properly to the control signal. Injector #6 output driver does not respond properly to the control signal.
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DESCRIPTION AND OPERATION (Continued)
HEX CODE 92 94* GENERIC SCAN TOOL CODE P1496 P0740 DRB SCAN TOOL DISPLAY 5 Volt Supply Output Too Low Torq Conv Clu, No RPM Drop At Lockup Fuel Level Sending Unit Volts Too Low Fuel Level Sending Unit Volts Too High Fuel Level Unit No Change Over Miles P0703 P1493 P1492 P0131 P0137 P1391 P0442 P0455 P0305 P0306 P1495 P1494 P1398 P1486 P1290 P0133 Brake Switch Stuck Pressed or Released Ambient/Batt Temp Sen VoltsToo Low Ambient/Batt Temp Sensor VoltsToo High Right Rear (or just) Upstream O2S Shorted to Ground Right Rear (or just) Downstream O2S Shorted to Ground Intermittent Loss of CMP or CKP Evap Leak Monitor Small Leak Detected Evap Leak Monitor Large Leak Detected Cylinder #5 Mis-fire Cylinder #6 Mis-fire Leak Detect ion Pump Solenoid Circuit Leak Detect Pump Sw or Mechanical Fault Mis-fire Adaptive Numerator at Limit Evap Leak Monitor Pinched Hose Found CNG System Pressure Too High Cat Mon Slow O2 Upstream
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DESCRIPTION OF DIAGNOSTIC TROUBLE CODE 5 volt output from regulator does not meet minimum requirement. Relationship between engine speed and vehicle speed indicates no torque converter clutch engagement (auto. trans. only). Open circuit between PCM and fuel gauge sending unit. Circuit shorted to voltage between PCM and fuel gauge sending unit. No movement of fuel level sender detected. No release of brake switch seen after too many accelerations. Battery temperature sensor input voltage below an acceptable range. Battery temperature sensor input voltage above an acceptable range. O2 sensor voltage too low, tested after cold start. O2 sensor voltage too low, tested after cold start. Intermittent loss of either camshaft or crankshaft position sensor A small leak has been detected by the leak detection monitor. The leak detection monitor is unable to pressurize Evap system, indicating a large leak. Misfire detected in cylinder #5. Misfire detected in cylinder #6. Leak detection pump solenoid circuit fault (open or short). Leak detection pump switch does not respond to input. CKP sensor target windows have too much variation Plug or pinch detected between purge solenoid and fuel tank. Compressed natural gas pressure sensor reading above acceptable voltage. Oxygen sensor response slower than minimum required switching frequency during catalyst monitor.
* Check Engine Lamp (MIL) will not illuminate if this Diagnostic Trouble Code was recorded.
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MONITORED SYSTEMS
There are new electronic circuit monitors that check fuel, emission, engine and ignition performance. These monitors use information from various sensor circuits to indicate the overall operation of the fuel, engine, ignition and emission systems and thus the emissions performance of the vehicle. The fuel, engine, ignition and emission systems monitors do not indicate a specific component problem. They do indicate that there is an implied problem within one of the systems and that a specific problem must be diagnosed. If any of these monitors detect a problem affecting vehicle emissions, the Malfunction Indicator (Check Engine) Lamp will be illuminated. These monitors generate Diagnostic Trouble Codes that can be displayed with the check engine lamp or a scan tool. The following is a list of the system monitors: EGR Monitor Misfire Monitor Fuel System Monitor Oxygen Sensor Monitor Oxygen Sensor Heater Monitor Catalyst Monitor Evaporative System Leak Detection Monitor Following is a description of each system monitor, and its DTC. Refer to the appropriate Powertrain Diagnostics Procedures manual for diagnostic procedures.
Response rate is the time required for the sensor to switch from lean to rich once it is exposed to a richer than optimum A/F mixture or vice versa. As the sensor starts malfunctioning, it could take longer to detect the changes in the oxygen content of the exhaust gas. The output voltage of the O2S ranges from 0 to 1 volt. A good sensor can easily generate any output voltage in this range as it is exposed to different concentrations of oxygen. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the threshold value.
HEX 66, and 7AOXYGEN SENSOR (O2S) MONITOR Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperature 300 to 350C (572 to 662F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. This maintains a 14.7 to 1 air fuel (A/F) ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrous oxide (NOx) from the exhaust. The O2S is also the main sensing element for the EGR, Catalyst and Fuel Monitors. The O2S may fail in any or all of the following manners: Slow response rate Reduced output voltage Dynamic shift Shorted or open circuits
HEX 67, 69, 7C, and 7DOXYGEN SENSOR HEATER MONITOR If there is an oxygen sensor (O2S) DTC as well as a O2S heater DTC, the O2S fault MUST be repaired first. After the O2S fault is repaired, verify that the heater circuit is operating correctly. Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperature 300 to 350C (572 to 662F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. This maintains a 14.7 to 1 Air Fuel (A/F) ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxide (NOx) from the exhaust. The voltage readings taken from the O2S are very temperature sensitive. The readings are not accurate below 300C. Heating of the O2S is done to allow the engine controller to shift to closed loop control as soon as possible. The heating element used to heat the O2S must be tested to ensure that it is heating the sensor properly. The O2S circuit is monitored for a drop in voltage. The sensor output is used to test the heater by isolating the effect of the heater element on the O2S output voltage from the other effects. HEX 2EEGR MONITOR The Powertrain Control Module (PCM) performs an on-board diagnostic check of the EGR system. The EGR system consists of two main components: a vacuum solenoid and a vacuum operated valve with a back pressure transducer. The EGR monitor is used to test whether the EGR system is operating within specifications. The diagnostic check activates only during selected engine/driving conditions. When the
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DESCRIPTION AND OPERATION (Continued)
conditions are met, the EGR is turned off (solenoid energized) and the O2S compensation control is monitored. Turning off the EGR shifts the air fuel (A/F) ratio in the lean direction. The O2S data should indicate an increase in the O2 concentration in the combustion chamber when the exhaust gases are no longer recirculated. While this test does not directly measure the operation of the EGR system, it can be inferred from the shift in the O2S data whether the EGR system is operating correctly. Because the O2S is being used, the O2S test must pass its test before the EGR test.
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HEX 6A,6B, 6C, 6D, 6E, AE, and AFMISFIRE MONITOR Excessive engine misfire results in increased catalyst temperature and causes an increase in HC emissions. Severe misfires could cause catalyst damage. To prevent catalytic convertor damage, the PCM monitors engine misfire. The Powertrain Control Module (PCM) monitors for misfire during most engine operating conditions (positive torque) by looking at changes in the crankshaft speed. If a misfire occurs the speed of the crankshaft will vary more than normal. HEX 76, 77, 78, and 79FUEL SYSTEM MONITOR To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide. The catalyst works best when the air fuel (A/F) ratio is at or near the optimum of 14.7 to 1. The PCM is programmed to maintain the optimum air/fuel ratio of 14.7 to 1. This is done by making short term corrections in the fuel injector pulse width based on the O2S output. The programmed memory acts as a self calibration tool that the engine controller uses to compensate for variations in engine specifications, sensor tolerances and engine fatigue over the life span of the engine. By monitoring the actual air-fuel ratio with the O2S (short term) and multiplying that with the program long-term (adaptive) memory and comparing that to the limit, it can be determined whether it will pass an emissions test. If a malfunction occurs such that the PCM cannot maintain the optimum A/F ratio, then the MIL will be illuminated. HEX 70, and B4CATALYST MONITOR To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide.
Normal vehicle miles or engine misfire can cause a catalyst to decay. A meltdown of the ceramic core can cause a reduction of the exhaust passage. This can increase vehicle emissions and deteriorate engine performance, driveability and fuel economy. The catalyst monitor uses dual oxygen sensors (O2Ss) to monitor the efficiency of the converter. The dual O2Ss strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter. The PCM calculates the A/F mixture from the output of the O2S. A low voltage indicates high oxygen content (lean mixture). A high voltage indicates a low content of oxygen (rich mixture). When the upstream O2S detects a lean condition, there is an abundance of oxygen in the exhaust gas. A functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstraem O2S will indicate limited activity in this condition. As the converter loses the ability to store oxygen, the condition can be detected from the behavior of the downstream O2S. When the efficiency drops, no chemical reaction takes place. This means the concentration of oxygen will be the same downstream as upstream. The output voltage of the downstream O2S copies the voltage of the upstream sensor. The only difference is a time lag (seen by the PCM) between the switching of the O2Ss. To monitor the system, the number of lean-to-rich switches of upstream and downstream O2Ss is counted. The ratio of downstream switches to upstream switches is used to determine whether the catalyst is operating properly. An effective catalyst will have fewer downstream switches than it has upstream switches i.e., a ratio closer to zero. For a totally ineffective catalyst, this ratio will be one-toone, indicating that no oxidation occurs in the device. The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over the legal limit, the MIL (check engine lamp) will be illuminated.
HEX A0, A1, B7, and B8LEAK DETECTION PUMP MONITOR The leak detection assembly incorporates two primary functions: it must detect a leak in the evaporative system and seal the evaporative system so the leak detection test can be run.
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TRIP DEFINITION
A Trip means vehicle operation (following an engine-off period) of duration and driving mode such that all components and systems are monitored at least once by the diagnostic system. The monitors must successfully pass before the PCM can verify that a previously malfunctioning component is meeting the normal operating conditions of that component. For misfire or fuel system malfunction, the MIL may be extinguished if the fault does not recur when monitored during three subsequent sequential driving cycles in which conditions are similar to those under which the malfunction was first determined. Anytime the MIL is illuminated, a DTC is stored. The DTC can self erase only when the MIL has been extinguished. Once the MIL is extinguished, the PCM must pass the diagnostic test for the most recent DTC for 40 warm-up cycles (80 warm-up cycles for the Fuel System Monitor and the Misfire Monitor). A warm-up cycle can best be described by the following: The engine must be running A rise of 40F in engine temperature must occur from the time when the engine was started Engine coolant temperature must reach at least 160F A driving cycle that consists of engine start up and engine shut off. Once the above conditions occur, the PCM is considered to have passed a warm-up cycle. Due to the conditions required to extinguish the MIL and erase the DTC, it is most important that after a repair has been made, all DTCs be erased and the repair verified.
COMPONENT MONITORS
There are several components that will affect vehicle emissions if they malfunction. If one of these components malfunctions the Malfunction Indicator Lamp (Check Engine) will illuminate. Some of the component monitors are checking for proper operation of the part. Electrically operated
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components now have input (rationality) and output (functionality) checks. Previously, a component like the Throttle Position sensor (TPS) was checked by the PCM for an open or shorted circuit. If one of these conditions occurred, a DTC was set. Now there is a check to ensure that the component is working. This is done by watching for a TPS indication of a greater or lesser throttle opening than MAP and engine rpm indicate. In the case of the TPS, if engine vacuum is high and engine rpm is 1600 or greater and the TPS indicates a large throttle opening, a DTC will be set. The same applies to low vacuum and 1600 rpm. Any component that has an associated limp in will set a fault after 1 trip with the malfunction present. Refer to the Diagnostic Trouble Codes Description Charts in this section and the appropriate Powertrain Diagnostic Procedure Manual for diagnostic procedures.
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EXHAUST SYSTEM The PCM cannot detect a plugged, restricted or leaking exhaust system. It may set a EGR or Fuel system fault or O2S. FUEL INJECTOR MECHANICAL MALFUNCTIONS The PCM cannot determine if a fuel injector is clogged, the needle is sticking or if the wrong injector is installed. However, these could result in a rich or lean condition causing the PCM to store a diagnostic trouble code for either misfire, an oxygen sensor, or the fuel system. EXCESSIVE OIL CONSUMPTION Although the PCM monitors engine exhaust oxygen content when the system is in closed loop, it cannot determine excessive oil consumption. THROTTLE BODY AIR FLOW The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. VACUUM ASSIST The PCM cannot detect leaks or restrictions in the vacuum circuits of vacuum assisted engine control system devices. However, these could cause the PCM to store a MAP sensor diagnostic trouble code and cause a high idle condition. PCM SYSTEM GROUND The PCM cannot determine a poor system ground. However, one or more diagnostic trouble codes may be generated as a result of this condition. The module should be mounted to the body at all times, also during diagnostic. PCM CONNECTOR ENGAGEMENT The PCM may not be able to determine spread or damaged connector pins. However, it might store diagnostic trouble codes as a result of spread connector pins.
NON-MONITORED CIRCUITS
The PCM does not monitor all circuits, systems and conditions that could have malfunctions causing driveability problems. However, problems with these systems may cause the PCM to store diagnostic trouble codes for other systems or components. For example, a fuel pressure problem will not register a fault directly, but could cause a rich/lean condition or misfire. This could cause the PCM to store an oxygen sensor or misfire diagnostic trouble code. The major non-monitored circuits are listed below along with examples of failures modes that do not directly cause the PCM to set a DTC, but for a system that is monitored.
FUEL PRESSURE The fuel pressure regulator controls fuel system pressure. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply or return line. However, these could result in a rich or lean condition causing the PCM to store an oxygen sensor or fuel system diagnostic trouble code. SECONDARY IGNITION CIRCUIT The PCM cannot detect an inoperative ignition coil, fouled or worn spark plugs, ignition cross firing, or open spark plug cables. CYLINDER COMPRESSION The PCM cannot detect uneven, low, or high engine cylinder compression.
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LOAD VALUE
ENGINE 2.4 Auto. Trans. 3.0L 3.3L 3.8L IDLE/NEUTRAL 4.4% of Maximun Load 4.2% of Maximun Load 5% of Maximun Load 4.7% of Maximun Load 2500 RPM/NEUTRAL 11.7% of Maximun Load 11.5% of Maximun Load 13.4% of Maximun Load 13.3% of Maximun Load
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16 13 13 14
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ROLLOVER VALVE
All vehicles have a rollover valve. The valve also prevents fuel flow through the fuel tank vent valve hoses should the vehicle rollover. All vehicles pass a 360 rollover. The charcoal filled evaporative canister stores the vapors. The rollover valve is not a serviceable item.
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(2) Push locking tab on connector to unlock (Fig. 12).
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(3) Push down on connector latch and pull connector from pump. (4) Remove hoses. (5) Remove bolts holding LDP and bracket to cradle. (6) Remove bracket from LDP.
INSTALLATION (1) Install LDP to bracket. (2) Install LDP and bracket to cradle. Torque bolts to 9.5-14 Nm (85-125 in. lbs.). Before installing hoses to LDP, make sure they are not cracked or split. If a hose leaks, it will cause the Check Engine Lamp to illuminate. (3) Install hoses to LDP. (4) Plug electrical connector into LDP. (5) Push connector locking tab into place. (6) Using DRB scan tool, verify proper operation of LDP.
ROLLOVER VALVES
All vehicles have 2 rollover valves on top of the fuel tank. The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover. The rollover valves on the fuel tank are not serviceable.
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22 22 21 22
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(7) If the engine speed did not change, the EGR valve may be defective, or EGR tube may be plugged with carbon, or the passages in the intake and exhaust manifolds may be plugged with carbon. (a) Remove EGR valve from engine. Refer to EGR Valve Removal in this group. (b) Apply vacuum to the vacuum motor fitting and observe the stem on the EGR valve. If the stem is moving, it can be assumed that the EGR valve is functioning correctly. The problem is in either a plugged EGR tube or plugged passages at the intake or exhaust manifolds, refer to step (c). If the stem will not move, replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one unit. Refer to EGR Valve Removal/Installation in this group. (c) Remove the EGR tube between the intake and exhaust manifolds. Check and clean the EGR tube and its related openings on the manifolds. Refer to EGR Tube in this group for procedures. (8) Do not attempt to clean the EGR valve. If the valve shows evidence of heavy carbon build-up near the base, replace it.
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DIAGNOSIS AND TESTING (Continued)
ulated shop air to the metal back- pressure fitting on the EGR valve. (6) By hand, open the throttle to the wide open position. Air SHOULD NOT BE HEARD emitting from the intake manifold while applying air pressure at the back-pressure fitting. (7) If air CAN BE HEARD emitting from the intake manifold, the poppet valve (Fig. 4) is leaking at the bottom of the EGR valve. Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one assembly. Refer to EGR Valve Removal/Installation in this group. Do not attempt clean the old EGR valve.
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(11) Reconnect the rubber hose to the vacuum inlet fitting (Fig. 4) on the EGR valve. (12) Disconnect the rubber hose at the vacuum outlet fitting (Fig. 4) on the EGR valve. (13) Connect a vacuum gauge to this fitting. (14) Disconnect the electrical connector (Fig. 4) at the valve control. This will simulate an open circuit (no ground from the PCM) at the valve. (15) Start the engine and bring to operating temperature. (16) Hold the engine speed to approximately 2000 rpm while checking for engine vacuum (full-manifold) at this fitting. To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present at valve. It must be high enough to hold the bleed valve in the transducer portion of the valve closed. Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the vacuum gauge. Heavy gloves should be worn. Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. (17) As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum outlet fitting. Without back-pressure, and engine at approximately 2000 rpm, the gauge reading will be low. This low reading is normal. At idle speed, the gauge reading will be erratic. This is also normal. (18) If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the valve. Note: The EGR valve, valve control and attaching hoses are serviced as one assembly. Refer to EGR Valve Removal/Installation in this group.
REMOVAL (1) Disconnect the electric and vacuum connectors from the electric EGR transducer (Fig. 6). (2) Remove EGR valve mounting bolts. (3) Clean all gasket surfaces and discard old gaskets. Check for any signs of leakage or cracked surfaces. Repair or replace as necessary. INSTALLATION (1) Install EGR valve and new gasket on intake manifold. Tighten mounting bolts to 22 Nm (200 in. lbs.) torque. (2) Connect the electrical and vacuum connectors to the electric EGR transducer.
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REMOVAL (1) Disconnect vacuum tube from electric EGR transducer. Inspect vacuum tube for damage (Fig. 7). (2) Remove electrical connector from solenoid. (3) Remove EGR valve bolts from intake manifold. (4) Open EGR transducer clip and remove electric EGR transducer. (5) Remove EGR valve from intake manifold. (6) Clean gasket surface and discard old gasket. Check for any signs of leakage or cracked surfaces. Repair or replace as necessary. INSTALLATION (1) Assemble EGR valve with new gasket onto the intake manifold. (2) Install mounting bolts. Tighten bolts to 22 Nm (200 in. lbs.) torque. (3) Install electric EGR transducer in clip with orientation tab in slot and snap closed. (4) Reconnect vacuum hose and electrical connector to electrical EGR transducer.
INSTALLATION (1) Loosely install the EGR tube on the intake and exhaust manifolds with new gaskets. (2) Tighten EGR tube flange bolts at the intake manifold to 22 Nm (200 in. lbs.) torque. (3) Tighten EGR tube to exhaust manifold nuts to 22 Nm (200 in. lbs.) torque.
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EMISSION CONTROL SYSTEM 2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 9 EXHAUST EMISSION CONTROLS 2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . 5
MONITORED CIRCUITS The PCM can detect certain problems in the electrical system. Open or Shorted Circuit The PCM can determine if sensor output (which is the input to PCM) is within proper range. It also determines if the circuit is open or shorted. Output Device Current Flow The PCM senses whether the output devices are electrically connected. If there is a problem with the circuit, the PCM senses whether the circuit is open, shorted to ground (), or shorted to (+) voltage. NONMONITORED CIRCUITS The PCM does not monitor the following circuits, systems or conditions that could have malfunctions that result in driveability problems. A DTC will not be displayed for these conditions. Fuel Pressure: Fuel pressure is controlled by the fuel injection pump. The PCM cannot detect problems in this component. Cylinder Compression: The PCM cannot detect uneven, low, or high engine cylinder compression. Exhaust System: The PCM cannot detect a plugged, restricted or leaking exhaust system. Fuel Injector Malfunctions: The PCM cannot determine if the fuel injector is clogged, or the wrong injector is installed. The fuel injectors on the diesel engine are not controlled by the PCM, although a
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ACCESSING DIAGNOSTIC TROUBLE CODES A stored DTC can be displayed through the use of the DRB III scan tool. The DRB III connects to the data link connector. The data link connector is located under the instrument panel near bottom of the steering column (Fig. 1).
HIGH AND LOW LIMITS The PCM compares input signal voltages from each input device. It will establish high and low limits that are programmed into it for that device. If the input voltage is not within specifications and other DTC criteria are met, a DTC will be stored in memory. Other DTC criteria might include engine rpm limits or input voltages from other sensors or switches. The other inputs might have to be sensed by the PCM when it senses a high or low input voltage from the control system device in question.
Intake Air Temperature Sensor Signal High Intake Air Temperature Sensor Signal Low Immobilizer Signal Lost Invalid SKIM Message Temperature of Engine Coolant SRC High Exceeded Temperature of Engine Coolant SRC Low Exceeded Fuel Temperature Sensor SRC High Exceeded Fuel Temperature Sensor SRC Low Exceeded EGR Open Circuit EGR Short Circuit Vehicle Speed Sensor PEC Frequency Too High Vehicle Speed Sensor Signal SRC High Exceeded
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Generic Scan Tool Code P0725 DRB III Scan Tool Display
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Engine Speed Sensor Dynamic Plausibility Engine Speed Sensor Over Speed Recognition Engine Speed Sensor Static Plausibilty Atmospheric Pressure Sensor SRC High Exceeded Atmospheric Pressure Sensor SRC Low Exceeded Needle Movement Sensor SRC High Exceeded Needle Movement Sensor SRC Low Exceeded Fuel Fuel Fuel Fuel Quantity Actuator Quantity Actuator Quantity Actuator Quantity Actuator Neg. Gov. Deviation Cold Neg. Gov. Deviation Warm Pos. Gov. Deviation Cold Pos. Gov. Deviation Warm
P1225
Control Sleeve Sensor Signal High Exceeded Control Sleeve Sensor Start End Pos. Not Attained Control Sleeve Sensor Stop End Pos. Not Attained Timing Governing Negative Governor Deviation Timing Governing Positive Governor Deviation Accelerator Accelerator Accelerator Accelerator Pedal Pedal Pedal Pedal Sensor Sensor Sensor Sensor Signal Signal Signal Signal High Exceeded Low Exceeded PWG Plaus With Low Idle Switch PWG Plaus With Potentiometer
P1230 P1515
Battery Voltage SRC High Exceeded Terminal #15 Plausibility After Startup Regulator Lower Regulator Limit Regulator Upper Regulator Limit Microcontroller Gate-Array Monitoring Microcontroller Gate-Array Watchdog Microcontroller Prepare Fuel Quantity Stop Microcontroller Recovery Was Occurred Microcontrller Redundant Overrun Monitoring Timing Solenoid Valve Controller Open Circuit Timing Solenoid Valve Controller Short Circuit Glow Relay Controller Open Circuit Glow Relay Controller Short Circuit Diagnostic Lamp Open Circuit Diagnostic Lamp Short Circuit A/C Control Short Circuit A/C Control Open Circuit Redundant Emer. Stop Plausibility In After-Run Redundant Emer Stop Powerstage Defective Cruise Status Indicator Lamp Short Circuit EEPROM EEPROM EEPROM EEPROM Plausibility Plausibility Plausibility Plausibility Checksum Error for Adj. Checksum Error in CC212 Communication With EEPROM Func. Switch Wrong or Missing
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P1695
Brake Signal Plaus With Redundant Contact Clutch Signal Plausibilty Inductive Aux. Speed Sensor Dynamic Plausibilty Inductive Aux. Speed Sensor Overspeed Recognition Inductive Aux Speed Sensor Plausibilty Inductive Aux. Speed Sensor Static Plausibilty
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DIAGNOSIS AND TESTING (Continued)
(5) Slowly apply 10 inches of vacuum to the fitting on the EGR valve motor. Vacuum should hold steady at 10 inches. If not, replace the EGR valve. If vacuum holds steady at 10 inches, proceed to next step. (6) While applying vacuum, and with the engine running at idle speed, the idle speed should drop, a rough idle may occur, or the engine may even stall. This is indicating that exhaust gas is flowing through the EGR tube between the intake and exhaust manifolds. (7) If the engine speed did not change, the EGR valve may be defective, the EGR tube may be plugged with carbon, or the passages in the intake and exhaust manifolds may be plugged with carbon. (a) Remove EGR valve from engine. Refer to EGR Valve Removal in this group. (b) Apply vacuum to the vacuum motor fitting and observe the stem on the EGR valve. If the stem is moving, it can be assumed that the EGR valve is functioning correctly. The problem is in either a plugged EGR tube or plugged passages at the intake or exhaust manifolds. Refer to step (c). If the stem will not move, replace the EGR valve. (c) Remove the EGR tube between the intake and exhaust manifolds. Check and clean the EGR tube and its related openings on the manifolds. Refer to EGR Tube in this group for procedures. Do not attempt to clean the EGR valve. If the valve shows evidence of heavy carbon buildup near the base, replace it.
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(5) Remove the two EGR valve mounting bolts (Fig. 2) and remove EGR valve. (6) Discard both of the old EGR mounting gaskets.
INSTALLATION (1) Clean the intake manifold of any old gasket material. (2) Clean the end of EGR tube of any old gasket material. (3) Position the EGR valve and new gasket to the intake manifold. (4) Install two EGR valve mounting bolts. Do not tighten bolts at this time. (5) Position new gasket between EGR valve and EGR tube. (6) Install two EGR tube bolts. Tighten all four mounting bolts to 23 Nm (204 in. lbs.). (7) Tighten EGR tube fitting at exhaust manifold. (8) Connect vacuum line to EGR valve. (9) Install the rubber hose from turbocharger to metal tube.
EGR TUBE
The EGR tube connects the EGR valve to the rear of the exhaust manifold (Fig. 2).
REMOVAL (1) Remove rubber hose from turbocharger to metal tube. (2) Remove two EGR tube mounting bolts at EGR valve end of tube (Fig. 2). (3) Loosen fitting at exhaust manifold end of tube (Fig. 2). (4) Remove EGR tube and discard old gasket. (5) Clean gasket mating surfaces and EGR tube flange gasket surfaces. (6) Check for signs of leakage or cracked surfaces at both ends of tube, exhaust manifold and EGR valve. INSTALLATION (1) Install a new gasket to EGR valve end of EGR tube. (2) Position EGR tube to engine. (3) Loosely tighten fitting at exhaust manifold end of tube. (4) Install 2 mounting bolts at EGR valve end of tube. Tighten bolts to 23 Nm (204 in. lbs.) torque. (5) Tighten fitting at exhaust manifold end of tube. (6) Install hose from turbocharger to metal tube.
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REMOVAL The EGR valve attaches to the rear of the cylinder head (Fig. 2). EGR transducer is attached to the air inlet duct. (1) Remove EGR transducer from air inlet duct. (2) Disconnect vacuum supply tube from EGR transducer solenoid. (3) Disconnect electrical connector from solenoid. (4) Remove air inlet duct. (5) Remove EGR tube to EGR valve screws. (6) Remove EGR valve mounting screws. Remove EGR valve and transducer. (7) Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages.
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EGR TUBE
The EGR tube attaches to the intake manifold plenum below the throttle body and EGR valve.
TORQUE
Description Torque EGR valve to cyl. head . . . . . . . 22 Nm (200 in. lbs.) EGR tube to EGR valve . . . . . . . . . . . 11 (95 in. lbs.) EGR tube to intake manifold . . . 11 Nm (95 in. lbs.)
REMOVAL (1) Remove screws attaching EGR tube to intake manifold (Fig. 3). (2) Remove EGR tube to EGR valve screws.