Jeep Grand Cherokee WJ Service Workshop Manual

GROUP TAB LOCATOR
Introduction
0
Lubrication & Maintenance
2
Suspension
3
Driveline
5
Brakes
7
Cooling
8A
Audio
8B
Chime/Buzzer
8E
Electronic Control Modules
8F
Engine Systems
8G
Heated Systems
8H
Horn
8I
Ignition Control
8J
Instrument Cluster
8L
Lamps
8M
Message Systems
8N
Power Systems
8O
Restraints
8P
Speed Control
8Q
Vehicle Theft Security
8R
Wipers/Washers
8W
Wiring
9
Engine
11
Exhaust System
13
Frame & Bumpers
14
Fuel System
19
Steering
21
Transaxle
22
Tires/Wheels
23
Body
24
Heating & Air Conditioning
25
Emissions Control
Service Manual Comment Forms (Rear of Manual)
INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FASTENER IDENTIFICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FASTENER USAGE
DESCRIPTION - FASTENER USAGE . . . . . . . . . 4
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR . . . . 4
INTERNATIONAL SYMBOLS
DESCRIPTION - INTERNATIONAL SYMBOLS . . . 4
METRIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VEHICLE EMISSION CONTROL INFORMATION
(VECI)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BODY CODE PLATE
DESCRIPTION
A metal Body Code pl ate i s l ocated i n the engi ne
compartment and attached to the top of the ri ght
frame rai l . The i nformati on l i sted on the pl ate (Fi g.
1) i s used for manufacturi ng and servi ce purposes.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bol t strength grades range from grade 2
to grade 8. The hi gher the grade number, the greater
the bol t strength. I denti fi cati on i s determi ned by the
l i ne marks on the top of each bol t head. The actual
bol t strength grade corresponds to the number of l i ne
marks pl us 2. The most commonl y used metri c bol t
strength cl asses are 9.8 and 10.9. The metri c
strength cl ass i denti fi cati on number i s i mpri nted on
the head of the bol t. The hi gher the cl ass number,
the greater the bol t strength. Some metri c nuts are
i mpri nted wi th a si ngl e-di gi t strength cl ass on the
nut face. Refer to the Fastener I denti fi cati on and
Fastener Strength Charts (Fi g. 2) and (Fi g. 3).
Fig. 1 Body Code Plate
WJ INTRODUCTION 1
Fig. 2 FASTENER IDENTIFICATION
2 INTRODUCTION WJ
FASTENER IDENTIFICATION (Continued)
Fig. 3 FASTENER STRENGTH
WJ INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)
FASTENER USAGE
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque speci fi cati ons references i n
thi s Servi ce Manual are i denti fi ed i n metri c and SAE
format.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage al l fasteners (nuts, bol ts, etc.)
for reassembl y. I f the fastener i s not sal vageabl e, a
fastener of equi val ent speci fi cati on must be used.
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR
Most stri pped threaded hol es can be repai red usi ng
a Hel i coi l . Fol l ow the vehi cl e or Hel i coi l recommen-
dati ons for appl i cati on and repai r procedures.
DESCRIPTION - INTERNATIONAL SYMBOLS
The graphi c symbol s i l l ustrated i n the fol l owi ng
I nternati onal Control and Di spl ay Symbol s Chart are
used to i denti fy vari ous i nstrument control s. The
symbol s correspond to the control s and di spl ays that
are l ocated on the i nstrument panel .
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
4 INTRODUCTION WJ
METRIC SYSTEM
DESCRIPTION
The metri c system i s based on quanti ti es of one,
ten, one hundred, one thousand and one mi l l i on.
The fol l owi ng chart wi l l assi st i n converti ng metri c
uni ts to equi val ent Engl i sh and SAE uni ts, or vi se
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters
(Nm)
Nm x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters
(Nm)
Nm x 0.7376 = ft-lbs
Inches Hg (60F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr.
(Km/h)
Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metri c Conversi on Chart to convert
torque val ues l i sted i n metri c Newton- meters (Nm).
Al so, use the chart to convert between mi l l i meters
(mm) and i nches (i n.) (Fi g. 4).
WJ INTRODUCTION 5
Fig. 4 METRIC CONVERSION CHART
6 INTRODUCTION WJ
METRIC SYSTEM (Continued)
TORQUE REFERENCES
DESCRIPTION
I ndi vi dual Torque Charts appear wi thi n many or
the Groups. Refer to the Standard Torque Speci fi ca-
ti ons Chart for torque references not l i sted i n the
i ndi vi dual torque charts (Fi g. 5).
Fig. 5 TORQUE SPECIFICATIONS
WJ INTRODUCTION 7
VEHICLE EMISSION CONTROL
INFORMATION (VECI)
DESCRIPTION
Al l vehi cl es are equi pped wi th a combi ned vehi cl e
emi ssi on control i nformati on (VECI ) l abel (s). The
l abel i s l ocated i n the engi ne compartment on the
vehi cl e hood (Fi g. 6). Two l abel s are used for vehi cl es
bui l t for sal e i n the country of Canada.
The VECI l abel (s) contai n the fol l owi ng:
Engi ne fami l y and di spl acement
Evaporati ve fami l y
Emi ssi on control system schemati c
Certi fi cati on appl i cati on
Spark pl ug and gap
The l abel al so contai ns an engi ne vacuum sche-
mati c. There are uni que l abel s for vehi cl es bui l t for
sal e i n the state of Cal i forni a and the country of
Canada. Canadi an l abel s are wri tten i n both the
Engl i sh and French l anguages. These l abel s are per-
manentl y attached and cannot be removed wi thout
defaci ng i nformati on and destroyi ng l abel .
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
attached to the top l eft si de of the i nstrument panel .
The VI N contai ns 17 characters that provi de data
concerni ng the vehi cl e. Refer to the decodi ng chart to
determi ne the i denti fi cati on of a vehi cl e.
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line X = Grand Cherokee 4X2 (LHD)
W = Grand Cherokee 4X4 (LHD)
6 Series 3 = Sport
4 = Laredo
5 = Limited
6 = Overland
7 Body Style 8 = 4dr Sport Utility
8 Engine S = 4.0 Liter Gasoline
N = 4.7 Liter Gasoline
9 Check Digit 0 through 9 or X
10 Model Year 2=2002
11 Assembly Plant C = Jefferson Assembly
12 thru 17 Vehicle Build Sequence
Fig. 6 VECI Label Location
1 - VECI LABEL (CANADIAN)
2 - VECI LABEL
3 - HOOD
8 INTRODUCTION WJ
VEHICLE SAFETY
CERTIFICATION LABEL
DESCRIPTION
A vehi cl e safety certi fi cati on l abel (Fi g. 7) i s
attached to every Dai ml erChrysl er Corporati on vehi -
cl e. The l abel certi fi es that the vehi cl e conforms to al l
appl i cabl e Federal Motor Vehi cl e Safety Standards.
The l abel al so l i sts:
Month and year of vehi cl e manufacture.
Gross Vehi cl e Wei ght Rati ng (GVWR). The gross
front and rear axl e wei ght rati ngs (GAWRs) are
based on a mi ni mum ri m si ze and maxi mum col d ti re
i nfl ati on pressure.
Vehi cl e I denti fi cati on Number (VI N).
Type of vehi cl e.
Type of rear wheel s.
Bar code.
Month, Day and Hour (MDH) of fi nal assembl y.
Pai nt and Tri m codes.
Country of ori gi n.
The l abel i s l ocated on the dri ver-si de door
shut-face.
Fig. 7 VEHICLE SAFETY CERTIFICATION LABEL -
TYPICAL
WJ INTRODUCTION 9
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PARTS & LUBRICANT RECOMMENDATION
STANDARD PROCEDURE - PARTS &
LUBRICANT RECOMMENDATIONS . . . . . . . . . 2
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE COOLANT . . . . . . . . 2
DESCRIPTION - ENGINE COOLANT . . . . . . . . 3
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION - ENGINE OIL . . . . . . . . . . . . . 4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION - TRANSFER CASE - NV242 . . 5
DESCRIPTION - TRANSFER CASE - NV247 . . 5
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . 5
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION - AUTOMATIC TRANSMISSION
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SCHEDULES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LIFT POINTS
STANDARD PROCEDURE - HOISTING AND
JACKING RECOMMENDATIONS . . . . . . . . . . . 6
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 7
EMERGENCY TOW HOOKS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TOWING
STANDARD PROCEDURE - TOWING
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 8
LUBRICATION &
MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 20 U.S. Gallons (76
Liters)****
Engine Oil - with Filter -
2.7L Diesel
6.5L (6.9 qts.)
4.0L
5.7 L (6.0 qts.)
4.7L
5.7 L (6.0 qts.)
Cooling System - 2.7L
Diesel
14.2L (15 qts.)***
Cooling System - 4.0L 14.1 L (15 qts.)***
Cooling System - 4.7L 13.7 L (14.5 qts.)***
AUTOMATIC TRANSMISSION
Service Fill - 42RE 3.8 L (4.0 qts.)
Service Fill - 545RFE 2WD - 5.2 L (11 pts.)
4WD - 6.2 L (13 pts.)
O-haul Fill - 42RE 9.1-9.5 L (19-20 pts.)
O-haul Fill - 545RFE 13.33 L (28.0 pts.)
Dry fill capacity Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or use
of an auxiliary cooler, these figures may vary. (Refer to
appropriate 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE).
TRANSFER CASE
NV242 1.35L (2.85 pts.)
NV247 1.6L (3.4 pts.)
FRONT AXLE 0.3 L (1 oz.)
186 FBI (Model 30) 1.18 L (2.5 pts.)*
* With Vari-Lok add 0.07 L (2.5 oz.) of Friction Modifier.
REAR AXLE 0.3 L (1 oz.)
198 RBI (Model 35) 1.66 L (3.5 pts.)*
226 RBA (Model 44) 2.24 L (4.75 pts.)**
* With Trac-lok add 0.07 L (2.5 oz.) of Friction Modifier.
** With Trac-lok or Vari-Lok, add 0.07 L (2.5 oz.) of
Friction Modifier.
*** Includes 0.9L (1.0 qts.) for coolant reservoir.
****Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
WJ LUBRICATION & MAINTENANCE 0 - 1
DESCRIPTION
Dai ml erChrysl er Corporati on uses i nternati onal
symbol s to i denti fy engi ne compartment l ubri cant
and fl ui d i nspecti on and fi l l l ocati ons (Fi g. 1).
PARTS & LUBRICANT
RECOMMENDATION
STANDARD PROCEDURE - PARTS &
LUBRICANT RECOMMENDATIONS
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 2) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
G. Chassi s l ubri cant i s i denti fi ed by the l atter L.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
When servi ce i s requi red, Dai ml erChrysl er Corpo-
rati on recommends that onl y Mopar brand parts,
l ubri cants and chemi cal s be used. Mopar provi des
the best engi neered products for servi ci ng
Dai ml erChrysl er Corporati on vehi cl es.
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon the cl i mate and vehi cl e oper-
ati ng condi ti ons. The recommended mi xture of 50/50
ethyl ene-gl ycol and water wi l l provi de protecti on
agai nst freezi ng to -37 deg. C (-35 deg. F). The anti -
freeze concentrati on must always be a mi ni mum of
44 percent, year-round i n al l cl i mates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maxi mum protecti on agai nst freezi ng i s provi ded
wi th a 68 percent anti freeze concentrati on, whi ch
prevents freezi ng down to -67.7 deg. C (-90 deg. F). A
hi gher percentage wi l l freeze at a warmer tempera-
ture. Al so, a hi gher percentage of anti freeze can
cause the engi ne to overheat because the speci fi c
heat of anti freeze i s l ower than that of water.
Use of 100 percent ethyl ene-gl ycol wi l l cause for-
mati on of addi ti ve deposi ts i n the system, as the cor-
rosi on i nhi bi ti ve addi ti ves i n ethyl ene-gl ycol requi re
the presence of water to di ssol ve. The deposi ts act as
i nsul ati on, causi ng temperatures to ri se to as hi gh as
149 deg. C (300) deg. F). Thi s temperature i s hot
enough to mel t pl asti c and soften sol der. The
i ncreased temperature can resul t i n engi ne detona-
ti on. I n addi ti on, 100 percent ethyl ene-gl ycol freezes
at 22 deg. C (-8 deg. F ).
PROPYLENE-GLYCOL MIXTURES
I ts overal l effecti ve temperature range i s smal l er
than that of ethyl ene-gl ycol . The freeze poi nt of 50/50
propyl ene-gl ycol and water i s -32 deg. C (-26 deg. F).
5 deg. C hi gher than ethyl ene-gl ycol s freeze poi nt.
The boi l i ng poi nt (protecti on agai nst summer boi l -
over) of propyl ene-gl ycol i s 125 deg. C (257 deg. F )
at 96.5 kPa (14 psi ), compared to 128 deg. C (263
deg. F) for ethyl ene-gl ycol . Use of propyl ene-gl ycol
can resul t i n boi l -over or freeze-up on a cool i ng sys-
tem desi gned for ethyl ene-gl ycol . Propyl ene gl ycol
al so has poorer heat transfer characteri sti cs than
ethyl ene gl ycol . Thi s can i ncrease cyl i nder head tem-
peratures under certai n condi ti ons.
Fig. 1 INTERNATIONAL SYMBOLS
Fig. 2 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCE WJ
Propyl ene-gl ycol /ethyl ene-gl ycol Mi xtures can
cause the destabi l i zati on of vari ous corrosi on i nhi bi -
tors, causi ng damage to the vari ous cool i ng system
components. Al so, once ethyl ene-gl ycol and propy-
l ene-gl ycol based cool ants are mi xed i n the vehi cl e,
conventi onal methods of determi ni ng freeze poi nt wi l l
not be accurate. Both the refracti ve i ndex and spe-
ci fi c gravi ty di ffer between ethyl ene gl ycol and propy-
l ene gl ycol .
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. 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. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
The use of al umi num cyl i nder bl ocks, cyl i nder
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% Ethyl ene Gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37C (-35F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
CAUTION: Mopar Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149C
(300F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22C (-8F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37C (-34F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7C (-90F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
ene-glycol.
COOLANT SELECTION AND ADDITIVES
heads and water pumps requi res speci al corrosi on
protecti on. Onl y Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (gl ycol base cool ant wi th
corrosi on i nhi bi tors cal l ed HOAT, for Hybri d Organi c
mi xed wi th 50% di sti l l ed water to obtai n to obtai n a
freeze poi nt of -37C (-35F). I f i t l oses col or or
FLUID TYPES (Continued)
becomes contami nated, drai n, fl ush, and repl ace wi th
fresh properl y mi xed cool ant sol uti on.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed. MOPAR provi des engi ne oi l s that conform to
thi s servi ce grade.
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . Use onl y engi ne oi l s wi th mul ti -
pl e vi scosi ti es such as 5W-30 or 10W-30. These are
speci fi ed wi th a dual SAE vi scosi ty grade whi ch i ndi -
cates the col d-to-hot temperature vi scosi ty range.
Sel ect an engi ne oi l that i s best sui ted to your par-
ti cul ar temperature range and vari ati on (Fi g. 3).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 4).
DESCRIPTION - ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
SAE VISCOSITY
pl e vi scosi ti es such as 5W-30 or 10W-30. These oi l s
are speci fi ed wi th a dual SAE vi scosi ty grade whi ch
i ndi cates the col d-to-hot temperature vi scosi ty range.
Fig. 3 Temperature/Engine Oil Viscosity - 4.7L
Fig. 4 API SYMBOL
tai ner.
cans (Fi g. 6).
DESCRIPTION
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
forms to MI L-L-2105C and API GL 5 qual i ty speci fi -
cati ons shoul d be used. Mopar Hypoi d Gear
Lubri cant conforms to these speci fi cati ons.
FRONT AXLE
Lubri cant i s SAE 75W-140 SYNTHETI C.
REAR AXLE
Lubri cant i s a thermal l y stabl e SAE 80W-90
gear l ubri cant.
Lubri cant for heavy-duty or trai l er tow use i s
SAE 75W-140 SYNTHETI C.
NOTE: Trac-lok and Vari-lok equipped axles
require a friction modifier be added to the lubricant.
DESCRIPTION - TRANSFER CASE - NV242
Recommended l ubri cant for the NV242 transfer
case i s Mopar ATF+4, type 9602 Automati c Trans-
mi ssi on Fl ui d.
DESCRIPTION - TRANSFER CASE - NV247
Mopar Transfer Case Lubri cant (P/N 05016796) i s
the onl y l ubri cant recommended for the NV247
transfer case.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Mopar ATF +4, type 9602, Automati c Transmi s-
si on Fl ui d i s the recommended fl ui d for
Dai ml erChrysl er automati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar ATF +4, type 9602, Automati c Transmi s-
si on Fl ui d when new i s red i n col or. The ATF i s dyed
red so i t can be i denti fi ed from other fl ui ds used i n
the vehi cl e such as engi ne oi l or anti freeze. The red
col or i s not permanent and i s not an i ndi cator of fl ui d
condi ti on. As the vehi cl e i s dri ven, the ATF wi l l begi n
to l ook darker i n col or and may eventual l y become
brown. This is normal. ATF+4 al so has a uni que
odor that may change wi th age. Consequentl y, odor
and col or cannot be used to i ndi cate the fl ui d condi -
ti on or the need for a fl ui d change.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous speci al addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on seal ers shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
Fig. 6 API Symbol
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use onl y Di esel Engi ne Oi l meeti ng standard MIL-
2104C or API Cl assi fi cati on CD or higher or CCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properl y formul ated engi ne oi l s, i t i s
recommended that SAE Grade 10W-40 engi ne oi l s
that meet Chrysl er materi al standard MS-6395, be
used. European Grade 10W-40 oi l s are al so accept-
abl e.
Oi l s of the SAE 5W-40 or 8W-80 grade number are
preferred when mi ni mum temperatures consi stentl y
fal l bel ow -12C.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
FLUID FILL/CHECK
LOCATIONS
INSPECTION - FLUID FILL/CHECK LOCATIONS
The fl ui d fi l l /check l ocati ons and l ubri cati on poi nts
are l ocated i n each appl i cabl e group.
MAINTENANCE SCHEDULES
DESCRIPTION
Mai ntenance Schedul e I nformati on not i ncl uded i n
thi s secti on, i s l ocated i n the appropri ate Owners
Manual .
LIFT POINTS
STANDARD PROCEDURE - HOISTING AND
JACKING RECOMMENDATIONS
FLOOR JACK
When properl y posi ti oned, a fl oor jack can be used
to l i ft a WJ vehi cl e (Fi g. 7). Support the vehi cl e i n
the rai sed posi ti on wi th jack stands at the front and
rear ends of the frame rai l s.
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under:
An axle tube.
Aluminum differential.
A body side sill.
A steering linkage component.
A drive shaft.
The engine or transmission oil pan.
The fuel tank.
A front suspension arm.
HOIST
A vehi cl e can be l i fted wi th:
A si ngl e-post, frame-contact hoi st.
A twi n-post, chassi s hoi st.
A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 7).
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
J UMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
Battery cabl e cl amp condi ti on, cl ean i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
Generator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, park the booster vehi cl e wi thi n cabl e reach.
Turn off al l accessori es, set the parki ng brake, pl ace
the automati c transmi ssi on i n PARK or the manual
transmi ssi on i n NEUTRAL and turn the i gni ti on
OFF.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake. Turn off al l accesso-
ri es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t.
Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to posi ti ve (+) termi nal . Connect BLACK
jumper cabl e cl amp to engi ne ground as cl ose to the
ground cabl e attachi ng poi nt as possi bl e (Fi g. 8).
(6) Start the engi ne i n the vehi cl e whi ch has the
booster battery, l et the engi ne i dl e a few mi nutes,
then start the engi ne i n the vehi cl e wi th the di s-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
Fig. 7 Correct Vehicle Lifting Locations
LIFT POINTS (Continued)
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
EMERGENCY TOW HOOKS
DESCRIPTION
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehi cl es are equi pped wi th front emer-
gency tow hooks (Fi g. 9). The tow hooks shoul d be
used for EMERGENCYpurposes onl y.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
TOWING
STANDARD PROCEDURE - TOWING
RECOMMENDATIONS
A vehi cl e equi pped wi th SAE approved wheel l i ft-
type towi ng equi pment can be used to tow WJ vehi -
cl es. When towi ng a 4WD vehi cl e usi ng a wheel -l i ft
towi ng devi ce, use tow dol l i es under the opposi te end
of the vehi cl e. A vehi cl e wi th fl atbed devi ce can al so
be used to transport a di sabl ed vehi cl e (Fi g. 10).
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
Secure l oose and protrudi ng parts.
Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
Fig. 8 Jumper Cable Clamp Connections
1 - ENGINE GROUND
2 - NEGATIVE JUMPER CABLE
3 - BATTERY NEGATIVE CABLE
4 - POSITIVE JUMPER CABLE
5 - BATTERY POSITIVE CABLE
6 - BATTERY
7 - TEST INDICATOR
Fig. 9 Emergency Tow Hooks
1 - TOW HOOK
Fig. 10 Tow Vehicles With Approved Equipment
J UMP STARTING (Continued)
Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl es fuel tank.
Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
Do not attach tow chai ns, T-hooks, or J-hooks to
a bumper, steeri ng l i nkage, dri ve shafts or a non-re-
i nforced frame hol e.
Do not tow a heavi l y l oaded vehi cl e. Use a fl at-
bed devi ce to transport a l oaded vehi cl e.
TWO-WHEEL-DRIVE VEHICLE TOWING
Dai ml erChrysl er Corporati on recommends that a
vehi cl e be towed wi th the rear end l i fted, whenever
possi bl e.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
TWO WHEEL DRIVE TOWING-REAR END LIFTED
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD vehi cl es can be towed wi th the front wheel s
on the surface for extended di stances at speeds not
exceedi ng 48 km/h (30 mph).
(1) Attach wheel l i ft devi ce to rear wheel s.
(2) Pl ace the transmi ssi on i n neutral .
(3) Rai se vehi cl e to towi ng posi ti on.
(4) Attach safety chai ns. Route chai ns so not to
i nterfere wi th tai l pi pe when vehi cl e i s l i fted.
(5) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
(6) Secure steeri ng wheel i n strai ght ahead posi -
ti on wi th a cl amp devi ce desi gned for towi ng.
(7) Pl ace transmi ssi on i n park.
TWO WHEEL DRIVE TOWING-FRONT END LIFTED
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
(3) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(4) Attach wheel l i ft devi ce to front wheel s and
rai se vehi cl e to towi ng posi ti on.
(5) Attach the safety chai ns.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Dai ml erChrysl er Corporati on recommends that a
4WD vehi cl e be transported on a fl at-bed devi ce. A
Wheel -l i ft devi ce can be used provi ded the trailing
wheels are off the ground and positioned in
tow dollies.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION.
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
FOUR WHEEL DRIVE TOWING REAR END LIFTED
(1) Attach wheel l i ft devi ce to front wheel s.
(3) Rai se the front of the vehi cl e off the ground
and i nstal l tow dol l i es under front wheel s.
(4) Attach wheel l i ft devi ce to rear wheel s and
(5) Attach safety chai ns. Route chai ns so not to
i nterfere wi th tai l pi pe when vehi cl e i s l i fted.
TOWING (Continued)
FOUR WHEEL DRIVE TOWING FRONT END
LIFTED
(3) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(4) Attach wheel l i ft devi ce to front wheel s and
(5) Attach the safety chai ns.
TOWING (Continued)
SUSPENSION
TABLE OF CONTENTS
page page
SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION
AND STEERING SYSTEM . . . . . . . . . . . . . . . . 1
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 3
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION AND
STEERING SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
3. Tire pressure. 3. Adjust tire pressure.
EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
WJ SUSPENSION 2 - 1
VEHICLE PULLS TO ONE
SIDE DURING BRAKING
1. Uneven tire pressure. 1. Adjust tire pressure.
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD
1. Radial tire lead. 1. Cross front tires.
2. Brakes dragging. 2. Repair brake as necessary.
3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Repair as necessary.
7. Cross caster out of spec. 7. Align vehicle.
KNOCKING, RATTLING
OR SQUEAKING
1. Worn shock bushings. 1. Replace shock.
2. Loose, worn or bent steering/
2. Inspect, tighten or replace components
as necessary.
3. Shock valve. 3. Replace shock.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/
as necessary.
2 - 2 SUSPENSION WJ
SUSPENSION (Continued)
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER . . . . . . . 3
STANDARD PROCEDURE - CASTER . . . . . . . 4
STANDARD PROCEDURE - TOE POSITION . . 4
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WHEEL ALIGNMENT
DESCRIPTION
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe posi ti on (Fi g. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated, Refer to
Lubrication And Maintenance for the recommended
maintenance schedule.
OPERATION
CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e rearward provi des posi ti ve caster. Ti l ti ng the
top of the knuckl e forward provi des negati ve caster.
Caster i s a di recti onal stabi l i ty angl e. Thi s angl e
enabl es the front wheel s to return to a strai ght
ahead posi ti on after turns (Fi g. 1).
CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re. The angl e i s not
adjustabl e, damaged component(s) must be repl aced
to correct the camber angl e (Fi g. 1).
WHEEL TOE POSITION i s the di fference
between the l eadi ng i nsi de edges and trai l i ng i nsi de
edges of the front ti res. I ncorrect wheel toe posi ti on
i s the most common cause of unstabl e steeri ng and
uneven ti re wear. The wheel toe posi ti on i s the final
front wheel al i gnment adjustment (Fi g. 1).
STEERING AXIS INCLINATION ANGLE i s
measured i n degrees and i s the angl e that the steer-
i ng knuckl es are ti l ted. The i ncl i nati on angl e has a
fi xed rel ati onshi p wi th the camber angl e. I t wi l l not
change except when a spi ndl e or bal l stud i s dam-
aged or bent. The angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the steeri ng
axi s i ncl i nati on angl e.
THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect
thrust angl e can cause off-center steeri ng and exces-
si ve ti re wear. Thi s angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the thrust
angl e (Fi g. 1).
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER
Before each al i gnment readi ng the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down three ti mes. Al ways rel ease the bumper i n the
down posi ti on.
To obtai n an accurate al i gnment, a 4 wheel al i gn-
ment machi ne must be used and the equi pment cal i -
brati on veri fi ed.
The wheel camber angl e i s preset. Thi s angl e i s not
adjustabl e and cannot be al tered.
WJ WHEEL ALIGNMENT 2 - 3
STANDARD PROCEDURE - CASTER
down posi ti on.
The wheel caster angl e i s preset. Thi s angl e i s not
adjustabl e and cannot be al tered.
STANDARD PROCEDURE - TOE POSITION
down posi ti on.
NOTE: For an accurate wheel toe position adjust-
ment the engine must be engine running.
(1) Appl y parki ng brakes.
(2) Start the engi ne and turn wheel s both ways
before strai ghteni ng the steeri ng wheel . Center and
secure the steeri ng wheel .
(3) Loosen the ti e rod adjustment sl eeve cl amp
bol ts (Fi g. 2).
(4) Turn the sl eeve to obtai n the preferred posi ti ve
TOE-I N speci fi cati on. Posi ti on the cl amp bol ts as
shown (Fi g. 2) for proper cl earance.
(5) Ti ghten the cl amp bol ts to 68 Nm (50 ft. l bs.).
Fig. 1 Wheel Alignment Measurements
1 - WHEEL CENTERLINE
2 - NEGATIVE CAMBER ANGLE
3 - PIVOT CENTERLINE
4 - SCRUB RADIUS
5 - TRUE VERTICAL
6 - KING PIN
7 - VERTICAL
8 - POSITIVE CASTER
2 - 4 WHEEL ALIGNMENT WJ
WHEEL ALIGNMENT (Continued)
NOTE: Make sure the toe setting does not change
during clamp tightening.
(6) Veri fy al i gnment speci fi cati ons, then turn the
engi ne off.
STEERING WHEEL CENTERING
NOTE: The steering wheel can be centered without
affecting the toe position.
(1) Loosen the drag l i nk adjustment sl eeve cl amp
bol ts.
(2) Turn the adjustment sl eeve to center the
wheel .
(3) Posi ti on the cl amp bol ts as shown (Fi g. 2)for
proper cl earance.
(4) Ti ghten the cl amp bol ts to 68 Nm (50 ft. l bs.).
(5) Road test the vehi cl e to veri fy the wheel i s cen-
tered.
SPECIFICATIONS
ALIGNMENT
NOTE: Specifications are in degrees.
FRONT WHEELS - STANDARD SUSPENSION
SPECIFICATIONS
PREFERRED CASTER
+ 6.75
CAMBER
0.37
TOTAL
TOE-IN
+ 0.20
RANGE + 6.0to
+ 7.5
0.75
to + 0.5
+ .14to
+ .26
MAX RT/LT
DIFFERENCE
0.5 0.5 0.5
FRONT WHEELS - UP-COUNTRY SUSPENSION
SPECIFICATIONS
PREFERRED CASTER
+ 6.5
CAMBER
0.37
TOTAL
TOE-IN
+ 0.20
RANGE + 5.7to
+ 7.2
0.75
to + 0
+ 0.0to
+ .36
MAX RT/LT
DIFFERENCE
0.5 0.5 0.06
REAR AXLE
SPECIFICATIONS
PREFERRED CAMBER
.37
THRUST
ANGLE
0
TOTAL
TOE-IN
+.37
RANGE 0to
.75
0.25 0to
+.70
Fig. 2 Steering Linkage
1 - DRAG LINK ADJUSTMENT SLEEVE
2 - TIE ROD ADJUSTMENT SLEEVE
WJ WHEEL ALIGNMENT 2 - 5
WHEEL ALIGNMENT (Continued)
FRONT
TABLE OF CONTENTS
page page
FRONT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - SERVICE
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . 6
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 8
BUSHINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HUB / BEARING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
KNUCKLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL - STEERING KNUCKLE . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LOWER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SHOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
STABILIZER BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRACK BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
UPPER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
UPPER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
FRONT
DESCRIPTION
The front suspensi on (Fi g. 1) i s a l i nk/coi l desi gn
compri sed of :
Dri ve axl e
Shock absorbers
Coi l spri ngs
Upper and l ower suspensi on arms
Stabi l i zer bar
Track bar
Jounce bumpers
CAUTION: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
WARNINGS AND CAUTIONS
CAUTION: Suspension components with rubber
2 - 6 FRONT WJ
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION Nm Ft. Lbs. In. Lbs.
Shock Absorber Upper Nut 35 26
Shock Absorber Lower Nut 28 250
Suspension Arm Upper Axle Bracket Nut 61 45
Suspension Arm Upper Frame Bracket Bolt 61 45
Suspension Arm Lower Axle Bracket Nut 163 120
Suspension Arm Lower Frame Bracket Bolt 156 115
Stabilizer Bar Retainer Bolts 92 68
Stabilizer Bar Link Upper Nut 106 78
Stabilizer Bar Link Lower Nut 106 78
Track Bar Frame Bracket Nut 108 80
Track Bar Axle Bracket Bolt 100 74
Hub Bearing Knuckle Bolts 102 75
Fig. 1 Front
1 - SHOCK
2 - COIL SPRING
3 - UPPER SUSPENSION ARM
4 - STABILIZER BAR
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
WJ FRONT 2 - 7
FRONT (Continued)
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
Spacer 8279
Nut, Long 7603
Bolt, Special 7604
Remover C-4150A
Remover/Installer 6289
Reciever 6761
Installer 6752
2 - 8 FRONT WJ
FRONT (Continued)
BUSHINGS
REMOVAL
(1) Remove the upper suspensi on arm from axl e.
(2) Posi ti on Spacer 8279 over the axl e bushi ng on
a 4x2 vehi cl e and ri ght si de on a 4x4 vehi cl e.
(3) Pl ace Recei ver 7932-1 over fl anged end of the
bushi ng. (Fi g. 2).
(4) Pl ace smal l end of Remover/I nstal l 7932-2
agai nst other si de of the bushi ng.
(5) I nstal l bol t 7604 through remover, bushi ng and
recei ver.
(6) I nstal l Long Nut 7603 and ti ghten nut too pul l
bushi ng out of the axl e bracket.
(7) Remove nut, bol t, recei ver, remover and bush-
i ng.
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 8279 in position for bushing installa-
tion.
INSTALLATION
(1) Pl ace Recei ver 7932-1on the other si de of the
axl e bracket.
(2) Posi ti on new bushi ng up to the axl e bracket.,
and l arge end of Remover/I nstal l 7932-2 agai nst the
bushi ng (Fi g. 3).
(3) I nstal l bol t 7604 through recei ver, bushi ng and
i nstal l er.
(4) I nstal l Long Nut 7603 and ti ghten nut to draw
the bushi ng i nto the axl e bracket.
(5) Remove tool s and i nstal l the upper suspensi on
arm.
HUB / BEARING
DESCRIPTION
The beari ng used on the front hub of thi s vehi cl e i s
the combi ned hub and beari ng uni t type assembl y.
Thi s uni t assembl y combi nes the front wheel mount-
i ng hub (fl ange) and the front wheel beari ng i nto a
one pi ece uni t. The wheel mounti ng studs are the
onl y repl aceabl e component of the hub/beari ng
assembl y.
OPERATION
The hub/beari ng assembl y i s mounted to the steer-
i ng knuckl e and i s retai ned by three mounti ng bol ts
accessi bl e from the back of the steeri ng knuckl e. The
hub/beari ng uni t i s not servi ceabl e and must be
repl aced as an assembl y i f the beari ng or the hub i s
determi ned to be defecti ve.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per, cal i per anchor, rotor
and ABS wheel speed sensor,(Refer to 5 - BRAKES/
ELECTRI CAL/FRONT WHEEL SPEED SENSOR -
REMOVAL).
(4) Remove the cotter pi n, nut retai ner and axl e
hub nut.
(5) Remove the hub beari ng mounti ng bol ts from
the back of the steeri ng knuckl e. Remove hub bear-
Fig. 2 Bushing Removal
1 - RECEIVER
2 - AXLE BRACKET
3 - BOLT
4 - REMOVER/INSTALLER
5 - LONG NUT
Fig. 3 Bushing Installation
1 - REMOVER/INSTALLER
2 - AXLE BRACKET
3 - BOLT
4 - RECEIVER
5 - LONG NUT
WJ FRONT 2 - 9
i ng (Fi g. 4) from the steeri ng knuckl e and off the
axl e shaft.
INSTALLATION
(1) I nstal l the hub beari ng to the knuckl e.
(2) I nstal l the hub beari ng to knuckl e bol ts and
ti ghten to 102 Nm (75 ft. l bs.).
(3) I nstal l the hub washer and nut. Ti ghten the
hub nut to 237 Nm (175 ft. l bs.). I nstal l the nut
retai ner and a new cotter pi n.
(4) I nstal l the brake rotor, cal i per anchor, cal i per
and ABS wheel speed sensor,(Refer to 5 - BRAKES/
ELECTRI CAL/FRONT WHEEL SPEED SENSOR -
I NSTALLATI ON).
(5) I nstal l the wheel and ti re assembl y (Refer to 22
- TI RES/WHEELS - STANDARD PROCEDURE).
(6) Remove the support and l ower the vehi cl e.
KNUCKLE
DESCRIPTION
The knuckl e i s a si ngl e casti ng wi th l egs machi ned
for the upper and l ower bal l joi nts. The knuckl e al so
has machi ned mounti ng l ocati ons for the front brake
cal i pers and hub beari ng.
OPERATION
The steeri ng knuckl e pi vot between the upper and
l ower bal l joi nt. Steeri ng l i nkage attached to the
knuckl e al l ows the vehi cl e to be steered.
REMOVAL - STEERING KNUCKLE
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. Removal and
i nstal l ati on of upper and l ower bal l studs requi re the
use of Tool Ki t 6289.
(1) Remove hub beari ng and axl e shaft.
(2) Di sconnect the ti e-rod or drag l i nk from the
steeri ng knuckl e arm,(Refer to 19 - STEERI NG/
LI NKAGE/TI E ROD END - REMOVAL) .
(3) Remove the cotter pi ns from the upper and
l ower bal l studs.
(4) Remove the upper and l ower bal l stud nuts.
(5) Stri ke the steeri ng knuckl e wi th a brass ham-
mer to l oosen knuckl e from the bal l studs. Remove
knuckl e from bal l studs (Fi g. 5).
INSTALLATION
(1) Posi ti on the steeri ng knuckl e on the bal l studs.
(2) I nstal l and ti ghten the bottom retai ni ng nut to
109 Nm (80 ft. l bs.) torque. I nstal l new cotter pi n.
(3) I nstal l and ti ghten the top retai ni ng nut to 101
Nm (75 ft. l bs.) torque. I nstal l new cotter pi n.
(4) I nstal l the hub beari ng and axl e shaft.
(5) Connect the ti e-rod or drag l i nk end to the
steeri ng knuckl e arm.,(Refer to 19 - STEERI NG/
LI NKAGE/TI E ROD END - I NSTALLATI ON) .
Fig. 4 Hub Bearing & Knuckle
1 - HUB BEARING
2 - KNUCKLE
Fig. 5 Steering Knuckle Removal/Installation
1 - AXLE YOKE
2 - UPPER BALL STUD
3 - LOWER BALL STUD
4 - STEERING KNUCKLE
2 - 10 FRONT WJ
HUB / BEARING (Continued)
LOWER BALL J OINT
REMOVAL
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 6).
LOWER CONTROL ARM
DESCRIPTION
The l ower suspensi on arms are hydroformed steel
and use voi ded oval bushi ngs at one end of the arm.
OPERATION
The bushi ngs provi de i sol ati on from the axl e. The
arms mount to the uni body frame rai l bracket and
the axl e brackets. The arm and bushi ngs provi de
l ocati on and react to l oads from the axl e.
REMOVAL
(1) Rai se the vehi cl e and support the front axl e.
(2) Remove the l ower suspensi on arm nut and bol t
from the axl e bracket (Fi g. 7).
(3) Remove the nut and bol t from the frame rai l
bracket and remove the l ower suspensi on arm (Fi g.
7).
INSTALLATION
(1) Posi ti on the l ower suspensi on arm i n the axl e
bracket and frame rai l bracket.
NOTE: The end of the arm with the oval bushing
attaches to the axle bracket.
(2) I nstal l the axl e bracket bol t and nut fi nger
ti ght.
(3) I nstal l the frame rai l bracket bol t and nut fi n-
ger ti ght.
(4) Remove support and l ower the vehi cl e.
(5) Wi th the vehi cl e on the ground ti ghten the
frame bracket bol t to 156 Nm (115 ft. l bs.). Ti ghten
the axl e bracket nut to 163 Nm (120 ft. l bs.).
(6) Check the al i gnment i f new parts were
i nstal l ed.
Fig. 6 Lower
1 - SPECIAL TOOL 628912
3 - SPECIAL TOOL 4212F
4 - SPECIAL TOOL 4212F
WJ FRONT 2 - 11
SHOCK
DESCRIPTION
The top of the shock absorbers are bol ted to the
body. The bottom of the shocks are bol ted to the axl e
brackets. The standard shocks have conventi onal
twi n tube constructi on and are l ow pressure gas
charged. Gas chargi ng prevents cavi tati on duri ng
rough road operati on. Up-Country shocks are mono
tube desi gn and are hi gh pressure gas charged.
OPERATION
The shock absorbers dampen jounce and rebound
moti on of the vehi cl e over vari ous road condi ti ons
and l i mi t suspensi on rebound travel .
REMOVAL
(1) Remove the nut, retai ner and grommet from
the shock stud i n the engi ne compartment (Fi g. 8).
(2) Rai se and support the front axl e.
(3) Remove the l ower mounti ng nuts from the axl e
bracket (Fi g. 9). Remove the shock absorber.
INSTALLATION
(1) Posi ti on the l ower retai ner and grommet on the
shock stud. I nsert the shock absorber through the
shock tower hol e.
(2) I nstal l the l ower shock studs i nto the axl e
bracket.
(3) I nstal l the mounti ng nuts and ti ghten to 28
Nm (250 i n. l bs.).
(5) I nstal l the upper grommet, retai ner and nut on
the stud i n the engi ne compartment. Hol d the shock
stud wi th a 8 mm wrench and ti ghten the nut to 35
Nm (26 ft. l bs.).
SPRING
DESCRIPTION
The coi l spri ngs mount up i n the wheel house whi ch
i s part of the uni ti zed body bracket. A rubber dough-
nut i sol ator i s l ocated between the top of the spri ng
and the body. The bottom of the spri ng seats on a
axl e i sol ator made of rubber wi th a steel i nsert.
Fig. 7 Lower Suspension Arm
2 - FRAME RAIL BRACKET
3 - AXLE BRACKET
Fig. 8 Upper Shock Mounting
1 - RETAINER
2 - STUD
3 - NUT
4 - GROMMET
Fig. 9 Lower Shock Mounting
1 - SHOCK ABSORBER
2 - MOUNTING NUTS
2 - 12 FRONT WJ
LOWER CONTROL ARM (Continued)
OPERATION
The coi l spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght. The i sol ators provi de road noi se
i sol ati on.
REMOVAL
(2) Remove the wheel and ti re assembl i es.
(3) Posi ti on a hydraul i c jack under the axl e to sup-
port i t.
(4) Remove shock absorbers l ower mounti ng nuts
from the axl e brackets.
(5) Remove the track bar mounti ng bol t from the
axl e bracket.
NOTE: Make sure the lower part of the shock does
not hold tension on the brake lines at the axle tube
housing located at the lower shock mounting area.
(6) Lower the axl e unti l the spri ng i s free from the
upper mount and i sol ator (Fi g. 10).
(7) Remove the spri ng from the vehi cl e.
(8) Remove and i nspect the upper and l ower
spri ng i sol ators.
INSTALLATION
(1) I nstal l the upper i sol ator.
(2) I nstal l the l ower i sol ator wi th the i sol ator l oca-
tor nub i n the axl e pad hol e (Fi g. 11).
(3) Posi ti on the coi l spri ng on the axl e spri ng pad.
CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 12).
(4) Rai se the axl e and gui de the spri ngs onto the
spri ng upper mounts and l ower shock studs i nto the
axl e brackets.
(5) I nstal l the shock absorbers l ower mounti ng
nuts.
Fig. 10 Front Coil Spring
1 - UPPER ISOLATOR
2 - COIL SPRING
3 - LOWER ISOLATOR
4 - STABILIZER LINK
Fig. 11 Lower Isolator
1 - LOCATING NUB
2 - LOWER ISOLATOR
3 - AXLE SPRING PAD
4 - LOCATING HOLE
Fig. 12 Isolator Spring Locator
1 - COIL SPRING
2 - SPRING LOCATOR
3 - LOWER ISOLATOR
WJ FRONT 2 - 13
SPRING (Continued)
(6) I nstal l the track bar to the axl e bracket and
i nstal l the mounti ng bol t.
NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar bolt.
(7) Remove the hydraul i c jack from under the
vehi cl e.
(8) Ti ghten al l suspensi on components to proper
torque.
(9) I nstal l the wheel and ti re assembl i es.
(10) Remove support and l ower vehi cl e.
STABILIZER BAR
DESCRIPTION
The bar extends across the front undersi de of the
chassi s and i s mounted to the frame rai l s. Li nks are
connected from the bar to the axl e brackets. The sta-
bi l i zer bar and l i nks are i sol ated by rubber bushi ngs.
OPERATION
The stabi l i zer bar i s used to control vehi cl e body
rol l duri ng turns. The spri ng steel bar hel ps to con-
trol the vehi cl e body i n rel ati onshi p to the suspen-
si on.
REMOVAL
(2) Remove l i nk nuts and bol ts (Fi g. 13) and
remove the l i nks.
(3) Remove the stabi l i zer bar retai ner bol ts (Fi g.
13)from the frame rai l s and remove the stabi l i zer
bar.
INSTALLATION
(1) Posi ti on the stabi l i zer bar on the frame rai l
and i nstal l the retai ners and bol ts. Ensure the bar i s
centered wi th equal spaci ng on both si des. Ti ghten
the bol ts to 92 Nm (68 ft. l bs.).
(2) I nstal l the l i nks onto the stabi l i zer bar and
axl e brackets and i nstal l the bol ts and nuts fi nger
ti ght.
(3) Remove the supports and l ower the vehi cl e.
(4) Wi th the vehi cl e on the ground ti ghten the sta-
bi l i zer bar l i nk nuts to 106 Nm (78 ft. l bs.).
TRACK BAR
DESCRIPTION
The bar i s attached to a frame rai l bracket and
axl e bracket. The bar i s forged and has non repl ace-
abl e i sol ator bushi ngs at both ends.
OPERATION
The track bar i s used to control front axl e l ateral
movement and provi des cross car l ocati on of the axl e
assembl y.
REMOVAL
(2) Remove the nut and bol t from the frame rai l
bracket (Fi g. 14).
(3) Remove the bol t from the axl e shaft tube
bracket (Fi g. 15). Remove the track bar.
INSTALLATION
(1) I nstal l the track bar to the axl e tube bracket.
I nstal l the retai ni ng bol t fi nger ti ght.
Fig. 13 Stabilizer Bar
1 - LINK
2 - STABILIZER BAR
3 - BUSHING
4 - RETAINER
Fig. 14 Track Bar Frame Rail Bracket
1 - FRAME RAIL
2 - TRACK BAR
2 - 14 FRONT WJ
SPRING (Continued)
(2) I nstal l track bar to the frame rai l bracket.
I nstal l the bol t and nut fi nger ti ght.
NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar to the frame rail
bracket.
(4) Wi th the vehi cl e on the ground ti ghten the nut
at the frame rai l bracket and to the bol t at the axl e
bracket to 100 Nm (74 ft. l bs.).
(5) Check al i gnment speci fi cati ons i f a new track
bar was i nstal l ed.
UPPER BALL J OINT
REMOVAL
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 16).
Fig. 16 Upper
Fig. 15 Track Bar Axle Bracket
1 - AXLE BRACKET
2 - TRACK BAR
WJ FRONT 2 - 15
TRACK BAR (Continued)
UPPER CONTROL ARM
DESCRIPTION
The upper suspensi on arms are hydroformed steel
and use rubber bushi ngs at each end of the arm.
OPERATION
The arms mount to the uni body frame rai l bracket
and the axl e brackets. The arm and bushi ngs provi de
l ocati on and react to l oads from the axl e. The bush-
i ngs provi de i sol ati on from the axl e.
REMOVAL
(1) Rai se vehi cl e and support the axl e.
(2) Remove the upper suspensi on arm mounti ng
nut and bol t (Fi g. 17) from the axl e bracket.
(3) Remove the nut and bol t (Fi g. 17) at the frame
rai l and remove the upper suspensi on arm.
INSTALLATION
(1) Posi ti on the upper suspensi on arm at the axl e
and frame rai l .
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(4) Wi th the vehi cl e on the ground ti ghten the axl e
bracket nut and the frame bracket bol t to 61 Nm (45
ft. l bs.).
(5) Check the al i gnment i f new parts were
i nstal l ed.
Fig. 17 Upper Suspension Arm
2 - FRAME BOLT
3 - AXLE BOLT
2 - 16 FRONT WJ
REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - REAR
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . 19
LOWER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
SHOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
STABILIZER BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
UPPER BALL JOINT
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT . . . . . . . . . . . . 21
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
UPPER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
REAR
DESCRIPTION
The rear suspensi on (Fi g. 1) i s compri sed of :
Dri ve axl e
Shock absorbers
Coi l spri ngs
Lower suspensi on arms
Upper suspensi on arm
Stabi l i zer bar
CAUTION: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle
ride comfort and prevent premature bushing wear.
WARNING
WARNING:: Suspension components with rubber
Fig. 1 Rear Suspension
1 - SHOCK
3 - COIL SPRING
4 - STABILIZER BAR
WJ REAR 2 - 17
DIAGNOSIS AND TESTING - REAR
SUSPENSION
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose, worn or bent suspension
components.
as necessary.
VEHICLE PULLS TO ONE
SIDE
3.Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.
KNOCKING, RATTLING
OR SQUEAKING
1. Worn shock bushings. 1. Replace shock.
2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
5. Loose, worn or bent suspension
components.
as necessary.
IMPROPER TRACKING 1. Loose, worn or bent suspension
components.
as necessary.
2. Bent axle. 2.Replace axle.
SPECIFICATIONS
TORQUE CHART
Shock Absorber Upper Nut 108 80
Shock Absorber Lower Nut 115 85
Suspension Arm Upper Ball Joint Nut 142 105
Suspension Arm Upper Frame Bolts 100 74
Ball Joint Plate Bolts 136 100
Suspension Arms Lower Axle Bracket Nut 163 120
Suspension Arms Lower Frame Bracket Nut 156 115
Stabilizer Bar Retainer Bolts 54 40
Stabilizer Bar Bar Link Nut 54 40
Stabilizer Bar Bracket Link Nut 92 68
2 - 18 REAR WJ
REAR (Continued)
SPECIAL TOOLS
REAR SUSPENSION
LOWER CONTROL ARM
DESCRIPTION
The l ower suspensi on arms are hydroformed steel
and use voi ded oval bushi ngs at each end of the arm.
OPERATION
The bushi ngs provi de i sol ati on from the axl e. The
arms mount to the uni body frame rai l bracket and
the axl e brackets. The arm and bushi ngs provi de
l ocati on and react to l oads.
REMOVAL
(1) Rai se the vehi cl e and support the rear axl e.
(2) Remove the l ower suspensi on arm nut and bol t
from the axl e bracket (Fi g. 2).
(3) Remove the nut and bol t (Fi g. 2) from the
frame rai l and remove the l ower suspensi on arm.
INSTALLATION
(1) Posi ti on the l ower suspensi on arm i n the axl e
bracket and frame rai l bracket.
NOTE: The end of the arm with the oval bushing
attaches to the axle bracket.
(2) I nstal l the axl e bracket bol t and nut fi nger
ti ght.
(3) I nstal l the frame rai l bracket bol t and nut fi n-
ger ti ght.
(5) Wi th the vehi cl e on the ground ti ghten the nut
at the frame to 156 Nm (115 ft. l bs.). Ti ghten the
nut at the axl e bracket to 163 Nm (120 ft. l bs.).
SHOCK
DESCRIPTION
The top of the shock absorbers are bol ted to the
body. The bottom of the shocks are bol ted to the axl e
brackets. The standard shocks have conventi onal
twi n tube constructi on and are l ow pressure gas
charged. Gas chargi ng prevents cavi tati on duri ng
rough road operati on. Up-Country shocks are mono
tube desi gn and are hi gh pressure gas charged.
OPERATION
The shock absorbers dampen jounce and rebound
moti on of the vehi cl e over vari ous road condi ti ons
and l i mi t suspensi on rebound travel .
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support the axl e.
CAUTION: Do not allow the axle to hang from the
upper suspension arm ball joint.
(2) Remove the upper nut and bol t from the frame
bracket (Fi g. 3).
(3) Remove the l ower nut and bol t from the axl e
bracket. Remove the shock absorber.
INSTALLATION
(1) I nstal l the shock absorber i n the frame bracket
and i nstal l the bol t and nut.
(2) I nstal l the shock absorber i n the axl e bracket
and i nstal l the bol t and nut.
(3) Ti ghten the upper mounti ng nuts to 108 Nm
(80 ft. l bs.). Ti ghten the l ower mounti ng nuts to 115
Nm (85 ft. l bs.).
Remover 8278
Fig. 2 Lower Suspension Arm
2 - AXLE BRACKET
3 - FRAME BRACKET
WJ REAR 2 - 19
REAR (Continued)
SPRING
DESCRIPTION
The coi l spri ngs mount up i n the wheel house whi ch
i s part of the uni ti zed body bracket. A rubber dough-
nut i sol ator i s l ocated between the top of the spri ng
and the body. The bottom of the spri ng seats on a
axl e i sol ator made of rubber wi th a steel i nsert. The
i sol ators provi de road noi se i sol ati on
OPERATION
The coi l spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght.
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support the axl e.
(3) Remove the stabi l i zer bar l i nk from the stabi -
l i zer bar (Fi g. 4).
(4) Remove the shock absorber l ower bol t from the
axl e bracket.
(5) Lower the hydraul i c jack and ti l t the axl e and
remove the coi l spri ng (Fi g. 4).
(6) Remove and i nspect the upper and l ower
spri ng i sol ators (Fi g. 4).
INSTALLATION
(1) I nstal l the upper i sol ator.
(2) I nstal l the l ower i sol ator wi th the i sol ator l oca-
tor nub i n the axl e pad hol e (Fi g. 5).
(3) Pul l down on the axl e and posi ti on the coi l
spri ng i n the l ower i sol ator.
CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 6).
(4) Rai se the axl e wi th the hydraul i c jack.
(5) I nstal l the shock absorber to the axl e bracket
and ti ghten to speci fi cati on.
(6) I nstal l the stabi l i zer bar l i nk to the stabi l i zer
bar.
(9) Ti ghten the stabi l i zer bar l i nks to speci fi cati on.
Fig. 3 Shock Absorber
1 - SHOCK
Fig. 4 Coil Spring
1 - COIL SPRING
2 - ISOLATOR
3 - STABILIZER LINK
4 - ISOLATOR
Fig. 5 Isolator Locator Nub
1 - LOWER ISOLATOR
2 - LOCATOR NUB
3 - AXLE SPRING PAD
2 - 20 REAR WJ
SHOCK (Continued)
STABILIZER BAR
DESCRIPTION
The stabi l i zer bar extends across the back si de of
the rear axl e. Li nks are connected between the bar
and frame rai l brackets. The stabi l i zer bar and l i nks
are i sol ated by rubber bushi ngs.
OPERATION
The stabi l i zer bar i s used to control vehi cl e body
rol l , duri ng turns. The bar hel ps control the vehi cl e
body i n rel ati onshi p to the suspensi on.
REMOVAL
(2) Remove the stabi l i zer bar l i nks from stabi l i zer
bar and frame mount. (Fi g. 7).
(3) Remove the stabi l i zer bar retai ner bol ts.
(4) Remove the stabi l i zer bar.
INSTALLATION
(1) Posi ti on the stabi l i zer bar on the axl e and
i nstal l the retai ners and bol ts. Ensure the bar i s cen-
tered wi th equal spaci ng on both si des. Ti ghten the
bol ts to 54 Nm (40 ft. l bs.).
(2) I nstal l the l i nks to the stabi l i zer bar and frame
brackets.
(3) Ti ghten the nuts at the stabi l i zer bar to 54
Nm (40 ft. l bs.).
(4) Ti ghten the nuts at the frame brackets to 92
Nm (68 ft. l bs.).
UPPER BALL J OINT
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The suspensi on arm uses verti cal spool bushi ngs to
i sol ate road noi se. The suspensi on arm i s bol ted
through bushi ngs to cage nuts i n the body and a bal l
joi nt pl ate to the top of the di fferenti al housi ng.
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The upper suspensi on arm provi des fore/aft and
l ateral l ocati on of the rear axl e. The suspensi on arm
travel i s l i mi ted through the use of jounce bumpers
i n compressi on and shock absorbers i n rebound.
REMOVAL
(2) Support the rear axl e wi th a hydraul i c jack.
(3) Remove the bal l joi nt nut from the top of the
upper suspensi on arm (Fi g. 8).
(4) Separate bal l joi nt from the arm wi th Remover
8278 (Fi g. 9).
NOTE: It may be necessary to strike the upper con-
trol arm with a hammer to separate the ball joint
from the arm.
(5) Remove the bal l joi nt mounti ng bol ts (Fi g.
10)from the di fferenti al housi ng.
(6) Remove the bal l joi nt from the di fferenti al
housi ng.
Fig. 6 Isolator Spring Locator - Typical
1 - LOWER ISOLATOR
2 - SPRING LOCATOR
3 - COIL SPRING
Fig. 7 Rear Stabilizer Bar
1 - LINK
2 - RETAINER
3 - BUSHING
4 - STABILIZER BAR
WJ REAR 2 - 21
SPRING (Continued)
INSTALLATION
(1) I nstal l the bal l joi nt on the di fferenti al hous-
i ng.
(2) I nstal l the bal l joi nt mounti ng bol ts and
(3) Rai se the rear axl e wi th a hydraul i c jack to
al i gn the upper arm wi th the bal l joi nt.
(4) Pul l the arm down on the bal l joi nt stud and
i nstal l a new nut. Ti ghten the nut to 142 Nm (105
ft. l bs.).
UPPER CONTROL ARM
DESCRIPTION
The suspensi on arm uses verti cal spool bushi ngs to
i sol ate road noi se. The suspensi on arm i s bol ted
through bushi ngs to cage nuts i n the body and a bal l
joi nt pl ate to the top of the di fferenti al housi ng.
OPERATION
The upper suspensi on arm provi des fore/aft and
l ateral l ocati on of the rear axl e. The suspensi on arm
travel i s l i mi ted through the use of jounce bumpers
i n compressi on and shock absorbers i n rebound.
REMOVAL
(2) Support the rear axl e wi th a hydraul i c jack.
(3) Remove the park brake cabl es and brake hose
from the arm (Fi g. 11).
(4) Remove the bal l joi nt nut from the top of the
upper suspensi on arm (Fi g. 12).
(5) Separate bal l joi nt from the arm wi th Remover
8278 (Fi g. 13).
Fig. 8 Ball Joint Nut
1 - BALL JOINT NUT
Fig. 9 Separate Ball Joint
1 - REMOVER
3 - BALL JOINT STUD
Fig. 10 Ball Joint Mounting Bolts
1 - BALL JOINT
2 - MOUNTING BOLTS
2 - 22 REAR WJ
UPPER BALL J OINT (Continued)
NOTE: It may be necessary to strike the upper con-
trol arm with a hammer to separate the ball joint
from the arm.
(6) Remove the upper suspensi on arm mounti ng
bol ts and remove the arm (Fi g. 14).
INSTALLATION
(1) Posi ti on the upper suspensi on arm i n the
frame rai l brackets.
(2) I nstal l the mounti ng bol ts and ti ghten to 100
Nm (74 ft. l bs.).
(3) Pul l the arm down on the bal l joi nt stud and
i nstal l a new nut. Ti ghten the nut to 142 Nm (105
ft. l bs.).
(4) I nstal l the park brake cabl es and brake hose to
the arm.
Fig. 11 Park Brake Cables And Brake Hose
2 - REAR BRAKE HOSE
3 - PARK BRAKE CABLES
Fig. 12 Ball Joint Nut
1 - BALL JOINT NUT
Fig. 13 Separate Ball Joint
1 - REMOVER
3 - BALL JOINT STUD
Fig. 14 Upper Suspension Arm Mounting Bolt
2 - MOUNTING BOLT
WJ REAR 2 - 23
UPPER CONTROL ARM (Continued)
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 1
FRONT TUBE AXLE . . . . . . . . . . . . . . . . . . . . . . 14
FRONT AXLE - 186FBI . . . . . . . . . . . . . . . . . . . . 15
REAR AXLE - 198RBI . . . . . . . . . . . . . . . . . . . . . 50
REAR AXLE - 226RBA . . . . . . . . . . . . . . . . . . . . 90
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURES . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5
PROPELLER SHAFT - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT - FRONT 4.7L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPELLER SHAFT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DOUBLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PROPELLER SHAFT
DIAGNOSIS AND TESTING
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
(Refer to 22 - TI RES/WHEELS - DI AGNOSI S AND
TESTI NG)
Brake rotors that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on. (Refer to 5 - BRAKES
- DI AGNOSI S AND TESTI NG)
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts.
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve uni versal
joi nts, or an i ncorrect propel l er shaft angl e, are usu-
al l y the cause of such a vi brati on.
WJ DIFFERENTIAL & DRIVELINE 3 - 1
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign material
on shaft.
1) Clean exterior of shaft and wash with
solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws and
tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.
3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline angles.
5) Rear spring center bolt not in seat. 5) Loosen spring u-bolts and seat center
bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out of
balance.
7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.
9) Re-index propeller shaft, test, and
evaluate.
10) Excessive drive pinion gear shaft
runout.
10) Re-index propeller shaft and evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws and
tighten to proper torque.
2) Lack of lubrication. 2) Replace U-joints as necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180 relative to the yoke may eliminate some
vibrations.
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90 apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 1).
Fig. 1 CLAMP SCREW - POSITION 1
1 - CLAMP
2 - SCREWDRIVER
3 - 2 PROPELLER SHAFT WJ
PROPELLER SHAFT (Continued)
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 2) and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/4 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 3).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt, and undercoati ng
from the propel l er shaft surface where the di al i ndi -
cator wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
that the effects of the wel d process wi l l not enter i nto
the measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) I f the propel l er shaft runout i s out of speci fi ca-
ti on, remove the propel l er shaft, i ndex the shaft 180,
and re-i nstal l the propel l er shaft. Measure shaft
runout agai n.
(6) I f the propel l er shaft runout i s now wi thi n
speci fi cati ons, mark the shaft and yokes for proper
ori entati on.
(7) I f the propel l er shaft runout i s not wi thi n spec-
i fi cati ons, veri fy that the runout of the transmi ssi on/
transfer case and axl e are wi thi n speci fi cati ons.
Correct as necessary and re-measure propel l er shaft
runout.
(8) Repl ace the propel l er shaft i f the runout sti l l
exceeds the l i mi ts.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURES
Thi s procedure appl i es to both the front propel l er
shafts and the rear propel l er shaft. To obtai n the
front (output) angl e on the C/V front propel l er shaft,
the i ncl i nometer i s pl aced on the machi ned ri ng of
the pi ni on fl ange. To obtai n the propel l er shaft angl e
measurement on the C/V front propel l er shaft, the
i ncl i nometer i s pl aced on the propel l er shaft tube.
PROPELLER SHAFT ANGLE
(1) Rai se and support the vehi cl e at the axl es as
l evel as possi bl e. Al l ow the wheel s and propel l er
shaft to turn.
(2) Remove any external beari ng snap ri ngs from
uni versal joi nt i f equi pped, so the i ncl i nometer base
wi l l si ts fl at.
Fig. 2 TWO CLAMP SCREWS
Fig. 3 CLAMP SCREWS SEPARATED
1 - INCH
WJ PROPELLER SHAFT 3 - 3
(3) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng cap i s faci ng downward, i f
necessary.
NOTE: Always make measurements from front to rear.
(4) Pl ace I ncl i nometer on yoke beari ng cap, or the
pi ni on fl ange ri ng, (A) paral l el to the shaft (Fi g. 4). Cen-
ter bubbl e i n si ght gl ass and record measurement.
NOTE: This measurement will give you the trans-
mission or Output Yoke Angle (A).
(5) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng cap, or propel l er shaft
tube on C/V propel l er shaft, paral l el to the shaft (Fi g.
5). Center bubbl e i n si ght gl ass and record measure-
ment. Thi s measurement can al so be taken at the
rear end of the shaft.
NOTE: This measurement will give you the propeller
shaft angle (C).
(6) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n transmi ssi on output operati ng angl e.
(7) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng cap paral l el to
the shaft (Fi g. 6). Center bubbl e i n si ght gl ass and
record measurement.
NOTE: This measurement will give you the pinion
shaft or input yoke angle (B).
(8) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n (Fi g.
7) for addi ti onal i nformati on.
Good cancel l ati on of U-joi nt operati ng angl es
(wi thi n 1).
Operati ng angl es l ess than 3.
Operati ng angl es l ess than 10 for doubl e cardan
U-joi nt.
At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
Fig. 4 OUTPUT YOKE ANGLE (A)
1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER
Fig. 5 PROPELLER SHAFT ANGLE (C)
1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER
Fig. 6 INPUT YOKE ANGLE (B)
1 - PINION YOKE BEARING CAP
2 - INCLINOMETER
SPECIFICATIONS
Front Shaft - Companion Flange Bolts 32 24 -
4.7L Front Shaft - Axle Yoke Nuts 19 14 -
4.7L Front Shaft - Transfer Case Bolts 27 20 -
Rear Shaft - Yoke Nuts 19 14 -
SPECIAL TOOLS
Fig. 7 U-JOINT ANGLE EXAMPLE
1 - 4.9Angle (C)
2 - 3.2Angle (B)
3 - Input Yoke
4 - 3.0Angle (A)
5 - Output Yoke
Inclinometer 7663
REMOVAL
NOTE: Different length propeller shafts are used for
different drivetrain applications. Ensure that the
correct propeller shaft is used.
(1) Pl ace vehi cl e on fl oor or dri ve-on hoi st wi th ful l
wei ght of vehi cl e on suspensi on.
(2) Shi ft the transmi ssi on and transfer case, i f nec-
essary, i nto the Neutral posi ti on.
(3) Measure the di stance from the face of the C/V
joi nt cup to the end of the C/V joi nt boot (Fi g. 8).
(4) The correct l ength i s 142.7 mm (5.61 i n.).
NOTE: If the measurement is not correct, the wrong
shaft may have been installed or a mating compo-
nent (front axle or transfer case) may be installed
incorrectly. Investigate and correct as necessary.
(5) Mark a l i ne across the compani on fl ange at the
transfer case and C/V joi nt at the rear of the front
propel l er shaft for i nstal l ati on reference.
(6) Mark a l i ne across the C/V joi nts and the pi n-
i on compani on fl anges for i nstal l ati on reference.
(7) Remove bol ts from the front C/V joi nt to the
pi ni on compani on fl ange.
(8) Remove bol ts from the rear C/V joi nt to the
transfer case compani on fl ange.
(9) Push the propel l er shaft forward to cl ear trans-
fer case compani on fl ange and remove the shaft.
INSTALLATION
NOTE: Different length propeller shafts are used for
different drivetrain applications. Ensure that the
correct propeller shaft is used.
(1) I nstal l the shaft between compani on fl anges.
(2) The shaft shoul d rotate freel y i n the pi ni on
fl ange.
(3) Al i gn marks on the compani on fl anges wi th the
marks on the C/V joi nts.
(4) I nstal l bol ts to the front C/V joi nt and ti ghten
(5) I nstal l the bol ts to the rear C/V joi nt and
ti ghten bol ts to 32 Nm (24 ft. l bs.).
(6) Veri fy propel l er shaft l ength.
(7) Lower vehi cl e.
4.7L
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove crossmember/ski d pl ate as necessary to
gai n access to the propel l er shaft.
(3) Shi ft transmi ssi on and transfer case, i f neces-
sary i nto Neutral .
(4) Mark a l i ne across the yoke at the transfer
case, l i nk yoke and propel l er shaft yoke at the rear of
the front propel l er shaft for i nstal l ati on reference
(Fi g. 9).
(5) Mark a l i ne across the propel l er shaft yoke and
pi ni on shaft yoke for i nstal l ati on reference.
Fig. 8 MEASUREMENT
1 - C/V JOINT CUP
2 - C/V BOOT END
3 - MEASUREMENT
Fig. 9 REFERENCE MARKS ON YOKES
1 - REFERENCE MARKS
(6) Remove the U-joi nt strap bol ts at the pi ni on
shaft yoke (Fi g. 10).
(7) Remove bol ts hol di ng rear uni versal joi nt to
the transfer case yoke.
(8) Separate the rear uni versal joi nt from the
transfer case yoke.
(9) Push rear of propel l er shaft upward to cl ear
transfer case yoke.
(10) Separate front uni versal joi nt from front axl e.
(11) Separate propel l er shaft from vehi cl e.
INSTALLATION
(1) Posi ti on front propel l er shaft under vehi cl e
wi th rear uni versal joi nt over the transfer case yoke.
(2) Pl ace front uni versal joi nt i nto the axl e pi ni on
yoke.
(3) Al i gn mark on the rear l i nk yoke and uni versal
joi nt to the mark on the transfer case yoke.
(4) Loosel y i nstal l bol ts to hol d uni versal joi nt to
transfer case yoke.
(5) Al i gn mark on front uni versal joi nt to the mark
on the axl e pi ni on yoke.
(6) Ti ghten the U-joi nt strap/cl amp bol ts at the
axl e yoke to 19 Nm (14 ft. l bs.).
(7) Ti ghten the uni versal joi nt to transfer case
(8) Lower the vehi cl e.
PROPELLER SHAFT - REAR
REMOVAL
(1) Rai se and support vehi cl e on safety stands.
(2) Shi ft the transmi ssi on and transfer case i f nec-
essary, to thei r neutral posi ti ons.
(3) Mark a l i ne across the axl e pi ni on yoke and the
propel l er shaft yoke for i nstal l ati on reference.
(4) Remove the bol ts hol di ng the uni versal joi nt
cl amps to the pi ni on yoke.
(5) Sl i de the sl i p yoke off of the transmi ssi on, or
transfer case, output shaft and remove the propel l er
shaft (Fi g. 11).
INSTALLATION
(1) Sl i de the sl i p yoke on the transmi ssi on, or
transfer case, output shaft.
(2) Al i gn the i nstal l ati on reference marks made on
the propel l er shaft and pi ni on yoke.
(3) Posi ti on uni versal joi nt i nto pi ni on yoke.
(4) I nstal l the uni versal joi nt cl amp and cl amp
bol ts to the pi ni on yoke. Ti ghten bol ts to 19 Nm (14
ft. l bs.).
Fig. 10 FRONT PROPELLER SHAFT - 4.7L
1 - FRONT AXLE
2 - BOOT
3 - PROPELLER SHAFT
4 - DOUBLE CARDAN U-JOINT
5 - TRANSFER CASE
6 - BOOT
7 - SLINGER
8 - CLAMP
9 - YOKE
Fig. 11 REAR PROPELLER SHAFT
1 - SLIDING YOKE
2 - PROPELLER SHAFT
3 - PINION YOKE
4 - CLAMP/STRAP
5 - BOLT
6 - OUTPUT SHAFT
PROPELLER SHAFT - FRONT 4.7L (Continued)
SINGLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable. If worn or leaking, they
must be replaced as an assembly.
(1) Remove the propel l er shaft.
(2) Tap the outsi de of the beari ng cap assembl y
wi th a dri ft to l oosen snap ri ng.
(3) Remove snap ri ngs from both si des of yoke
(Fi g. 12).
(4) Set the yoke i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the yoke.
(5) Posi ti on the yoke wi th the grease fi tti ng, i f
equi pped, poi nti ng up.
(6) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and press the cap through the yoke to
rel ease the l ower beari ng cap (Fi g. 13).
(7) I f the beari ng cap wi l l not pul l out of the yoke
by hand after pressi ng, tap the yoke ear near the
beari ng cap to di sl odge the cap.
(8) To remove the opposi te beari ng cap, turn the
yoke over and strai ghten the cross i n the open hol e.
Then, careful l y press the end of the cross unti l the
remai ni ng beari ng cap can be removed (Fi g. 14).
CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.
Fig. 12 REMOVE SNAP RING
1 - SNAP RING
Fig. 13 PRESS OUT BEARING
1 - PRESS
2 - SOCKET
Fig. 14 PRESS OUT REMAINING BEARING
1 - CROSS
2 - BEARING CAP
ASSEMBLY
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores.
(2) Posi ti on the cross i n the yoke wi th i ts l ube fi t-
ti ng, i f equi pped, poi nti ng up (Fi g. 15).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 16). Keep the
needl e beari ngs upri ght i n the beari ng cap.
(4) Press the beari ng cap i nto the yoke bore
enough to cl ear snap ri ng groove.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4 to i nstal l the oppo-
si te beari ng cap.
NOTE: If the joint is stiff or binding, strike the yoke
with a soft hammer to seat the needle bearings.
(7) Add grease to l ube fi tti ng, i f equi pped.
(8) I nstal l the propel l er shaft.
DOUBLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable they must be replaced as
an assembly.
(1) Remove the propel l er shaft.
(2) Mark the propel l er shaft yoke and l i nk yoke for
assembl y reference.
(3) Tap the outsi de of the beari ng cap assembl y
wi th dri ft to l oosen snap ri ngs.
(4) Remove al l the beari ng cap snap ri ngs (Fi g.
17).
Fig. 15 CROSS IN YOKE
1 - CROSS
2 - YOKE
Fig. 16 INSTALL BEARING ON TRUNNION
1 - BEARING CAP
2 - TRUNNION
Fig. 17 SNAP RINGS
SINGLE CARDAN UNIVERSAL J OINTS (Continued)
(5) Remove any grease fi tti ngs i f equi pped.
(6) Posi ti on a socket on the press wi th an i nsi de
di ameter l arge enough to recei ve the beari ng cap
under the l i nk yoke.
(7) Pl ace another socket wi th an outsi de di ameter
smal l er than the beari ng cap on the upper beari ng cap.
(8) Press one beari ng cap from the outboard si de of
the l i nk yoke enough to grasp the cap wi th vi se jaws
(Fi g. 18).
(9) Grasp protrudi ng beari ng cap wi th vi se jaws
and tap l i nk yoke wi th a mal l et and dri ft to remove
beari ng cap (Fi g. 19).
(10) Fl i p assembl y and repeat Step 6, Step 7, Step
8 and Step 9 to remove the opposi te beari ng cap.
(11) Remove the cross centeri ng ki t assembl y and
spri ng (Fi g. 20).
(12) Press the remai ni ng beari ng caps out the
other end of the l i nk yoke as descri bed above to com-
pl ete the di sassembl y.
ASSEMBLY
CAUTION: All alignment marks on the link yoke and
propeller shaft yoke must be aligned during assem-
bled.
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores.
(2) Fi t a cross i nto the propel l er shaft yoke (Fi g. 21).
Fig. 18 PRESS OUT BEARING
Fig. 19 REMOVE BEARING FROM YOKE
Fig. 20 REMOVE CENTERING KIT
Fig. 21 INSTALL CROSS IN YOKE
DOUBLE CARDAN UNIVERSAL J OINTS (Continued)
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 22). Keep nee-
dl e beari ngs upri ght i n the beari ng cap.
(4) Press beari ng cap i nto the yoke bore enough to
cl ear snap ri ng groove (Fi g. 23).
(5) I nstal l a snap ri ng.
(6) Fl i p propel l er shaft yoke and i nstal l other bear-
i ng cap onto the opposi te trunni on and i nstal l a snap
ri ng (Fi g. 24).
(7) Fi t the l i nk yoke onto the remai ni ng trunni ons
and press both beari ng caps i nto pl ace and i nstal l
snap ri ngs (Fi g. 25).
Fig. 22 INSTALL BEARING CAP
Fig. 23 PRESS BEARING CAP
Fig. 25 INSTALL LINK YOKE
(8) I nstal l centeri ng ki t assembl y i nsi de the l i nk
yoke (Fi g. 26).
NOTE: Making sure the spring is properly posi-
tioned.
(9) Pl ace two beari ng caps on opposi te trunni ons of
the remai ni ng cross. Fi t the open trunni ons i nto the
l i nk yoke bores and the beari ng caps i nto the center-
i ng ki t (Fi g. 27).
(10) Press the remai ni ng two beari ng caps i nto
pl ace and i nstal l snap ri ngs (Fi g. 28).
(11) Tap the snap ri ngs to seat them i nto the
grooves (Fi g. 29).
Fig. 26 CENTERING KIT
Fig. 27 REMAINING CROSS
Fig. 29 SEAT SNAP RINGS
(12) Veri fy for proper assembl y. Fl exi ng the joi nt
beyond center, the joi nt shoul d snap over-center i n
both di recti ons i f correctl y assembl ed (Fi g. 30).
(13) I nstal l the propel l er shaft.
Fig. 30 VERIFY ASSEMBLY
FRONT TUBE AXLE
TABLE OF CONTENTS
page page
FRONT TUBE AXLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT TUBE AXLE
REMOVAL
(2) Posi ti on a l i fti ng devi ce under the axl e and
secure axl e to l i ft.
(3) Remove the wheel s and ti res.
(4) Remove the brake rotors (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/ROTORS - REMOVAL)
and cal i pers.
(5) Di sconnect wheel sensor wi ri ng harness from
the vehi cl e wi ri ng harness.
(6) Remove stabi l i zer bar l i nks at the axl e.
(7) Remove shock absorbers from axl e brackets.
(8) Removet track bar.
(9) Remove ti e rod and drag l i nk from the steeri ng
knuckl e.
(10) Remove steeri ng damper from the axl e
bracket.
(11) Remove upper and l ower suspensi on arms
from the axl e brackets.
(12) Lower the l i ft enough to remove the axl e. The
coi l spri ngs wi l l drop wi th the axl e.
(13) Remove the coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners are tightened. If not at their nor-
mal ride position, ride height and handling could be
affected.
(1) I nstal l spri ngs and retai ner cl i ps and ti ghten
retai ner bol ts to 21 Nm (16 ft. l bs.).
(2) Li ft and posi ti on axl e under the vehi cl e and
al i gn i t wi th the spri ng pads.
(3) Posi ti on upper and l ower suspensi on arms i n
the axl e brackets and l oosel y i nstal l bol ts and nuts.
(4) I nstal l track bar to the axl e bracket and l oosel y
i nstal l bol t.
(5) I nstal l shock absorbers and ti ghten bol ts to 23
Nm (17 ft. l bs.).
(6) I nstal l stabi l i zer bar l i nks to the axl e brackets
and ti ghten nuts to 95 Nm (70 ft. l bs.).
(7) I nstal l drag l i nk and ti e rod to the steeri ng
knuckl es.
(8) I nstal l steeri ng damper to the axl e bracket and
ti ghten nut to 75 Nm (55 ft. l bs.).
(9) I nstal l the brake rotors and cal i pers.
(10) Connect wheel speed sensor wi ri ng harness, i f
equi pped.
(12) Remove l i ft from the axl e and l ower the vehi -
cl e.
(13) Ti ghten upper suspensi on arm nuts to 75 Nm
(55 ft. l bs.). Ti ghten l ower suspensi on arm nuts to
115 Nm (85 ft. l bs.).
(14) Ti ghten track bar bol t at the axl e bracket to
100 Nm (74 ft. l bs.).
(15) Check the front wheel al i gnment.
3 - 14 FRONT TUBE AXLE WJ
FRONT AXLE - 186FBI
TABLE OF CONTENTS
page page
FRONT AXLE - 186FBI
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 30
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 31
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
AXLE - C/V JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
AXLE - U-JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 42
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
FRONT AXLE - 186FBI
DESCRIPTION
The Front Beam-desi gn I ron (FBI ) axl e consi sts of
a cast i ron di fferenti al housi ng wi th axl e shaft tubes
extendi ng from ei ther si de. The tubes are pressed
i nto the di fferenti al housi ng and wel ded. The axl es
are semi -fl oati ng axl e shafts, meani ng the l oads are
supported by the hub beari ngs. The axl e shafts are
retai ned by nuts at the hub beari ngs.
The di fferenti al case i s a one-pi ece desi gn. Di ffer-
enti al beari ng prel oad and ri ng gear backl ash i s
adjusted by the use of shi ms l ocated between the di f-
ferenti al beari ng cups and housi ng. Pi ni on beari ng
prel oad i s set and mai ntai ned by the use of a col l aps-
i bl e spacer. A di fferenti al cover provi des a means for
i nspecti on and servi ci ng.
An opti onal Vari -Lok di fferenti al has a one-pi ece
di fferenti al case whi ch contai ns the gerotor pump
assembl y and the cl utch mechi ni sm. Thi s uni t i s ser-
vi ced as an assembl y.
OPERATION
The axl e recei ves power from the transfer case
through the front propel l er shaft. The front propel l er
shaft i s connected to the pi ni on gear whi ch rotates
the di fferenti al through the gear mesh wi th the ri ng
gear bol ted to the di fferenti al case. The engi ne power
i s transmi tted to the axl e shafts through the pi ni on
mate and si de gears. The si de gears are spl i ned to
the axl e shafts.
STANDARD DIFFERENTIAL
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi ni on
gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the pi n-
i on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
WJ FRONT AXLE - 186FBI 3 - 15
VARI-LOK DIFFERENTIAL
I n a standard di fferenti al i f one wheel spi ns, the
opposi te wheel wi l l generate onl y as much torque as
the spi nni ng wheel .
A gerotor pump and cl utch pack are used to pro-
vi de the torque transfer capabi l i ty. One axl e shaft i s
spl i ned to the gerotor pump and one of the di fferen-
ti al si de gears, whi ch provi des the i nput to the pump.
As a wheel begi ns to l ose tracti on, the speed di ffer-
enti al i s transmi tted from one si de of the di fferenti al
to the other through the si de gears. The moti on of
one si de gear rel ati ve to the other turns the i nner
rotor of the pump. Si nce the outer rotor of the pump
i s grounded to the di fferenti al case, the i nner and
outer rotors are now movi ng rel ati ve to each other
and therefore creates pressure i n the pump. The tun-
i ng of the front and rear axl e ori fi ces and val ves
i nsi de the gerotor pump i s uni que and each system
i ncl udes a torque-l i mi ti ng pressure rel i ef val ve to
protect the cl utch pack, whi ch al so faci l i tates vehi cl e
control under extreme si de-to-si de tracti on vari a-
ti ons. The resul ti ng pressure i s appl i ed to the cl utch
pack and the transfer of torque i s compl eted.
Under condi ti ons i n whi ch opposi te wheel s are on
surfaces wi th wi del y di fferent fri cti on characteri sti cs,
Vari -l ok del i vers far more torque to the wheel on
the hi gher tracti on surface than do conventi onal
Trac-l ok systems. Because conventi onal Trac-l ok
di fferenti al s are i ni ti al l y pre-l oaded to assure torque
transfer, normal dri vi ng (where i nner and outer
wheel speeds di ffer duri ng corneri ng, etc.) produces
torque transfer duri ng even sl i ght si de-to-si de speed
vari ati ons. Si nce these devi ces rel y on fri cti on from
thi s prel oad to transfer torque, normal use tends to
cause wear that reduces the abi l i ty of the di fferenti al
to transfer torque over ti me. By desi gn, the Vari -l ok
system i s l ess subject to wear, remai ni ng more con-
si stent over ti me i n i ts abi l i ty to transfer torque. The
coupl i ng assembl y i s servi ced as a uni t. From a ser-
vi ce standpoi nt the coupl i ng al so benefi ts from usi ng
the same l ubri cant suppl y as the ri ng and pi ni on
gears.
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
Check for i nsuffi ci ent l ubri cant.
I ncorrect ri ng gear backl ash.
Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
Fig. 1 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 2 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
3 - 16 FRONT AXLE - 186FBI WJ
FRONT AXLE - 186FBI (Continued)
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de-gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
Damaged dri ve shaft.
Mi ssi ng dri ve shaft bal ance wei ght(s).
Worn or out-of-bal ance wheel s.
Loose wheel l ug nuts.
Worn U-joi nt(s).
Loose/broken spri ngs.
Damaged axl e shaft beari ng(s).
Loose pi ni on gear nut.
Excessi ve pi ni on yoke run out.
Bent axl e shaft(s).
Check for l oose or damaged frontend components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear-end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
TESTI NG)
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
Hi gh engi ne i dl e speed.
Transmi ssi on shi ft operati on.
Loose engi ne/transmi ssi on/transfer case mounts.
Worn U-joi nts.
Loose spri ng mounts.
Loose pi ni on gear nut and yoke.
Excessi ve ri ng gear backl ash.
Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
VARI-LOK
(1) Park the vehi cl e on a l evel surface or rai se
vehi cl e on hoi st so that the vehi cl e i s l evel .
(2) Remove the axl e fi l l pl ug.
(3) Veri fy that the axl e fl ui d l evel i s correct. The
fl ui d l evel i s correct i f the fl ui d i s l evel wi th the bot-
tom of the fi l l hol e.
(4) Shi ft the transfer case i nto the 4WD ful l -ti me
posi ti on.
(5) Dri ve the vehi cl e i n a ti ght ci rcl e for 2 mi nutes
at 5mph to ful l y pri me the pump.
(6) Bl ock the ti res opposi te the axl e to be tested to
prevent the vehi cl e from movi ng.
(7) Shi ft the transfer case i nto the 4WD Low posi -
ti on and the transmi ssi on i nto the Park posi ti on.
(8) Rai se both the wheel s of the axl e to be tested
off of the ground.
(9) Rotate the l eft wheel by hand at a mi ni mum of
one revol uti on per second whi l e an assi stant rotates
the ri ght wheel i n the opposi te di recti on.
(10) The l eft wheel shoul d spi n freel y at fi rst and
then i ncrease i n resi stance wi thi n 5 revol uti ons unti l
the wheel s cannot be conti nuousl y rotated i n opposi te
di recti ons.
(11) The Vari -l ok di fferenti al has engaged prop-
erl y i f the wheel s cannot be rotated i n opposi te di rec-
ti ons for a moment. After the wheel s stop rotati ng for
a moment, the fl ui d pressure wi l l drop i n the di ffer-
enti al and the wheel s begi n to rotate once agai n.
(12) I f the system does not operate properl y,
repl ace the Vari -l ok di fferenti al .
REMOVAL
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to l i ft.
(5) Remove the brake cal i pers and rotors (Refer to
5 - BRAKES/HYDRAULI C/MECHANI CAL/ROTORS
- REMOVAL) from the axl e.
(6) Di sconnect the wheel sensor wi ri ng harness
from the vehi cl e wi ri ng harness.
(7) Di sconnect the vent hose from the axl e shaft
tube.
(8) Mark propel l er shaft and yoke/pi ni on fl ange for
i nstal l ati on al i gnment reference.
(9) Remove propel l er shaft.
(10) Di sconnect stabi l i zer bar l i nks at the axl e.
(11) Di sconnect shock absorbers from axl e brack-
ets.
(12) Di sconnect track bar.
(13) Di sconnect the ti e rod and drag l i nk from the
steeri ng knuckl e.
(14) Di sconnect the steeri ng damper from the axl e
bracket.
(15) Di sconnect the upper and l ower suspensi on
arms from the axl e brackets.
(16) Lower the l i fti ng devi ce enough to remove the
axl e. The coi l spri ngs wi l l drop wi th the axl e.
(17) Remove the coi l spri ngs from the axl e.
INSTALLATION
track bar fasteners can be tightened. If springs are
not at their normal ride position, ride height and
handling could be affected.
(1) I nstal l the spri ngs and retai ner cl i ps. Ti ghten
the retai ner bol ts to 21 Nm (16 ft. l bs.).
(2) Support the axl e on a l i fti ng devi ce and posi -
ti on axl e under the vehi cl e.
(3) Rai se the axl e and al i gn i t wi th the spri ng
pads.
(4) Posi ti on the upper and l ower suspensi on arms
i n the axl e brackets. Loosel y i nstal l bol ts and nuts to
hol d suspensi on arms to the axl e brackets.
(5) I nstal l vent hose to the axl e shaft tube.
(6) I nstal l track bar i n the axl e bracket and i nstal l
the bol t l oosel y.
(7) I nstal l shock absorbers and ti ghten the bol ts to
23 Nm (17 ft. l bs.).
(8) I nstal l stabi l i zer bar l i nks to the axl e brackets
and ti ghten the nuts to 95 Nm (70 ft. l bs.).
(9) I nstal l drag l i nk and ti e rod to the steeri ng
knuckl es.
(10) I nstal l steeri ng damper to the axl e bracket
and ti ghten the nut to 75 Nm (55 ft. l bs.).
(11) I nstal l the brake rotors (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/ROTORS - I NSTALLA-
TI ON) and cal i pers.
(12) Connect the wheel speed sensor wi ri ng har-
ness to the vehi cl e wi ri ng harness.
(13) Al i gn the previ ousl y made marks on the pro-
pel l er shaft and the yoke/pi ni on fl ange.
(14) I nstal l propel l er shaft to pi ni on fl ange bol ts ,
i f equi pped.
(15) I nstal l propel l er shaft to yoke straps and
bol ts, i f equi pped.
(16) Check and fi l l axl e l ubri cant.
(18) Remove the l i fti ng devi ce from the axl e and
l ower the vehi cl e.
(19) Ti ghten the upper suspensi on arm nuts to 75
Nm (55 ft. l bs.). Ti ghten the l ower suspensi on arm
nuts to 115 Nm (85 ft. l bs.).
(20) Ti ghten the track bar bol t at the axl e bracket
to 100 Nm (74 ft. l bs.).
(21) Check the front wheel al i gnment.
ADJUSTMENTS
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched onto each gear (Fi g. 3). A pl us
(+) number, mi nus () number or zero (0) i s etched
i nto the face of the pi ni on gear. Thi s number i s the
amount (i n thousandths of an i nch) the depth vari es
from the standard depth setti ng of a pi ni on etched
wi th a (0). The standard setti ng from the center l i ne
of the ri ng gear to the back face of the pi ni on i s 92.1
mm (3.625 i n.). The standard depth provi des the best
gear tooth contact pattern. Refer to Backl ash and
Contact Pattern Anal ysi s paragraph i n thi s secti on
for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th a sel ect shi m/oi l sl i nger. The shi ms are
pl aced between the rear pi ni on beari ng and the pi n-
i on gear head (Fi g. 4).
Fig. 3 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 4 ADJUSTMENT SHIM LOCATIONS
1 - PINION DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
5 - COLLAPSIBLE SPACER
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on. Add or subtract thi s number from the
thi ckness of the ori gi nal depth shi m/oi l sl i nger to
compensate for the di fference i n the depth vari ances.
Refer to the Pi ni on Gear Depth Vari ance chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the pi ni on
gear head (1, 2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
PINION DEPTH MEASUREMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the housi ng. Take
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 5).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 8804 and rear pi ni on beari ng onto Screw 6741
(Fi g. 5).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto the housi ng through pi n-
i on beari ng cups (Fi g. 6).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
hand ti ght (Fi g. 5).
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on, i n the housi ng si de beari ng cradl es (Fi g. 7).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Postti on Scooter Bl ock/Di al I ndi cator so di al
probe and scooter bl ock are fl ush on the surface of
the pi ni on hei ght bl ock (Fi g. 5). Hol d scooter bl ock
and zero the di al i ndi cator.
(7) Hol d scooter bl ock agai nst the pi ni on hei ght
bl ock and sl owl y sl i de across the pi ni on hei ght bl ock
to the arbor (Fi g. 8). Move the scooter bl ock ti l l the
di al probe crests the arbors and record the hi ghest
readi ng.
(8) Sel ect a shi m/oi l sl i nger equal to the di al i ndi -
cator readi ng pl us the pi ni on depth vari ance number
etched i n the face of the pi ni on (Fi g. 3). For exampl e,
i f the depth vari ance i s 2, add +0.002 i n. to the di al
i ndi cator readi ng.
Fig. 5 PINION GEAR DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 6 PINION HEIGHT BLOCK
1 - PINION BLOCK
Fig. 7 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
Fig. 8 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
DIFFERENTIAL
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms posi ti oned behi nd the
di fferenti al si de beari ng cones. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t Dummy
Beari ngs D-348 i n pl ace of the di fferenti al si de bear-
i ngs and a Di al I ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on i s i nstal l ed, and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng and the prel oad speci fi cati on added together.
The gear backl ash measurement determi nes the
thi ckness of the shi m used on the ri ng gear si de of
the di fferenti al case. Subtract the gear backl ash shi m
thi ckness from the total overal l shi m thi ckness and
sel ect that amount for the pi ni on gear si de of the di f-
ferenti al (Fi g. 9). Di fferenti al shi m measurements
are performed wi th spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(3) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(4) I nstal l di fferenti al case i n the housi ng.
CAUTION: When installing a Vari-Lok differential,
the oil feed tube must point to the bottom of the
housing. If differential is forced in with the oil feed
towards the top, the anti-rotation tabs will be dam-
aged.
(5) Record the thi ckness of Dummy Shi ms 8107.
I nsert the shi ms between the dummy beari ngs and
the di fferenti al housi ng (Fi g. 10).
1 - PINION DEPTH SHIM/OIL SLINGER
3 - RING GEAR
Fig. 10 DUMMY SHIM LOCATION
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
(6) I nstal l the beari ng caps i n thei r correct posi -
ti ons and snug the bol ts (Fi g. 11).
(7) Wi th a dead-bl ow hammer, seat the di fferenti al
dummy beari ngs to each si de of the housi ng (Fi g. 12)
and (Fi g. 13).
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear (Fi g. 14).
(9) Attach a di al i ndi cator C-3339 to Pi l ot Stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
between the ri ng gear bol t heads (Fi g. 14).
Fig. 11 BEARING CAP BOLTS
1 - BEARING CAP
Fig. 12 SEAT DUMMY BEARING PINION SIDE
1 - HAMMER
Fig. 13 SEAT DUMMY BEARING RING GEAR SIDE
2 - HAMMER
Fig. 14 DIFFERENTIAL SIDE PLAY MEASUREMET
3 - PILOT STUD
4 - DIAL INDICATOR
(10) Push and hol d di fferenti al case to pi ni on gear
si de of the housi ng and zero di al i ndi cator (Fi g. 15).
(11) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 16).
(12) Add 0.152 mm (0.006 i n.) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(13) Rotate di al i ndi cator out of the way on the
pi l ot stud.
(14) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(15) I nstal l the pi ni on gear i n the housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
(16) I nstal l di fferenti al case and Dummy Beari ngs
D-348 i n the housi ng.
(17) I nstal l a si ngl e dummy shi m i n the ri ng gear
si de. I nstal l beari ng caps and ti ghten bol ts snug.
(18) Seat ri ng gear si de dummy beari ng (Fi g. 13).
(19) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 14).
(20) Push and hol d di fferenti al case toward pi ni on
gear and zero di al i ndi cator (Fi g. 17).
Fig. 15 ZERO DIAL INDICATOR
1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - INDICATOR EXTENSION
4 - DIAL INDICATOR FACE
Fig. 16 RECORED DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
1 - DIAL INDICATOR
3 - PINION GEAR
(Fi g. 18). Add dummy shi m thi ckness to thi s readi ng.
Thi s wi l l be the total shi m thi ckness to achi eve zero
backl ash.
(22) Subtract 0.076 mm (0.003 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(23) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(24) Rotate di al i ndi cator out of the way on pi l ot
stud.
from the housi ng.
(26) I nstal l si de beari ngs and cups on di fferenti al
case.
(27) I nstal l spreader W-129-B wi th Adapter Set
6987 on the housi ng and spread axl e openi ng enough
to recei ve di fferenti al case.
(28) Pl ace the beari ng prel oad shi ms i n the axl e
housi ng, agai nst the axl e tubes.
(29) I nstal l di fferenti al case i nto the housi ng.
CAUTION: When installing a Vari-Lok differential,
the oil feed tube must point to the bottom of the
housing. If differential is forced in with the oil feed
towards the top, the anti-rotation tabs will be dam-
aged.
(30) Remove spreader from the housi ng.
(31) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(32) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 19).
Fig. 18 RECORED DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
Fig. 19 RING GEAR BACKLASH
1 - DIAL INDICATOR
(33) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(34) Zero di al i ndi cator face to poi nter.
(35) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the housi ng to the other (Fi g.
20).
(36) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Wi th a boxed end wrench on a ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
21)and adjust pi ni on depth and gear backl ash as nec-
essary.
Fig. 20 BACKLASH SHIM ADJUSTMENT
Fig. 21 GEAR TOOTH CONTACT PATTERNS
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es i s torque to rotate pi ni on and di f-
ferenti al combi ned. Thi s wi l l veri fy the correct di ffer-
enti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on shoul d
be the torque to rotate the pi ni on pl us 0.79-1.24 Nm
(7-11 i n. l bs.).
SPECIFICATIONS
AXLE SPECIFICATIONS
Axle Ratio 3.31, 3.55, 3.73, 3.91
Differential Side Gear Clearance 0.13-0.20 mm (0.005-0.008 in.)
Differential Bearing Preload 0.152 mm (0.006 in.)
Ring Gear Diameter 186 mm (7.33 in.)
Ring Gear Backlash 0.13-0.20 mm (0.005-0.008 in.)
Pinion Gear Std. Depth 92.08 mm (3.625 in.)
Pinion Bearing Preload - Original Bearings 1-2 Nm (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 1.7-3.4 Nm (15-30 in. lbs.)
Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 61 45 -
Ring Gear Bolts 108 80 -
Axle Nut 237 175 -
Hub Bearing Bolts 102 75 -
SPECIAL TOOLS
PULLER C-293-PA
PLUG SP-3289
ADAPTER C-293-42
PULLER C-452
FLANGE WRENCH C-3281
DIAL INDICATOR C-3339
INSTALLER C-3716-A
HANDLE C-4171
INSTALLER C-4308
REMOVER C-4307
INSTALLER W-162-D
CUP 8109
SEAL INSTALLER 8110
TURNBUCKLE 6797
PINION DEPTH SET 6774
DUMMY SHIMS 8107
PINION BLOCK 8804
SEAL REMOVER 7794-A
CLAMP INSTALLER C-4975-A
SPANNER WRENCH 6958
SPREADER W-129-B
ADAPTER KIT 6987B
PILOT STUD C-3288-B
REMOVER D-158
INSTALLER D-144
INSTALLER 6448
AXLE SHAFTS
REMOVAL
I f the axl e shaft and hub beari ng are bei ng
removed i n order to servi ce another component, the
axl e shaft and hub beari ng can be removed as an
assembl y.
(2) Remove the wheel and ti re assembl y.
(3) Remove brake cal i per, rotor and ABS wheel
speed sensor.
(4) Remove cotter pi n, nut retai ner and axl e nut.
(5) Remove the hub beari ng bol ts (Fi g. 22).
(6) Remove hub beari ng and axl e shaft assembl y
(Fi g. 23). Avoid damaging the axle shaft oil seals
in the axle housing.
(7) Remove brake rotor shi el d from the hub bear-
i ng or knuckl e.
INSTALLATION
(1) Thoroughl y cl ean the axl e shaft and appl y a
thi n fi l m of Mopar Wheel Beari ng Grease or equi va-
l ent to the shaft spl i nes, seal contact surface and hub
bore.
(2) I nstal l brake rotor shi el d to the knuckl e.
(3) I nstal l hub beari ng and axl e shaft assembl y or
axl e shaft i nto the housi ng and di fferenti al si de
gears. Avoi d damagi ng the axl e shaft oi l seal s i n the
axl e housi ng.
(4) I nstal l the hub beari ng.
(5) I nstal l hub beari ng bol ts and ti ghten to 102
Nm (75 ft. l bs.).
(6) I nstal l axl e hub washer and nut and ti ghten
nut to 237 Nm (175 ft. l bs.). I nstal l the nut retai ner
and a new cotter pi n.
(7) I nstal l ABS wheel speed sensor, brake rotor
and cal i per.
(8) I nstal l the wheel and ti re assembl y.
Fig. 22 HUB BEARING BOLTS
1 - AXLE SHAFT
2 - AXLE
3 - KNUCKLE
4 - HUB BEARING
Fig. 23 HUB BEARING AND AXLE ASSEMBLY
1 - AXLE
2 - KNUCKLE
3 - HUB BEARING
4 - AXLE SHAFT
AXLE SHAFT SEALS
REMOVAL
(2) Remove axl e shafts.
(3) Remove di fferenti al assembl y.
(4) Remove i nner axl e shaft seal s wi th a pry bay.
INSTALLATION
(1) Remove any seal er remai ni ng from ori gi nal
seal s.
(2) I nstal l oi l seal s wi th Di scs 8110 and Turn-
buckl e 6797 (Fi g. 24). Ti ghten tool unti l di sc bottoms
i n housi ng.
(3) I nstal l di fferenti al and axl e shafts.
(4) Fi l l di fferenti al wi th l ubri cant.
AXLE - C/V J OINT
REMOVAL
NOTE: The only service procedure to be performed
on the axle C/V joint, is the replacement of the joint
seal boot. If any failure of internal axle shaft com-
ponents is diagnosed during a vehicle road test, the
axle shaft must be replaced as an assembly.
(1) Remove axl e shaft.
(2) Remove l arge and smal l C/V boot cl amps (Fi g.
25) and di scard.
(3) Sl i d boot off the C/V joi nt housi ng and sl i de i t
down the axl e shaft.
(4) Remove C/V joi nt from axl e then sl i d boot off
the axl e.
(5) Thoroughl y cl ean and i nspect axl e C/V joi nt
assembl y and axl e shaft for any si gns of excessi ve
wear.
INSTALLATION
(1) Sl i de new boot over axl e shaft.
(2) I nstal l C/V joi nt onto the axl e shaft.
(3) Di stri bute 1/2 the amount of grease provi ded i n
seal boot servi ce package (DO NOT USE ANY
OTHER TYPE OF GREASE) i nto axl e C/V joi nt
assembl y housi ng. Put the remai ni ng amount i nto
the seal i ng boot.
(4) Posi ti on boot on the axl e l ocati ng grove and on
the C/V joi nt.
Fig. 24 AXLE SEAL TOOLS
1 - TURNBUCKLE
2 - DISCS
Fig. 25 OUTER C/V BOOT CLAMPS
1 - C/V JOINT HOUSING
2 - LARGE CLAMP
3 - AXLE SHAFT
4 - SMALL CLAMP
5 - SEALING BOOT
CAUTION: Boot must not be dimpled, stretched or
out of shape in any way. If not shaped correctly,
equalize pressure in boot and shape it by hand.
(5) I nstal l the two boot cl amps.
(6) Cri mp the boot cl amps wi th Cl amp I nstal l er
C-4975A. Pl ace cl amp tool over bri dge of cl amp (Fi g.
26).
(7) Ti ghten nut on the tool unti l jaws on tool are
cl osed compl etel y together (Fi g. 27) and (Fi g. 28).
(8) I nstal l the axl e shaft.
AXLE - U-J OINT
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Do not over tighten the vise
jaws, to avoid distorting the yoke.
(1) Remove axl e shaft.
(2) Remove the beari ng cap retai ni ng snap ri ngs
(Fi g. 29).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(3) Locate a socket wi th an i nsi de di ameter i s
l arger than the beari ng cap. Pl ace the socket (recei v-
er) agai nst the yoke and around the peri meter of the
beari ng cap to be removed.
(4) Locate a socket wi th an outsi de di ameter i s
smal l er than the beari ng cap. Pl ace the socket (dri v-
er) agai nst the opposi te beari ng cap.
(5) Posi ti on the yoke wi th the sockets i n a vi se
(Fi g. 30).
(6) Ti ghten the vi se jaws to force the beari ng cap
i nto the l arger socket (recei ver).
(7) Rel ease the vi se jaws. Remove the sockets and
beari ng cap that was parti al l y forced out of the yoke.
(8) Repeat the above procedure for the remai ni ng
beari ng cap and remove spi der from the propel l er
shaft yoke.
Fig. 26 CRIMPING TOOL
1 - INSTALLER
2 - AXLE SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 27 SMALL BOOT CLAMP
1 - CLAMP
2 - INSTALLER
3 - AXLE SHAFT
4 - SEALING BOOT
Fig. 28 LARGE BOOT CLAMP
1 - CLAMP TOOL
2 - SEALING BOOT
3 - OUTER C/V JOINT
4 - BOOT CLAMP
AXLE - C/V J OINT (Continued)
INSTALLATION
(1) Pack the beari ng caps 1/3 ful l of wheel beari ng
l ubri cant. Appl y extreme pressure (EP), l i thi um-base
l ubri cant to ai d i n i nstal l ati on.
(2) Posi ti on the spi der i n the yoke. I nsert the seal s
and beari ngs, then tap beari ng caps i nto the yoke
bores far enough to hol d the spi der i n posi ti on.
(3) Pl ace the socket (dri ver) agai nst one beari ng
cap. Posi ti on the yoke wi th the socket i n a vi se.
(4) Ti ghten the vi se to force the beari ng caps i nto
the yoke. Force the caps enough to i nstal l the retai n-
i ng cl i ps.
(5) I nstal l the beari ng cap retai ni ng cl i ps.
(6) I nstal l axl e shaft.
PINION SEAL
REMOVAL
(2) Remove wheel and ti re assembl i es.
(3) Remove brake rotors and cal i pers, refer to 5
Brakes for procedures.
(4) Mark propel l er shaft and pi ni on compani on
fl ange for i nstal l ati on reference.
(5) Remove the propel l er shaft from the pi ni on
compani on fl ange.
(6) Rotate the pi ni on gear a mi ni mum of ten ti mes
and veri fy the pi ni on rotates smoothl y.
(7) Record torque necessary to rotate the pi ni on
gear wi th a i nch pound torque wrench.
(8) Usi ng a short pi ece of pi pe and Spanner
Wrench 6958 to hol d the pi ni on compani on fl ange
and remove the pi ni on nut and washer.
(9) Remove pi ni on compani on fl ange wi th Remover
C-452 and Fl ange Wrench C-3281.
(10) Remove pi ni on seal wi th Remover 7794-A and
a sl i de hammer (Fi g. 31).
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th an appropri ate
i nstal l er (Fi g. 32).
(2) I nstal l pi ni on compani on fl ange on the pi ni on
gear wi th I nstal l er W-162-D, Cup 8109 and Wrench
6958.
CAUTION: Never exceed the minimum tightening
torque 298 Nm (220 ft. lbs.) while installing pinion
nut at this point. Damage to collapsible spacer or
bearings may result.
(3) I nstal l the pi ni on washer and a new nut on
the pi ni on gear. Tighten the nut only enough to
remove the shaft end play.
Fig. 29 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 30 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET
2 - VISE
3 - SMALL-DIAMETER SOCKET
AXLE - U-J OINT (Continued)
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
(4) Rotate pi ni on a mi ni mum of ten ti me and ver-
i fy pi ni on rotates smoothl y. Rotate the pi ni on shaft
wi th an i nch pound torque wrench. Rotati ng torque
shoul d be equal to the readi ng recorded duri ng
removal pl us 0.56 Nm (5 i n. l bs.) (Fi g. 33).
(5) I f the rotati ng torque i s l ow, use Spanner
Wrench 6958 to hol d the pi ni on compani on fl ange
(Fi g. 34), and ti ghten the pi ni on shaft nut i n 6.8 Nm
(5 ft. l bs.) i ncrements unti l proper rotati ng torque i s
achi eved.
CAUTION: If maximum tightening torque is reached
prior to reaching the required rotating torque, the
collapsible spacer may have been damaged.
Replace the collapsible spacer.
Fig. 31 PINION SEAL
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 32 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 33 PINION ROTATION TORQUE
1 - PINION YOKE/COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
Fig. 34 PINION SHAFT NUT
1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH
PINION SEAL (Continued)
(6) I nstal l propel l er shaft wi th i nstal l ati on refer-
ence marks al i gned.
(7) Fi l l di fferenti al wi th gear l ubri cant.
(8) I nstal l brake rotors and cal i pers.
(9) I nstal l wheel and ti re assembl i es.
COLLAPSIBLE SPACER
REMOVAL
(3) Remove brake rotors and cal i pers. Refer to 5
Brakes for procedures.
(4) Mark the propel l er shaft and pi ni on compani on
fl ange for i nstal l ati on reference.
(5) Remove propel l er shaft from the pi ni on com-
pani on fl ange.
(6) Rotate pi ni on gear a mi ni mum of ten ti mes and
veri fy pi ni on rotates smoothl y.
(7) Record pi ni on gear rotati ng torque wi th a
torque wrench for i nstal l ati on reference.
(8) Remove pi ni on nut and washer. Usi ng a short
pi ece of pi pe and Spanner Wrench 6958 to hol d the
pi ni on compani on fl ange.
C-452 and Fl ange Wrench C-3281.
(10) Remove pi ni on shaft seal wi th Remover
7794-A and sl i de hammer (Fi g. 35).
(11) Remove front pi ni on beari ng usi ng a pai r of
pi ck tool s to pul l the beari ng strai ght off pi ni on
shaft.
NOTE: If bearing becomes bound on the pinion
shaft, lightly tap the end of the pinion gear with a
rawhide/rubber mallet.
(12) Remove the col l apsi bl e spacer.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft.
(2) I nstal l pi ni on front beari ng.
(4) I nstal l pi ni on compani on fl ange wi th I nstal l er
W-162-D, Cup 8109 and Fl ange Hol der 6958.
(5) I nstal l pi ni on washer and a new nut on the
pi ni on gear. Ti ghten the nut to 298 Nm (220 ft. l bs.)
mi ni mum. Do not overtighten. Maxi mum torque i s
500 Nm (368 ft. l bs.).
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(6) Usi ng Spanner Wrench 6958, a l ength of 1 i n.
pi pe and a torque wrench set at 500 Nm (368 ft. l bs.)
crush col l apsi bl e spacer unti l beari ng end pl ay i s
taken up (Fi g. 37).
(7) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l the requi red rotati ng torque i s
achi eved. Measure the rotati ng torque frequentl y to
avoi d over crushi ng the col l apsi bl e spacer.
veri fy pi ni on rotates smoothl y. Check rotati ng torque
wi th an i nch pound torque wrench. The rotati ng
torque shoul d be the amount recorded duri ng
removal pl us:
Ori gi nal Beari ngs: 0.56 Nm (5 i n. l bs.).
Fig. 35 PINION SEAL PULLER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 36 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
New Beari ngs: 1.7 to 3.4 Nm (15 to 30 i n. l bs.).
(9) I nstal l propel l er shaft wi th reference marks
al i gned.
(11) Add gear l ubri cant i f necessary.
DIFFERENTIAL
REMOVAL
(2) Remove l ubri cant fi l l hol e pl ug from the di ffer-
enti al housi ng cover.
(3) Remove di fferenti al cover and drai n l ubri cant.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Never use water,
steam, kerosene or gasoline for cleaning.
(5) Remove hub beari ngs and axl e shafts.
(6) Note i nstal l ati on reference l etters stamped on
the beari ng caps and housi ng machi ned seal i ng sur-
face (Fi g. 38).
(7) Loosen the di fferenti al beari ng cap bol ts.
(8) Posi ti on Spreader W-129-B wi th Adapter Ki t
6987B on di fferenti al l ocati ng hol es (Fi g. 39). I nstal l
hol d down cl amps and ti ghten the tool turnbuckl e
fi nger-ti ght.
Fig. 37 PINION COMPANION FLANGE
1 - COMPANION FLNAGE
3 - SPANNER WRENCH
Fig. 38 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
Fig. 39 DIFFERENTIAL SPREADER LOCATION
2 - ADAPTER
3 - HOLD DOWN CLAMPS
4 - SPREADER
5 - TURNBUCKLE
COLLAPSIBLE SPACER (Continued)
(9) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to stud. Load the l ever adapter agai nst the opposi te
si de of the housi ng (Fi g. 40) and zero the i ndi cator.
(10) Spread housi ng enough to remove the di ffer-
enti al case from the housi ng. Measure the di stance
wi th the di al i ndi cator (Fi g. 41).
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could dis-
torted and damaged the housing.
(11) Remove the di al i ndi cator.
(12) Hol d di fferenti al case i n posi ti on and remove
di fferenti al beari ng cap bol ts and caps.
(13) Remove di fferenti al from the housi ng and tag
di fferenti al beari ng cups to ensure l ocati on (Fi g. 42).
(14) Remove di fferenti al case prel oad shi ms from
the axl e housi ng.
(15) Remove spreader from housi ng. Tag di fferen-
ti al beari ng prel oad shi ms to ensure correct l ocati on.
Fig. 40 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 41 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
Fig. 42 DIFFERENTIAL CASE REMOVAL
3 - BEARING CUPS
DIFFERENTIAL (Continued)
DISASSEMBLY
(1) Remove the ri ng gear.
(2) Dri ve out the rol l pi n hol di ng pi ni on gear mate
shaft wi th a hammer and punch (Fi g. 43).
(3) Remove pi ni on gear mate shaft from the di ffer-
enti al case and the pi ni on mate gears.
(4) Rotate di fferenti al si de gears and remove the
pi ni on mate gears and thrust washers (Fi g. 44).
(5) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l pi ni on mate gears and thrust washers.
(3) I nstal l pi ni on gear mate shaft. Al i gn the rol l
pi n hol es i n shaft and the di fferenti al case.
(4) I nstal l the rol l pi n i n the di fferenti al case (Fi g.
45).
(5) I nstal l the ri ng gear.
(6) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
Fig. 43 MATE SHAFT ROLL PIN
1 - PUNCH
2 - LOCKPIN
3 - MATE SHAFT
Fig. 44 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 45 MATE SHAFT ROLL PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
6987B on di fferenti al l ocati ng hol es. I nstal l hol d
down cl amps and ti ghten the tool turnbuckl e fi nger-
ti ght.
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng (Fi g.
46). Make sure the di fferenti al beari ng cups remai n
on the beari ngs and the prel oad shi ms remai n
between the face of the beari ng cup and housi ng. Tap
the di fferenti al case to ensure the beari ngs cups and
shi ms are ful l y seated i n the housi ng.
CAUTION: On a Vari-lok differential the oil feed
tube must be pointed at the bottom of the housing.
If differential is installed with the oil feed tube
pointed at the top, the anti-rotation tabs will be
damaged.
(6) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 47).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 61 Nm (45 ft.
l bs.).
(10) I nstal l the hub beari ngs and axl e shafts.
3 - BEARING CUPS
Fig. 47 Bearing Cap Reference
(11) Appl y a bead 6.35mm (1/4 i nch) of red Mopar
Si l i cone Rubber Seal ant or equi val ent to the housi ng
cover (Fi g. 48).
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(12) I nstal l di fferenti al cover and ti ghten cover
bol ts i n a cri ss-cross pattern to 41 Nm (30 ft. l bs.).
(13) Fi l l di fferenti al wi th gear l ubri cant to bottom
of the fi l l pl ug hol e.
(14) Ti ghten fi l l pl ug to 34 Nm (25 ft. l bs.).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from housi ng.
(2) Remove beari ngs from the di fferenti al case
wi th Pul l er C-293-PA, Adapters 8352 and Pl ug
SP-3289 (Fi g. 49).
INSTALLATION
NOTE: If replacement differential side bearings or
differential case are being installed, differential side
bearing shim requirements may change. Refer to
CAUTION: Vari-lok plenum must be fully seated
against the differential case prior to installing the
ring gear side differential bearing.
(1) I nstal l di fferenti al si de beari ngs wi th Handl e
C-4171 and I nstal l er C-3726-A (Fi g. 50).
(2) I nstal l di fferenti al i n housi ng.
Fig. 48 DIFFERENTIAL COVER
1 - COVER
2 - SEALANT
3 - SEALANT BEAD
Fig. 49 DIFFERENTIAL CASE BEARING
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Nevar replace one gear without replac-
ing the other matching gear.
(1) Rai se and support vehi cl e
(2) Mark pi ni on compani on fl ange and propel l er
shaft for i nstal l ati on al i gnment.
(3) Remove propel l er shaft from pi ni on compani on
fl ange and ti e propel l er shaft to underbody.
(4) Remove di fferenti al from axl e housi ng.
(5) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw (Fi g. 51).
(6) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
NOTE: On Veri-Lok differential the side bearing
and oil feed plenum must be removed before
removing the ring gear bolts.
(7) Dri ver ri ng gear off the di fferenti al case wi th a
rawhi de hammer (Fi g. 51).
(8) Wi th Spanner Wrench 6958 and a short l ength
of 1 i n. pi pe, hol d pi ni on compani on fl ange and
remove pi ni on nut and washer (Fi g. 52).
(9) Remove pi ni on compani on fl ange from pi ni on
shaft wi th Remover C-452 and Fl ange Wrench
C-3281.
Fig. 50 DIFFERENTIAL CASE BEARING
1 - INSTALLER
2 - HANDLE
Fig. 51 RING GEAR
2 - RING GEAR
3 - HAMMER
Fig. 52 Pinion Flange
1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH
DIFFERENTIAL CASE BEARINGS (Continued)
(10) Remove pi ni on gear and col l apsi bl e spacer
from housi ng (Fi g. 53).
(11) Remove front pi ni on beari ng cup, beari ng, oi l
sl i nger and pi ni on seal wi th Remover D-158 and
Handl e C-4171 (Fi g. 54).
(12) Remove rear pi ni on beari ng cup (Fi g. 55) wi th
Remover C-4307 and Handl e C-4171.
(13) Remove col l apsi bl e prel oad spacer from pi ni on
gear (Fi g. 56).
(14) Remove rear pi ni on beari ng from the pi ni on
wi th Pul l er/Press C-293-PA and Adapters C-293-42
(Fi g. 57). Remove oi l sl i nger/pi ni on depth shi m from
the pi ni on shaft and record thi ckness.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and the pinion head to
achieve proper ring and pinion gear mesh. If ring
and pinion gears are reused, the pinion oil slinger/
depth shim should not require replacement. Refer
to Adujstments (Pinion Gear Depth) to select the
proper thickness shim before installing pinion gear.
(1) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of pi ni on beari ng cups.
(2) I nstal l rear beari ng cup wi th I nstal l er C-4308
and Handl e C-4171 and veri fy cup i s seated (Fi g. 58).
(3) I nstal l beari ng cup wi th I nstal l er D-144 and
Handl e C-4171 (Fi g. 59) and veri fy cup i s seated.
(4) I nstal l front pi ni on beari ng, and oi l sl i nger i f
equi pped.
Fig. 53 REMOVE PINION GEAR
1 - RAWHIDE HAMMER
Fig. 54 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 55 REAR PINION BEARING CUP
1 - REMOVER
2 - HANDLE
PINION GEAR/RING GEAR (Continued)
Fig. 56 COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
Fig. 57 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
l i p of pi ni on seal and i nstal l seal wi th an appropri ate
(6) I nstal l rear pi ni on beari ng and oi l sl i nger/depth
shi m onto the pi ni on shaft wi th I nstal l er 6448 and a
press (Fi g. 61).
(7) I nstal l a new col l apsi bl e spacer on pi ni on shaft
and i nstal l the pi ni on i nto the housi ng (Fi g. 62).
(8) I nstal l pi ni on compani on fl ange, wi th I nstal l er
W-162-B, Cup 8109 and Spanner Wrench 6958.
(9) I nstal l pi ni on washer and a new nut onto the
pi ni on gear and ti ghten the nut to 298 Nm (220 ft.
l bs.). Do not over-tighten.
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified
preload torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(10) Use Fl ange Wrench 6958, a l ength of 1 i n.
pi pe and a torque wrench set at 500 Nm (368 ft. l bs.)
and crush col l apsi bl e spacer unti l beari ng end pl ay i s
taken up (Fi g. 63).
(11) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l b.)
i ncrements unti l the requi red rotati ng torque i s
achi eved. Measure the rotati ng torque frequentl y to
avoi d over crushi ng the col l apsi bl e spacer (Fi g. 64).
(12) Rotate the pi ni on a mi ni mum of ten ti mes.
Veri fy pi ni on rotates smoothl y and check rotati ng
torque wi th an i nch pound torque wrench (Fi g. 64).
Pi ni on gear rotati ng torque i s:
Ori gi nal Beari ngs: 1 to 2.25 Nm (10 to 20 i n.
l bs.).
(13) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
Fig. 60 PINION SEAL
1 - HANDLE
2 - INSTALLER
1 - INSTALLER
2 - OIL SLINGER
3 - PINION GEAR
4 - REAR PINION BEARING
5 - PRESS
Fig. 62 COLLAPSIBLE PRELOAD SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
(14) I nvert the di fferenti al case i n the vi se.
(15) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 108 Nm (80 ft. l bs.) (Fi g. 65).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
NOTE: If equipped with Veri-Lok differential install
oil feed plenum and side bearing.
(16) I nstal l di fferenti al i n housi ng and veri fy di f-
ferenti al beari ng prel oad, gear mesh and contact pat-
tern. Refer to Adjustment for procedure.
(17) I nstal l di fferenti al cover and fi l l wi th gear
l ubri cant.
al i gned.
(19) Remove supports and l ower vehi cl e.
Fig. 63 Pinion Nut
1 - PINION FLANGE
2 - FRONT AXLE
3 - SPANNER WRENCH
Fig. 64 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE/FLANGE
Fig. 65 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
REAR AXLE - 198RBI
TABLE OF CONTENTS
page page
REAR AXLE - 198RBI
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 56
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 65
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 66
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
AXLE BEARINGS/SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 77
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
DIFFERENTIAL-TRAC-LOC
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 79
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86
REAR AXLE - 198RBI
DESCRIPTION
The Rear Beam-desi gn I ron (RBI ) axl e housi ng has
an i ron center casti ng wi th axl e shaft tubes extend-
i ng from ei ther si de. The tubes are pressed i nto and
wel ded to the di fferenti al housi ng to form a one-pi ece
axl e housi ng. The axl es has semi -fl oati ng axl e shafts,
meani ng that l oads are supported by the axl e shaft
and beari ngs. The axl e shafts are retai ned by beari ng
retai ner pl ates on the axl es whi ch are bol ted to
fl anges at the outboard end of the axl e tubes.
The di fferenti al case i s a one-pi ece desi gn. Di ffer-
enti al beari ng prel oad and ri ng gear backl ash i s
adjusted by the use of sel ecti ve spacer shi ms. Pi ni on
beari ng prel oad i s set and mai ntai ned by the use of a
col l apsi bl e spacer. A di fferenti al cover provi des a
means for i nspecti on and servi ce.
Axl es wi th opti onal Trac-Lok di fferenti al have a
one-pi ece di fferenti al case, and the same i nternal
components as a standard di fferenti al , pl us two
cl utch di sc packs.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
3 - 50 REAR AXLE - 198RBI WJ
TRAC-LOK DIFFERENTIAL
Thi s di fferenti al s cl utches are engaged by two con-
current forces. The fi rst bei ng the prel oad force
exerted through Bel l evi l l e spri ng washers wi thi n the
cl utch packs. The second i s the separati ng forces gen-
erated by the si de gears as torque i s appl i ed through
the ri ng gear (Fi g. 3).
Thi s desi gn provi des the di fferenti al acti on needed
for turni ng corners and for dri vi ng strai ght ahead
duri ng peri ods of unequal tracti on. When one wheel
l ooses tracti on, the cl utch packs transfer addi ti onal
torque to the wheel havi ng the most tracti on. Thi s
di fferenti al resi st wheel spi n on bumpy roads and
provi de more pul l i ng power when one wheel l ooses
tracti on. Pul l i ng power i s provi ded conti nuousl y unti l
both wheel s l oose tracti on. I f both wheel s sl i p due to
unequal tracti on, Trac-l ok operati on i s normal . I n
extreme cases of di fferences of tracti on, the wheel
wi th the l east tracti on may spi n.
GEAR NOISE
gears, or the carri er housi ng not havi ng the proper
ti on, decel erati on, coast, or constant l oad.
Fig. 1 STRAIGHT AHEAD DRIVING
1 - WHEELS ROTATE AT CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
Fig. 2 DIFFERENTIAL ON TURNS
Fig. 3 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
WJ REAR AXLE - 198RBI 3 - 51
REAR AXLE - 198RBI (Continued)
greatl y:
Gear damage.
BEARING NOISE
noi se can be ei ther a whi ni ng, or a growl i ng sound.
source.
LOW SPEED KNOCK
U-joi nt or by worn si degear thrust washers. A worn
VIBRATION
caused by a:
Worn U-joi nt(s).
Check for l oose or damaged front-end components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
TESTI NG)
DRIVELINE SNAP
Worn U-joi nts.
DIAGNOSTIC CHART
necessary.
as necessary.
gear bearings.
pre-load.
surfaces.
necessary.
properly.
and quantity.
and quantity.
wheel/tire.
level.
cover.
damage.
adjustment.
contact pattern.
pinion.
pre-load.
bolts.
VARI-LOK
posi ti on.
off of the ground.
di recti ons.
REMOVAL
secure axl e.
(4) Remove brake cal i pers and rotors.
(5) Di sconnect parki ng brake cabl es from brackets
and l ever.
(6) Remove wheel speed sensors.
(7) Remove brake hose at the axl e juncti on bl ock.
Do not di sconnect the brake hydraul i c l i nes at the
cal i pers.
tube.
(9) Mark propel l er shaft and yokes for i nstal l ati on
reference.
(11) Di sconnect stabi l i zer bar l i nks.
(12) Remove upper suspensi on arm rear axl e bal l
joi nt nut.
(13) Separate rear axl e bal l joi nt from the upper
suspensi on arm wi th Remover 8278 (Fi g. 4).
(14) Di sconnect shock absorbers from axl e.
(16) Di sconnect l ower suspensi on arms from the
axl e brackets.
(17) Separate the axl e from the vehi cl e.
INSTALLATION
track bar fasteners are tightened. If springs are not
at their normal ride position, vehicle ride height and
(1) Rai se axl e wi th l i ft and al i gn coi l spri ngs.
(2) I nstal l l ower suspensi on arms i n axl e brackets.
I nstal l nuts and bol ts, do not ti ghten bol ts at thi s
ti me.
(3) I nstal l upper suspensi on arm on rear axl e bal l
joi nt.
(4) I nstal l rear axl e bal l joi nt nut and ti ghten to
122 Nm (90 ft.l bs.) (Fi g. 5).
(5) I nstal l track bar and attachment bol ts, do not
ti ghten bol ts at thi s ti me.
(6) I nstal l shock absorbers and ti ghten nuts to 60
Nm (44 ft. l bs.).
(7) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
36 Nm (27 ft. l bs.).
(8) I nstal l wheel speed sensors.
(9) Connect parki ng brake cabl e to brackets and
l ever.
(11) I nstal l the brake hose to the axl e juncti on
bl ock.
(12) I nstal l axl e vent hose.
(13) Al i gn propel l er shaft and pi ni on yoke refer-
ence marks. I nstal l U-joi nt straps and nuts ti ghten to
19 Nm (14 ft. l bs.).
(14) I nstal l the wheel s and ti res.
(15) Add gear l ubri cant, i f necessary.
(17) Ti ghten l ower suspensi on arm bol ts to 177
Nm (130 ft. l bs.).
(18) Ti ghten track bar bol ts to 100 Nm (74 ft.
l bs.).
ADJUSTMENTS
pi ni on gear are etched i nto the face of each gear (Fi g.
6). A pl us (+) number, mi nus () number or zero (0) i s
etched i nto the face of the pi ni on gear. Thi s number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched wi th a (0). The standard setti ng from the cen-
ter l i ne of the ri ng gear to the back face of the pi ni on
i s 96.850 mm (3.813 i n.). The standard depth pro-
vi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s paragraph i n
thi s secti on for addi ti onal i nformati on.
Fig. 4 REAR BALL JOINT
1 - REMOVER
3 - BALL JOINT STUD
Fig. 5 REAR BALL JOINT NUT
2 - REAR AXLE BALL JOINT
3 - REAR AXLE
achi eved wi th a sel ect shi m. The shi ms are pl aced
between the rear pi ni on beari ng and the pi ni on gear
head (Fi g. 7).
essary.
Original Pinion
Gear Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 7 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
3 - RING GEAR
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 8).
(Fi g. 8).
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 10).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 6732 has different step diame-
being serviced.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n the housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock (Fi g. 8). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator face to the poi nter. Ti ghten
di al i ndi cator face l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
Fig. 8 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
1 - PINION BLOCK
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 11). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the pi ni on depth vari ance number etched i n
the face of the pi ni on (Fi g. 6). For exampl e, i f the
depth vari ance i s 2, add +0.002 i n. to the di al i ndi -
cator readi ng.
DIFFERENTIAL
di fferenti al cas beari ng cups. The proper shi m thi ck-
ness can be determi ned usi ng sl i p-fi t Dummy Bear-
i ngs D-348 i n pl ace of the di fferenti al si de beari ngs
and a Di al I ndi cator C-3339. Before proceedi ng wi th
the di fferenti al beari ng prel oad and gear backl ash
measurements, measure the pi ni on gear depth and
prepare the pi ni on for i nstal l ati on. Establ i shi ng
are performed wi th the spreader W-129-B removed.
PRELOAD SHIM SELECTION
enti al case.
(3) I nstal l Dummy Beari ngs D-348 on di fferenti al
case.
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 12 SHIM LOCATIONS
3 - RING GEAR
(5) Record the thi ckness of Dummy Shi ms 8107.
I nsert the shi ms between the dummy beari ngs and
the di fferenti al housi ng (Fi g. 13).
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts (Fi g. 14).
(7) Usi ng a dead-bl ow type hammer seat the di ffer-
enti al dummy beari ngs to each si de of the housi ng
(Fi g. 15) and (Fi g. 16).
Fig. 13 SHIM POINT
1 - DUMMY SHIM
4 - DUMMY BEARINGS
Fig. 14 BEARING CAP BOLTS
1 - BEARING CAP
Fig. 15 SEAT PINION SIDE BEARING
1 - MALLET
Fig. 16 SEAT RING GEAR SIDE BEARING
2 - MALLET
(9) Attach a Di al I ndi cator C-3339 to pi l ot stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
between the ri ng gear bol t heads (Fi g. 17).
(Fi g. 19).
(12) Add 0.152 mm (0.006 i n.) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
pi l ot stud.
from the housi ng.
(15) I nstal l the pi ni on gear i n axl e housi ng. I nstal l
rotati ng torque.
D-348 i n the housi ng.
surface between the ri ng gear bol t heads. (Fi g. 17).
(Fi g. 21). Add dummy shi m thi ckness to thi s readi ng.
Thi s wi l l be the total shi m thi ckness to achi eve zero
backl ash.
(23) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
Fig. 17 DIFFERENTIAL SIDE PLAY
3 - PILOT STUD
4 - DIAL INDICATOR
2 - PILOT STUD
3 - DIAL INDICATOR
4 - ZERO DIAL INDICATOR FACE
Fig. 19 DIFFERENTIAL TO RING GEAR SIDE
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
the shi m thi ckness requi red on the pi ni on si de of the
housi ng.
stud.
from the housi ng.
case.
(27) I nstal l spreader W-129-B uti l i zi ng some i tems
from Adapter Set 6987, on the housi ng and spread
axl e openi ng enough to recei ve di fferenti al case.
CAUTION: Never spread over 0.38 mm (0.015 in.). If
housing is over-spread, it could be distorted or
damaged.
(28) Pl ace the beari ng prel oad shi ms i n the hous-
i ng, agai nst the axl e tubes.
(30) Remove spreader from the housi ng.
(31) I nstal l di fferenti al beari ng caps i n thei r ori gi -
nal l ocati ons.
(32) I nstal l beari ng cap bol ts and ti ghten to 77
Nm (57 ft. l bs.).
readi ng shoul d be between 0.12-0.20 mm (0.005-0.008
i n.). I f backl ash i s not wi thi n speci fi cati ons transfer
the necessary amount of shi m thi ckness from one
si de of the axl e housi ng to the other (Fi g. 23).
Gear Contact Pattern Anal ysi s procedure.
3 - PINION GEAR
Fig. 21 DIFFERENTIAL TO RING GEAR SIDE
1 - DIAL INDICATOR
3 - PINION GEAR
Fig. 22 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
teeth.
tern.
shop towel .
24) and adjust pi ni on depth and gear backl ash as
necessary.
Fig. 23 BACKLASH SHIM
Fig. 24 GEAR TOOTH CONTACT PATTERNS
(7-11 i n. l bs.).
SPECIFICATIONS
AXLE SPECIFICATIONS
Axle Ratio 3.07, 3.31, 3.55, 3.73, 4.11
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Bearing Preload - New Bearings 1.7-3.9 Nm (15-35 in. lbs.)
Ring Gear Bolts 129-142 95-105 -
Pinion Nut Minimum 272 200 -
Pinion Mate Shaft Screw 16.25 12 -
Axle Bearing Retainer Plate
Nuts
61 45 -
SPECIAL TOOLS
PULLER C-293-PA
ADAPTER 8352
ADAPTER C-293-40
PLUG SP-3289
Puller C-452
Wrench C-3281
Spanner Wrench 6958
INSTALLER 8112
CUP 8109
HANDLE C-4171
INSTALLER C-3716-A
INSTALLER D-130
INSTALLER D-146
REMOVER C-4345
REMOVER D-149
INSTALLER W-262
PINION DEPTH 6774
TRAC-LOK TOOLS 6960
FIXTURE 6965
SHIMS DUMMY 8107
SPREADER W-129-B
ADAPTER KIT 6987
PILOT STUDS C-3288-B
PULLER 6790
DIAL INDICATOR C-3339
SPLITTER BEARING 1130
INSTALLER 7913-A
AXLE SHAFTS
REMOVAL
(1) Pl ace transmi ssi on i n neutral .
(3) Remove wheel and ti re assembl y.
(4) Remove brake cal i per and rotor.
(5) Remove nuts hol di ng axl e retai ner pl ate to axl e
tube from the rear of the axl e fl ange.
(6) Pul l axl e shaft from the axl e wi th Sl i de Ham-
mer 7420 and Adapter 6790. Mount the adapter to
the axl e wi th l ug nuts.
NOTE: The axle bearing race is normally loose in
the axle tube.
INSTALLATION
(1) I nsal l axl e i nto the axl e tube wi th the fl at area
of the retai ner pl ate upward.
(2) I nsert retai ni ng pl ate studs i nto the brake
backi ng pl ate and axl e tube fl ange.
(3) I nstal l retai ner nuts and ti ghten nuts to 61
Nm (45 ft. l bs.).
(4) I nstal l the brake rotor and cal i per.
(5) I nstal l wheel and ti re.
(6) Check and fi l l the di fferenti al wi th gear l ubri -
cant.
AXLE BEARINGS/SEALS
REMOVAL
(1) Remove axl e shaft from vehi cl e.
the axle tube.
(2) Dri l l a shal l ow hol e i nto soft steel axl e beari ng
retai ni ng ri ng wi th a 3/8 i n. dri l l bi t (Fi g. 25). Use a
dri l l depth stop to avoi d marki ng the axl e.
(3) Wi th a col d chi sel cut the retai ni ng ri ng across
dri l l ed hol e. (Fi g. 26)
(4) Sl i de retai ni ng ri ng from axl e shaft.
Fig. 25 DRILL RETAINING RING
1 - DRILL BIT
2 - AXLE
3 - RETAINING PLATE
4 - RETAINING RING
Fig. 26 RETAINING RING
1 - AXLE
2 - COLD CHISEL
3 - VISE
4 - RETAINING RING
(5) Remove axl e beari ng from the shaft wi th, a
press and Spl i tter 1130 pl aced between the seal and
beari ng (Fi g. 27).
(6) Remove seal from axl e.
(7) Remove retai ni ng pl ate from axl e shaft.
INSTALLATION
(1) Veri fy axl e shaft retai ni ng pl ate i s fl at wi th a
strai ght edge.
NOTE: If the plate is warped or the studs are loose
in the plate replace the retaining plate.
(2) I nstal l retai ni ng pl ate on the axl e shaft (Fi g.
28).
(3) Appl y a coat of mul ti -purpose grease on seal i ng
surface of axl e seal .
(4) I nstal l seal on the axl e shaft wi th cavi ty away
from retai ni ng pl ate (Fi g. 28).
(5) Lubri cate beari ng wi th Mopar Wheel Beari ng
Grease or equi val ent. Wi pe excess grease from the
beari ng.
(6) I nstal l beari ng on the axl e shaft wi th I nstal l er
7913 and a press (Fi g. 29).
Fig. 27 AXLE BEARING AND SEAL
1 - SPLITTER
2 - AXLE
3 - BLOCKS
4 - PRESS PLATES
Fig. 28 AXLE BEARING AND SEAL COMPONENTS
1 - RETAINING RING
2 - SEAL
3 - AXLE
4 - RETAINING PLATE
5 - AXLE BEARING
Fig. 29 PRESS BEARING ON AXLE
1 - PRESS RAM
2 - INSTALLER
3 - AXLE BEARING
4 - SEAL
5 - RETAINING PLATE
6 - AXLE
AXLE BEARINGS/SEALS (Continued)
(7) Press metal retai ni ng ri ng onto axl e shaft wi th
I nstal l er 7913 and a press (Fi g. 30).
(8) I nstal l axl e i n vehi cl e.
PINION SEAL
REMOVAL
(4) Mark propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove propel l er shaft from the yoke.
(7) Record rotati ng torque of the pi ni on gear wi th
an i nch pound di al -type torque wrench, for i nstal l a-
ti on reference.
(8) Hol d the pi ni on yoke wi th Spanner Wrench
6958 and remove the pi ni on nut and washer (Fi g.
31).
(9) Remove pi ni on yoke wi th Remover C-452 and
Wrench C-3281 (Fi g. 32).
(10) Remove pi ni on gear seal wi th Remover
7794-A and sl i de hammer (Fi g. 33).
INSTALLATION
(2) I nstal l yoke on pi ni on gear wi th Screw 8112,
Cup 8109 and Spanner Wrench 6958 (Fi g. 35).
CAUTION: Do not exceed the minimum tightening
torque 271 Nm (200 ft. lbs.) when installing the pin-
ion yoke at this point. Damage to the collapsible
spacer or bearings may result.
(3) I nstal l yoke washer and a new nut on the pi n-
i on gear and ti ghten the nut unti l there i s zero bear-
i ng end-pl ay.
Fig. 30 BEARING RETAINING RING
1 - PRESS
2 - AXLE
3 - AXLE BEARING
4 - INSTALLER
5 - METAL RETAINING RING
Fig. 31 PINION YOKE HOLDER
1 - PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
4 - LOWER CONTROL ARM
Fig. 32 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - YOKE PULLER
(4) Ti ghten the nut to 271 Nm (200 ft. l bs.).
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be
installed.
(5) Rotate the pi ni on gear a mi ni mum of ten ti mes
and veri fy pi ni on rotates smoothl y. Rotate pi ni on
shaft an i nch pound torque wrench. Rotati ng torque
shoul d be equal to recorded readi ng pl us an addi -
ti onal 0.56 Nm (5 i n. l bs.) (Fi g. 36).
Fig. 33 PINION SEAL
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 34 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 35 PINION YOKE
1 - PINION YOKE
1 - TORQUE WRENCH
2 - PINION YOKE
(6) I f the rotati ng torque i s l ow, use Spanner
Wrench 6958 to hol d the pi ni on yoke (Fi g. 37), and
ti ghten the pi ni on nut i n 6.8 Nm (5 ft. l bs.) i ncre-
ments unti l the proper rotati ng torque i s achi eved.
CAUTION: If maximum tightening torque is reached
prior to reaching required rotating torque, the col-
lapsible spacer may have been damaged. Replace
the collapsible spacer.
(7) I nstal l the propel l er shaft wi th reference marks
al i gned.
(8) Add gear l ubri cant to the di fferenti al i f neces-
sary.
COLLAPSIBLE SPACER
REMOVAL
(3) Remove rear brake cal i pers and rotors.
i nstal l ati on reference and remove propel l er shaft.
(6) Record rotate torque of the pi ni on gear, wi th an
i nch pound torque wrench.
(7) Hol d pi ni on yoke wi th Spanner Wrench 6958
and remove pi ni on nut and washer (Fi g. 38).
(9) Remove pi ni on shaft seal wi th Remover 7794-A
and sl i de hammer (Fi g. 40).
(10) Remove front pi ni on beari ng usi ng a pai r of
pi ck tool s to pul l the beari ng off the pi ni on gear
shaft.
NOTE: If the pinion bearing becomes bound on the
pinion shaft, lightly tap the end of the shaft with a
INSTALLATION
(1) I nstal l a new col l apsi bl e spacer on pi ni on
shaft.
(2) I nstal l pi ni on front beari ng on the pi ni on shaft.
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
1 - 1 in. PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 39 PINION YOKE PULLER
1 - WRENCH
2 - PINION YOKE
3 - PULLER
(4) I nstal l yoke wi th Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fi g. 42).
(5) I nstal l yoke washer and new nut on the pi ni on
gear. Ti ghten the nut to 271 Nm (200 ft. l bs.).
installed.
(6) Usi ng yoke wi th Spanner Wrench 6958 and a
torque wrench set at 474 Nm (350 ft. l bs.), (Fi g. 43)
sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.) i ncre-
ments unti l the rotati ng torque i s achi eved. Measure
the rotati ng torque frequentl y to avoi d over crushi ng
the col l apsi bl e spacer (Fi g. 44).
NOTE: If more than 474 Nm (350 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
Fig. 40 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 42 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 43 PINION NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
(7) Check rotati ng torque wi th an i nch pound
torque wrench (Fi g. 44). The rotati ng torque of the
pi ni on gear shoul d be, the readi ng recorded duri ng
removal pl us an addi ti onal 0.56 Nm (5 i n. l bs.).
al i gn.
(9) I nstal l rear brake cal i pers and rotors (Refer to
5 - BRAKES/HYDRAULI C/MECHANI CAL/ROTORS
- I NSTALLATI ON).
DIFFERENTIAL
REMOVAL
(2) Remove fi l l hol e pl ug from the di fferenti al
housi ng cover.
(3) Remove di fferenti al housi ng cover and drai n
fl ui d.
(4) Cl ean the housi ng cavi ty wi th fl ushi ng oi l , l i ght
engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
(6) Note the reference l etters stamped on the beari ng
caps and housi ng machi ned seal i ng surface (Fi g. 45).
hol ddown cl amps and ti ghten the turnbuckl e fi nger-
ti ght.
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 45 BEARING CAP REFERENCE
Fig. 46 SPREADER LOCATION
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
opposi te si de of the housi ng (Fi g. 47) and zero the
i ndi cator.
(12) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
di fferenti al beari ng cups to i ndi cate l ocati on (Fi g. 49).
(14) Remove spreader from housi ng.
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
1 - DIAL INDICATOR
2 - SPREADER
3 - BEARING CUPS
DISASSEMBLY
(1) Remove pi ni on shaft l ock screw (Fi g. 50).
(2) Remove pi ni on shaft.
(3) Rotate di fferenti al si de gears and remove di f-
ferenti al pi ni ons and thrust washers (Fi g. 51).
washers.
ASSEMBLY
ers.
(2) I nstal l di fferenti al pi ni on gears and thrust
washers.
(3) I nstal l the pi ni on mate shaft.
(4) Al i gn hol e i n the pi ni on mate shaft wi th the
hol e i n the di fferenti al case and i nstal l the pi ni on
mate shaft l ock screw.
INSTALLATION
bearing shim requirements may change. Refer
(1) Posi ti on Spreader W-129-B wi th Adapter set
6987 on di fferenti al housi ng l ocati ng hol es. I nstal l
the hol ddown cl amps and ti ghten the tool turnbuckl e
fi nger-ti ght.
(0.015 in). If housing is over-spread, it could be dis-
torted or damaged.
(3) Spread housi ng enough to i nstal l the case i n
the housi ng.
(5) I nstal l di fferenti al case i n housi ng (Fi g. 52).
Veri fy di fferenti al beari ng cups remai n i n posi ti on on
the beari ngs and prel oad shi ms are between the face
of the beari ng cup and the housi ng. Tap the di fferen-
ti al case to ensure beari ngs cups and shi ms are
seated i n the housi ng.
tube must be pointed at the bottom of the housing
(Fig. 53). If differential is installed with the oil feed
tube pointed at the top, the anti-rotation tabs will be
damaged.
(6) I nstal l beari ng caps i n thei r ori gi nal l ocati ons
(Fi g. 54).
(9) Ti ghten beari ng cap bol ts i n a cri ss-cross pat-
tern to 77 Nm (57 ft. l bs.).
(10) I nstal l the axl e shafts.
Fig. 50 SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 51 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
(11) Appl y a 6.35mm (1/4 i n.) bead of red Mopar
cover (Fi g. 55).
2 - DOWEL
4 - SPREADER
5 - TURNBUCKLE
Fig. 53 VARI-LOK
1 - ANTI-ROTATION TAB
2 - OIL FEED TUBE
Fig. 55 DIFFERENTIAL COVER - TYPICAL
1 - COVER
2 - SEALANT
3 - SEALANT BEAD
(12) I nstal l cover and ti ghten bol ts i n a cri ss-cross
pattern to 41 Nm (30 ft. l bs.).
(13) Refi l l the di fferenti al wi th Mopar Hypoi d
Gear Lubri cant or equi val ent to bottom of the fi l l
pl ug hol e.
(14) I nstal l fi l l hol e pl ug.
DIFFERENTIAL-TRAC-LOC
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. A contai ner of Mopar Trac-l ok Lubri cant
(fri cti on modi fi er) shoul d be added after repai r ser-
vi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 56).
(6) I f rotati ng torque i s l ess than 41 Nm (56 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
DISASSEMBLY
(1) Cl amp si de gear Hol di ng Fi xture 6965 i n a vi se
and posi ti on the di fferenti al case on the Hol di ng Fi x-
ture (Fi g. 57).
Fig. 56 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 57 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
(2) Remove ri ng gear i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(3) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 58).
(4) Remove pi ni on gear mate shaft wi th a dri ft and
hammer (Fi g. 59).
(5) I nstal l and l ubri cate Step Pl ate C-6960-3 (Fi g.
60).
(6) Assembl e Threaded Adapter C-6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(7) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter Di sc C-6960-1 (Fi g. 61) to prevent
adapter from turni ng.
(8) I nstal l Forci ng Screw C-6960-4 and ti ghten
screw to 122 Nm (90 ft. l bs.) maxi mum to compress
Bel l evi l l e spri ngs i n cl utch packs (Fi g. 62).
(9) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 63).
(10) I nsert Turni ng Bar C-6960-2 i nto the pi ni on
mate shaft hol e i n the case (Fi g. 64).
(11) Loosen the Forci ng Screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and the di f-
ferenti al case can be turned usi ng Turni ng Bar.
(12) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(13) Remove pi ni on gears from di fferenti al case.
(14) Remove Forci ng Screw, Step Pl ate and
Threaded Adapter.
Fig. 58 MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 59 PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
Fig. 60 Step Plate
1 - LOWER SIDE GEAR
3 - STEP PLATE
DIFFERENTIAL-TRAC-LOC (Continued)
Fig. 61 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - STEP PLATE
5 - FORCING SCREW
6 - THREAD ADAPTER DISC
Fig. 62 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
Fig. 63 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 64 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
(15) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 65).
(16) Remove di fferenti al case from the Hol di ng Fi x-
ture. Remove si de gear, cl utch pack retai ner and cl utch
pack. Keep pl ates i n correct order duri ng removal .
CLEANING
Cl ean al l components i n cl eani ng sol vent and dry
components wi th compressed ai r.
INSPECTION
I nspect cl utch pack pl ates for wear, scori ng or dam-
age. Repl ace both cl utch packs i f any one component
i n ei ther pack i s damaged. I nspect si de and pi ni on
gears for cracks chi ps or damage and repl ace as nec-
essary. I nspect di fferenti al case and pi ni on shaft and
repl ace i f worn or damaged.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Lubri cate components wi th gear l ubri cant.
(2) Assembl e cl utch di scs i nto packs and secure
di sc packs wi th retai ni ng cl i ps (Fi g. 66).
NOTE: Dished plate is position with the convex side
against the side gear.
(3) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(4) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 67).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
Fig. 65 SIDE GEARS AND CLUTCH DISCS
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 66 CLUTCH PACK
1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
6 - PLATES
Fig. 67 CLUTCH PACK AND LOWER SIDE GEAR
2 - SIDE GEAR AND CLUTCH PACK
(5) Posi ti on the di fferenti al case on the Hol di ng
Fi xture 6965.
(6) I nstal l l ubri cated Step Pl ate C-6960-3 i n l ower
si de gear (Fi g. 68).
(7) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 68).
(8) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C-6960-1 i nto top si de gear.
screw to sl i ghtl y compress cl utch di sc.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar C-6960-2 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
Threaded Adapter.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(2) Remove di fferenti al case from axl e housi ng.
(3) Remove beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, Adapter 8352 and Pl ug
SP-3289 (Fi g. 69).
Fig. 68 CLUTCH PACK AND UPPER SIDE GEAR
3 - STEP PLATE
Fig. 69 Differential Bearing
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
INSTALLATION
NOTE: If differential side bearings or differential
case are replaced, differential side bearing shim
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-3716-A and Handl e C-4171 (Fi g. 70).
(2) I nstal l di fferenti al i n axl e housi ng.
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without the
other gear.
(2) Mark pi ni on yoke and propel l er shaft for
(3) Di sconnect propel l er shaft from pi ni on yoke
and ti e shaft to underbody.
(4) Remove di fferenti al from the housi ng.
jaw.
case.
(7) Dri ve ri ng gear from di fferenti al case wi th a
6958 and remove the pi ni on yoke nut and washer
(Fi g. 72).
Fig. 70 Differential Side Bearing
1 - INSTALLER
2 - HANDLE
Fig. 71 RING GEAR
2 - RING GEAR
3 - HAMMER
1 - 1 in. PIPE
2 - PINION YOKE
3 - HOLDER
(9) Remove pi ni on yoke from pi ni on shaft wi th
Remover C-452 and Fl ange Wrench C-3281 (Fi g. 73).
(10) Remove pi ni on gear from housi ng (Fi g. 74).
(12) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(13) Remove front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C-4171 (Fi g. 76).
Fig. 73 PINION YOKE REMOVER
1 - FLANGE WRENCH
2 - YOKE
3 - REMOVER
Fig. 74 PINION GEAR REMOVAL
1 - RAWHIDE HAMMER
Fig. 75 PINION SEAL
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
1 - REMOVER
2 - HANDLE
(14) Remove rear beari ng cup (Fi g. 77) wi th
Remover D-149 and Handl e C-4171.
(15) Remove col l apsi bl e prel oad spacer (Fi g. 78).
(16) Remove rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-40 (Fi g.
79).
(17) Remove depth shi ms from the pi ni on gear
shaft and record shi m thi ckness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
1 - REMOVER
2 - HANDLE
2 - SHOULDER
3 - PINION GEAR
4 - SHIM
5 - REAR BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
to outsi de surface of the pi ni on beari ng cups.
(2) I nstal l pi ni on rear beari ng cup wi th I nstal l er
D-146 and Dri ver Handl e C-4171 (Fi g. 80) and veri fy
cup i s seated.
(3) I nstal l pi ni on front beari ng cup wi th I nstal l er
D-130 and Handl e C-4171 (Fi g. 81) and veri fy cup i s
seated.
(4) I nstal l pi ni on front beari ng and oi l sl i nger, i f
equi pped.
(6) I nstal l depth shi m on the pi ni on gear.
(7) I nstal l rear beari ng and sl i nger i f equi pped, on
the pi ni on gear wi th I nstal l er W-262 and a press
(Fi g. 83).
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
1 - HANDLE
2 - INSTALLER
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
i on shaft and i nstal l pi ni on gear i n the housi ng (Fi g.
84).
(9) I nstal l yoke wi th I nstal l er C-3718 and Spanner
Wrench 6958 (Fi g. 85).
(10) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
installed.
(12) Usi ng Spanner Wrench 6958 and a torque
wrench set at 474 Nm (350 ft. l bs.), (Fi g. 86) sl owl y
ti ghten the nut i n 6.8 Nm (5 ft. l bs.) i ncrements
unti l the rotati ng torque i s achi eved. Measure the
rotati ng torque frequentl y to avoi d over crushi ng the
col l apsi bl e spacer (Fi g. 87).
(13) Check beari ng rotati ng torque wi th a i nch
pound torque wrench (Fi g. 87). The pi ni on gear rotat-
i ng torque shoul d be:
Ori gi nal Beari ngs: 1 to 2.25 Nm (10 to 20 i n.
l bs.).
hol e al i gnment.
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
1 - INSTALLER
2 - PINION YOKE
Fig. 86 PINION NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
ti ghten to 136 Nm (100 ft. l bs.) (Fi g. 88).
(17) I nstal l di fferenti al i n housi ng and veri fy di f-
ferenti al beari ng prel oad, gear mesh and contact pat-
tern. Refer to Ajustments for procedure.
CAUTION: When installing a Vari-lok differential
(Fig. 89), the oil feed tube must point to the bottom
of the housing. If differential is installed with the oil
feed tube pointed toward the top, the anti-rotation
tabs will be damaged.
l ubri cant.
(19) I nstal l the propel l er shaft wi th the reference
marks al i gned.
Fig. 88 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
Fig. 89 VARI-LOK
2 - OIL FEED TUBE
REAR AXLE - 226RBA
TABLE OF CONTENTS
page page
REAR AXLE - 226RBA
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 90
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 97
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 105
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 106
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
AXLE BEARINGS/SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 114
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 117
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 119
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 119
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 121
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
REAR AXLE - 226RBA
DESCRIPTION
The Rear Beam-desi gn Al umi num (RBA) axl e hous-
i ng has an al umi num center casti ng (di fferenti al
housi ng) wi th axl e shaft tubes extendi ng from ei ther
si de. The tubes are pressed i nto the di fferenti al hous-
i ng to form a one-pi ece axl e housi ng. The axl e has
semi -fl oati ng axl e shafts, meani ng that vehi cl e l oad
i s supported by the axl e shaft and beari ngs.
The di fferenti al case i s a one-pi ece desi gn. Di fferen-
ti al beari ng prel oad and ri ng gear backl ash i s adjusted
wi th sel ecti ve shi ms. Pi ni on beari ng prel oad i s set and
mai ntai ned by the use of a col l apsi bl e spacer. The cover
provi des a means for i nspecti on and servi ce.
Opti onal Trac-Lok di fferenti al di fferenti al has a
one-pi ece di fferenti al case, and the same i nternal
components as a standard di fferenti al , pl us two
cl utch di sc packs.
Opti onal Vari -Lok di fferenti al has a one-pi ece di f-
ferenti al case whi ch contai ns the gerotor pump
assembl y and the cl utch mechi ni sm. The uni t i s ser-
vi ced onl y as an assembl y.
OPERATION
The axl e recei ves power from the transfer case
through the front propel l er shaft. The front propel l er
shaft i s connected to the pi ni on gear whi ch rotates
the di fferenti al through the gear mesh wi th the ri ng
gear bol ted to the di fferenti al case. The engi ne power
i s transmi tted to the axl e shafts through the pi ni on
mate and si de gears. The si de gears are spl i ned to
the axl e shafts.
Duri ng strai ght-ahead dri vi ng the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must travel
a greater di stance than the i nsi de wheel to compl ete a
turn. The di fference must be compensated for to prevent
the ti res from scuffi ng and ski ddi ng through turns. To
accompl i sh thi s, the di fferenti al al l ows the axl e shafts
to turn at unequal speeds (Fi g. 2). I n thi s i nstance, the
i nput torque appl i ed to the pi ni on gears i s not di vi ded
equal l y. The pi ni on gears now rotate around the pi ni on
mate shaft i n opposi te di recti ons. Thi s al l ows the si de
gear and axl e shaft attached to the outsi de wheel to
rotate at a faster speed.
3 - 90 REAR AXLE - 226RBA WJ
TRAC-LOK DIFFERENTIAL
The di fferenti al cl utches are engaged by two con-
current forces. The fi rst bei ng the prel oad force
exerted through Bel l evi l l e spri ng washers wi thi n the
cl utch packs. The second i s the separati ng forces gen-
erated by the si de gears as torque i s appl i ed through
the ri ng gear (Fi g. 3).
Thi s desi gn provi des the di fferenti al acti on needed
for turni ng corners and for dri vi ng strai ght ahead
duri ng peri ods of unequal tracti on. When one wheel
l ooses tracti on, the cl utch packs transfer addi ti onal
torque to the wheel havi ng the most tracti on. The
di fferenti al resi st wheel spi n on bumpy roads and
provi de more pul l i ng power when one wheel l ooses
tracti on. Pul l i ng power i s provi ded conti nuousl y unti l
both wheel s l oose tracti on. I f both wheel s sl i p due to
unequal tracti on, the operati on i s normal . I n extreme
cases of di fferences of tracti on, the wheel wi th the
l east tracti on may spi n.
VARI-LOK DIFFERENTIAL
I n a standard di fferenti al , i f one wheel spi ns, the
opposi te wheel wi l l generate onl y as much torque as
the spi nni ng wheel .
A gerotor pump and cl utch pack are used to pro-
vi de the torque transfer capabi l i ty. One axl e shaft i s
spl i ned to the gerotor pump and one of the di fferen-
ti al si de gears, whi ch provi des the i nput to the pump.
As a wheel begi ns to l ose tracti on, the speed di ffer-
enti al i s transmi tted from one si de of the di fferenti al
to the other through the si de gears. The moti on of
one si de gear rel ati ve to the other turns the i nner
rotor of the pump. Si nce the outer rotor of the pump
i s grounded to the di fferenti al case, the i nner and
outer rotors are now movi ng rel ati ve to each other
Fig. 1 OPERATION-STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
Fig. 2 OPERATION-ON TURNS
Fig. 3 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
WJ REAR AXLE - 226RBA 3 - 91
REAR AXLE - 226RBA (Continued)
and therefore creates pressure i n the pump. The tun-
i ng of the front and rear axl e ori fi ces and val ves
i nsi de the gerotor pump i s uni que and each system
i ncl udes a torque-l i mi ti ng pressure rel i ef val ve to
protect the cl utch pack, whi ch al so faci l i tates vehi cl e
control under extreme si de-to-si de tracti on vari a-
ti ons. The resul ti ng pressure i s appl i ed to the cl utch
pack and the transfer of torque i s compl eted.
Under condi ti ons i n whi ch opposi te wheel s are on
surfaces wi th wi del y di fferent fri cti on characteri sti cs,
Vari -l ok del i vers far more torque to the wheel on
the hi gher tracti on surface than do conventi onal
Trac-l ok systems. Because conventi onal Trac-l ok
di fferenti al s are i ni ti al l y pre-l oaded to assure torque
transfer, normal dri vi ng (where i nner and outer
wheel speeds di ffer duri ng corneri ng, etc.) produces
torque transfer duri ng even sl i ght si de-to-si de speed
vari ati ons. Si nce these devi ces rel y on fri cti on from
thi s prel oad to transfer torque, normal use tends to
cause wear that reduces the abi l i ty of the di fferenti al
to transfer torque over ti me. By desi gn, the Vari -l ok
system i s l ess subject to wear, remai ni ng more con-
si stent over ti me i n i ts abi l i ty to transfer torque. The
coupl i ng assembl y i s servi ced as a uni t. From a ser-
vi ce standpoi nt the coupl i ng al so benefi ts from usi ng
the same l ubri cant suppl y as the ri ng and pi ni on
gears.
GEAR NOISE
gears, or the carri er housi ng not havi ng the proper
ti on, decel erati on, coast, or constant l oad.
greatl y:
Gear damage.
BEARING NOISE
noi se can be ei ther a whi ni ng, or a growl i ng sound.
source.
LOW SPEED KNOCK
U-joi nt or by worn si degear thrust washers. A worn
VIBRATION
caused by a:
Worn U-joi nt(s).
Check for l oose or damaged front-end components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
TESTI NG)
DRIVELINE SNAP
Worn U-joi nts.
DIAGNOSTIC CHART
necessary.
as necessary.
gear bearings.
pre-load.
surfaces.
necessary.
properly.
and quantity.
and quantity.
wheel/tire.
level.
cover.
damage.
adjustment.
contact pattern.
pinion.
pre-load.
bolts.
VARI-LOK
posi ti on.
off of the ground.
di recti ons.
REMOVAL
secure axl e.
(5) Di sconnect parki ng brake cabl es from brackets
and l ever.
(6) Remove wheel speed sensors.
(7) Remove brake hose at the axl e juncti on bl ock.
Do not di sconnect the brake hydraul i c l i nes at the
cal i pers.
tube.
(9) Mark propel l er shaft and yokes for i nstal l ati on
reference.
(11) Di sconnect stabi l i zer bar l i nks.
(12) Remove upper suspensi on arm rear axl e bal l
joi nt nut.
(13) Separate rear axl e bal l joi nt from the upper
suspensi on arm wi th Remover 8278 (Fi g. 4).
(14) Di sconnect shock absorbers from axl e.
(16) Di sconnect l ower suspensi on arms from the
axl e brackets.
(17) Separate the axl e from the vehi cl e.
INSTALLATION
track bar fasteners are tightened. If springs are not
at their normal ride position, vehicle ride height and
(1) Rai se axl e wi th l i ft and al i gn coi l spri ngs.
(2) I nstal l l ower suspensi on arms i n axl e brackets.
I nstal l nuts and bol ts, do not ti ghten bol ts at thi s
ti me.
(3) I nstal l upper suspensi on arm on rear axl e bal l
joi nt.
(4) I nstal l rear axl e bal l joi nt nut and ti ghten to
122 Nm (90 ft.l bs.) (Fi g. 5).
(5) I nstal l track bar and attachment bol ts, do not
ti ghten bol ts at thi s ti me.
(6) I nstal l shock absorbers and ti ghten nuts to 60
Nm (44 ft. l bs.).
(7) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
36 Nm (27 ft. l bs.).
(8) I nstal l wheel speed sensors.
(9) Connect parki ng brake cabl e to brackets and
l ever.
(11) I nstal l the brake hose to the axl e juncti on
bl ock.
(12) I nstal l axl e vent hose.
(13) Al i gn propel l er shaft and pi ni on yoke refer-
ence marks. I nstal l U-joi nt straps and nuts ti ghten to
19 Nm (14 ft. l bs.).
(14) I nstal l the wheel s and ti res.
(17) Ti ghten l ower suspensi on arm bol ts to 177
Nm (130 ft. l bs.).
(18) Ti ghten track bar bol ts to 100 Nm (74 ft.
l bs.).
Fig. 4 REAR BALL JOINT
1 - REMOVER
3 - BALL JOINT STUD
Fig. 5 REAR BALL JOINT NUT
2 - REAR AXLE BALL JOINT
3 - REAR AXLE
ADJUSTMENTS
pi ni on gear are etched i nto the face of each gear (Fi g.
6). A pl us (+) number, mi nus () number or zero (0) i s
etched i nto the face of the pi ni on gear. Thi s number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched wi th a (0). The standard setti ng from the cen-
ter l i ne of the ri ng gear to the back face of the pi ni on
i s 109.52 mm (4.312 i n.). The standard depth pro-
vi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern i n thi s secti on for
addi ti onal i nformati on.
achi eved wi th a sel ect shi m/oi l baffl e. The shi ms are
pl aced between the rear pi ni on beari ng and the pi n-
i on gear head (Fi g. 7).
essary.
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
3 - RING GEAR
Original Pinion
Gear Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
measurements wi th Pi ni on Gauge Set 6775 and Di al
I ndi cator C-3339 (Fi g. 8).
(Fi g. 8).
(4) Pl ace Arbor Di sc 6927A on Arbor D-115-3 i n
posi ti on i n the housi ng si de beari ng cradl es (Fi g. 10).
I nstal l di fferenti al beari ng caps i n thei r ori gi nal posi -
ti ons on arbor di scs and ti ghten cap bol ts to 85 Nm
(63 ft. l bs.).
Fig. 8 PINION GEAR DEPTH GAUGE
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
1 - PINION BLOCK
NOTE: Arbor Discs 6927A has different step diame-
being serviced.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock (Fi g. 8). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator face to the poi nter. Ti ghten
di al i ndi cator face l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 11). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a depth shi m equal to the di al i ndi cator
readi ng pl us the pi ni on depth vari ance number
etched i n the face of the pi ni on (Fi g. 6). For exampl e,
i f the depth vari ance i s 2, add +0.002 i n. to the di al
i ndi cator readi ng.
DIFFERENTIAL BEARING PRELOAD & GEAR
BACKLASH
di fferenti al si de beari ng cones. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t Dummy
Beari ngs 6929-A i n pl ace of the di fferenti al si de bear-
i ngs and a Di al I ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on for i nstal l ati on. Establ i shi ng
are performed wi th the spreader W-129-B removed.
SHIM SELECTION
enti al case.
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
(3) I nstal l Dummy Beari ngs 6929-A on di fferenti al case.
(5) Record the thi ckness of Dummy Shi ms 8107,
then i nsert the shi ms between the dummy beari ngs
and the di fferenti al housi ng (Fi g. 13).
(6) I nstal l the beari ng caps i n thei r ori gi nal posi -
ti ons and snug the bol ts (Fi g. 14).
(7) Wi th a dead-bl ow hammer, seat the di fferenti al
dummy beari ngs to each si de of the housi ng (Fi g. 15)
and (Fi g. 16).
3 - RING GEAR
Fig. 13 DUMMY SHIM POINT
1 - DUMMY SHIMS
2 - HOUSING
4 - DUMMY BEARINGS
Fig. 14 TIGHTEN BEARING CAP BOLTS
1 - BEARING CAPS
2 - HOUSING
Fig. 15 SEAT DUMMY BEARING
1 - HAMMER
2 - HOUSING
(9) Attach the Di al I ndi cator C-3339 to pi l ot stud
and posi ti on the i ndi cator pl unger on the fl at surface
between the ri ng gear bol ts (Fi g. 17).
(Fi g. 19).
(12) Add 0.0254 mm (0.001 i n.) to the zero end
pl ay total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
pi l ot stud.
Fig. 16 SEAT DUMMY BEARING
1 - HOUSING
2 - HAMMER
Fig. 17 DIFFERENTIAL SIDE PLAY MEASUREMENT
2 - HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 18 DIFFERENTIAL CASE PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
Fig. 19 DIFFERENTIAL CASE RING GEAR SIDE
1 - READ DIAL INDICATOR
from the housi ng.
(15) I nstal l the pi ni on gear i n the housi ng. I nstal l
rotati ng torque.
6929-A i n the housi ng.
surface between the ri ng gear bol t heads. (Fi g. 17).
(Fi g. 21). Add Dummy Shi m thi ckness to thi s read-
i ng. Thi s wi l l be the total shi m thi ckness to achi eve
zero backl ash.
(23) Subtract backl ash shi m thi ckness from the
total prel oad shi m thi ckness. The remai nder i s the
shi m thi ckness requi red on the pi ni on si de of the
housi ng.
stud.
from the housi ng.
case.
(27) I nstal l spreader W-129-B, uti l i zi ng some i tems
from Adapter Set 6987, on the housi ng and spread
axl e openi ng enough to recei ve di fferenti al case.
(28) Pl ace the beari ng prel oad shi ms i n the hous-
i ng agai nst the axl e tubes.
3 - PINION GEAR
4 - HOUSING
Fig. 21 DIFFERENTIAL CASE RING GEAR SIDE
1 - READ DIAL INDICATOR
3 - PINION GEAR
readi ng shoul d be between 0.076 mm (0.003 i n.) and
0.15 mm (0.006 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the housi ng to the other (Fi g.
23).
Gear Contact Pattern procedure.
wi l l show i f the pi ni on depth i s correct i n the axl e
housi ng. I t wi l l al so show i f the ri ng gear backl ash
has been adjusted correctl y. The backl ash can be
adjusted wi thi n speci fi cati ons to achi eve desi red
tooth contact patterns.
teeth.
tern.
shop towel .
24) and adjust pi ni on depth and gear backl ash as
necessary.
Fig. 22 RING GEAR BACKLASH
1 - DIAL INDICATOR
Fig. 23 BACKLASH SHIM
Fig. 24 Gear Contact Patterns
(7-11 i n. l bs.).
SPECIFICATIONS
AXLE SPECIFICATIONS
Axle Ratio 3.31, 3.55, 3.73, 3.91
Ring Gear Backlash 0.076.-0.15 mm (0.003-0.006 in.)
Pinion Bearing Preload - New Bearings 2.8-4 Nm (25-35 in. lbs.)
Ring Gear Bolts 136 100 -
Pinion Nut 298-380 220-280 -
Pinion Mate Shaft Screw 17.6 13 -
Axle Bearing Retainer Plate
Nuts
61 45 -
SPECIAL TOOLS
Puller Set C-293-PA
Adapter 8353
Adapter 8353
Adapter Plug C-293-3
Remover C-452
Wrench Flange C-3281
Installer C-3718
Handle C-4171
Remover C-4307
Installer C-4308
Installer C-4340
Pilot Studs C-3288-B
Dial Indicator C-3339
Trac-lok Tool C-4487
Installer C-3972-A
Installer D-129
Remover D-103
Spreader
Installer 6448
Adapter 6790
Pinion Depth Set 6955
Bearing Dummy Set 6956
Gauge Block 8144
Shims Dummy 8107
Wrench Spanner 6958
Fixture Holding 6963-A
Remover 7794-A
Splitter Bearing 1130
Installer Gear/Bearing 7913-A
AXLE SHAFTS
REMOVAL
(1) Pl ace transmi ssi on i n neutral .
(4) Remove brake cal i per and rotor.
(5) Remove nuts hol di ng axl e retai ner pl ate to axl e
tube from the rear of the axl e fl ange.
(6) Pul l axl e shaft from the axl e wi th Sl i de Ham-
mer 7420 and Adapter 6790. Mount the adapter to
the axl e wi th l ug nuts.
the axle tube.
INSTALLATION
(1) I nsal l axl e i nto the axl e tube wi th the fl at area
of the retai ner pl ate upward.
(2) I nsert retai ni ng pl ate studs i nto the brake
backi ng pl ate and axl e tube fl ange.
(3) I nstal l retai ner nuts and ti ghten nuts to 61
Nm (45 ft. l bs.).
(4) I nstal l the brake rotor and cal i per.
(5) I nstal l wheel and ti re.
(6) Check and fi l l the di fferenti al wi th gear l ubri -
cant.
AXLE BEARINGS/SEALS
REMOVAL
(1) Remove axl e shaft from vehi cl e.
the axle tube.
(2) Dri l l a shal l ow hol e i nto soft steel axl e beari ng
retai ni ng ri ng wi th a 3/8 i n. dri l l bi t (Fi g. 25). Use a
dri l l depth stop to avoi d marki ng the axl e.
(3) Wi th a col d chi sel cut the retai ni ng ri ng across
dri l l ed hol e. (Fi g. 26)
(4) Sl i de retai ni ng ri ng from axl e shaft.
Fig. 25 DRILL RETAINING RING
1 - DRILL BIT
2 - AXLE
3 - RETAINING PLATE
4 - RETAINING RING
Fig. 26 RETAINING RING
1 - AXLE
2 - COLD CHISEL
3 - VISE
4 - RETAINING RING
(5) Remove axl e beari ng from the shaft wi th, a
press and Spl i tter 1130 pl aced between the seal and
(6) Remove seal from axl e.
(7) Remove retai ni ng pl ate from axl e shaft.
INSTALLATION
(1) Veri fy axl e shaft retai ni ng pl ate i s fl at wi th a
strai ght edge.
NOTE: If the plate is warped or the studs are loose
in the plate replace the retaining plate.
(2) I nstal l retai ni ng pl ate on the axl e shaft (Fi g.
28).
(3) Appl y a coat of mul ti -purpose grease on seal i ng
surface of axl e seal .
(4) I nstal l seal on the axl e shaft wi th cavi ty away
from retai ni ng pl ate (Fi g. 28).
(5) Lubri cate beari ng wi th Mopar Wheel Beari ng
Grease or equi val ent. Wi pe excess grease from the
beari ng.
(6) I nstal l beari ng on the axl e shaft wi th I nstal l er
7913 and a press (Fi g. 29).
Fig. 27 AXLE BEARING AND SEAL
1 - SPLITTER
2 - AXLE
3 - BLOCKS
4 - PRESS PLATES
Fig. 28 AXLE BEARING AND SEAL COMPONENTS
1 - RETAINING RING
2 - SEAL
3 - AXLE
4 - RETAINING PLATE
5 - AXLE BEARING
Fig. 29 PRESS BEARING ON AXLE
1 - PRESS RAM
2 - INSTALLER
3 - AXLE BEARING
4 - SEAL
5 - RETAINING PLATE
6 - AXLE
(7) Press metal retai ni ng ri ng onto axl e shaft wi th
(8) I nstal l axl e i n vehi cl e.
PINION SEAL
REMOVAL
(5) Remove the propel l er shaft from the yoke.
(6) Rotate pi ni on gear three or four ti mes and ver-
i fy that pi ni on rotates smoothl y.
(7) Record torque necessary to rotate the pi ni on
gear wi th a i nch pound di al -type torque wrench.
(8) Usi ng a short pi ece of pi pe and Spanner
Wrench 6958 to hol d the pi ni on yoke and remove pi n-
i on nut and washer (Fi g. 31).
C-452 and Fl ange Wrench C-3281. (Fi g. 32)
Fig. 30 BEARING RETAINING RING
1 - PRESS
2 - AXLE
3 - AXLE BEARING
4 - INSTALLER
5 - METAL RETAINING RING
Fig. 31 Pinion Yoke Holder
1 - PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 32 Pinion Yoke Remover
1 - FLANGE WRENCH
2 - YOKE
3 - YOKE PULLER
INSTALLATION
l i p of pi ni on seal . I nstal l seal wi th an appropri ate i n
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
C-3718 and Spanner Wrench 6958 (Fi g. 35).
(3) I nstal l a new nut on the pi ni on gear. Tighten
the nut only enough to remove the shaft end
play.
CAUTION: Do not exceed the minimum tightening
torque 298 Nm (220 ft. lbs.) when installing the pin-
ion yoke retaining nut at this point. Damage to col-
lapsible spacer or bearings may result.
(4) Rotate the pi ni on a mi ni mum of ten ti mes and
veri fy pi ni on rotates smoothl y. Rotate the pi ni on
shaft usi ng an i nch pound torque wrench. Rotati ng
torque shoul d be equal to the readi ng recorded dur-
i ng removal , pl us 0.56 Nm (5 i n. l bs.) (Fi g. 36).
Fig. 33 Pinion Seal Remover
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
1 - HANDLE
2 - INSTALLER
1 - INSTALLER
2 - PINION YOKE
4 - SPANNER WRENCH
1 - TORQUE WRENCH
2 - PINION YOKE
(5) I f rotati ng torque i s l ow, use Wrench 6958 to
hol d the pi ni on yoke (Fi g. 37) and ti ghten the pi ni on
shaft nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l
rotati ng torque i s achi eved.
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
al i gned.
(7) Fi l l di fferenti al wi th gear l ubri cant.
(8) I nstal l the brake rotors and cal i pers.
COLLAPSIBLE SPACER
REMOVAL
i nstal l ati on reference and remove propel l er shaft.
(6) Record rotate torque of the pi ni on gear, wi th an
i nch pound torque wrench.
(7) Hol d pi ni on yoke wi th Spanner Wrench 6958
and remove pi ni on nut and washer (Fi g. 38).
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
1 - 1 in. PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 39 PINION YOKE PULLER
1 - WRENCH
2 - PINION YOKE
3 - PULLER
(9) Remove pi ni on shaft seal wi th Remover 7794-A
and sl i de hammer (Fi g. 40).
(10) Remove front pi ni on beari ng usi ng a pai r of pi ck
tool s to pul l the beari ng off the pi ni on gear shaft.
NOTE: If the pinion bearing becomes bound on the
pinion shaft, lightly tap the end of the shaft with a
INSTALLATION
(1) I nstal l a new col l apsi bl e spacer on pi ni on
shaft.
(2) I nstal l pi ni on front beari ng on the pi ni on shaft.
Wrench 6958 (Fi g. 42).
(5) I nstal l yoke washer and new nut on the pi ni on
gear. Ti ghten the nut to 271 Nm (200 ft. l bs.).
pinion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be installed.
(6) Usi ng yoke wi th Spanner Wrench 6958 and a
torque wrench set at 380 Nm (280 ft. l bs.), (Fi g. 43)
sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.) i ncre-
ments unti l the rotati ng torque i s achi eved. Measure
the rotati ng torque frequentl y to avoi d over crushi ng
the col l apsi bl e spacer (Fi g. 44).
Fig. 43 PINION NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
Fig. 40 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 42 Pinion Yoke Installer
1 - INSTALLER
2 - PINION YOKE
4 - SPANNER WRENCH
(7) Check rotati ng torque wi th an i nch pound
torque wrench (Fi g. 44). The rotati ng torque of the
pi ni on gear shoul d be, the readi ng recorded duri ng
removal pl us an addi ti onal 0.56 Nm (5 i n. l bs.).
(8) I nstal l propel l er shaft wi th reference marks al i gn.
(9) I nstal l rear brake rotors and cal i pers.
DIFFERENTIAL
REMOVAL
(2) Remove fi l l hol e pl ug from the di fferenti al
housi ng cover.
(3) Remove di fferenti al housi ng cover and drai n
fl ui d.
(4) Cl ean the housi ng cavi ty wi th fl ushi ng oi l , l i ght
engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
(6) Note the reference l etters stamped on the beari ng
caps and housi ng machi ned seal i ng surface (Fi g. 45).
hol ddown cl amps and ti ghten the turnbuckl e fi nger-
ti ght.
1 - TORQUE WRENCH
2 - PINION YOKE
2 - DOWEL
4 - SPREADER
5 - TURNBUCKLE
opposi te si de of the housi ng (Fi g. 47) and zero the
i ndi cator.
(12) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
di fferenti al beari ng cups to i ndi cate l ocati on (Fi g. 49).
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
1 - DIAL INDICATOR
2 - SPREADER
3 - BEARING CUPS
DISASSEMBLY
(1) Remove pi ni on shaft l ock screw (Fi g. 50).
(2) Remove pi ni on shaft.
(3) Rotate di fferenti al si de gears and remove di f-
ferenti al pi ni ons and thrust washers (Fi g. 51).
washers.
ASSEMBLY
ers.
(2) I nstal l di fferenti al pi ni on gears and thrust
washers.
(3) I nstal l the pi ni on mate shaft.
(4) Al i gn hol e i n the pi ni on mate shaft wi th the
hol e i n the di fferenti al case and i nstal l the pi ni on
mate shaft l ock screw.
INSTALLATION
bearing shim requirements may change. Refer
(1) Posi ti on Spreader W-129-B wi th Adapter set
6987 on di fferenti al housi ng l ocati ng hol es. I nstal l
the hol ddown cl amps and ti ghten the tool turnbuckl e
fi nger-ti ght.
(0.015 in). If housing is over-spread, it could be dis-
torted or damaged.
(3) Spread housi ng enough to i nstal l the case i n
the housi ng.
(5) I nstal l di fferenti al case i n housi ng (Fi g. 52).
Veri fy di fferenti al beari ng cups remai n i n posi ti on on
the beari ngs and prel oad shi ms are between the face
of the beari ng cup and the housi ng. Tap the di fferen-
ti al case to ensure beari ngs cups and shi ms are
seated i n the housi ng.
tube must be pointed at the bottom of the housing
(Fig. 53). If differential is installed with the oil feed
tube pointed at the top, the anti-rotation tabs will be
damaged.
(6) I nstal l beari ng caps i n thei r ori gi nal l ocati ons
(Fi g. 54).
(9) Ti ghten beari ng cap bol ts i n a cri ss-cross pat-
tern to 77 Nm (57 ft. l bs.).
(10) I nstal l the axl e shafts.
Fig. 50 SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 51 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
(11) Appl y a 6.35mm (1/4 i n.) bead of red Mopar
cover (Fi g. 55).
2 - DOWEL
4 - SPREADER
5 - TURNBUCKLE
Fig. 53 VARI-LOK
2 - OIL FEED TUBE
Fig. 55 DIFFERENTIAL COVER - TYPICAL
1 - COVER
2 - SEALANT
3 - SEALANT BEAD
(12) I nstal l cover and ti ghten bol ts i n a cri ss-cross
(13) Refi l l the di fferenti al wi th Mopar Hypoi d
Gear Lubri cant or equi val ent to bottom of the fi l l
pl ug hol e.
(14) I nstal l fi l l hol e pl ug.
DIFFERENTIAL - TRAC-LOK
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. A contai ner of Mopar Trac-l ok Lubri cant
(fri cti on modi fi er) shoul d be added after repai r ser-
vi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 56).
(6) I f rotati ng torque i s l ess than 41 Nm (56 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
DISASSEMBLY
(1) Cl amp si de gear Hol di ng Fi xture 6965 i n a vi se
and posi ti on the di fferenti al case on the Hol di ng Fi x-
ture (Fi g. 57).
(2) Remove ri ng gear i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
Fig. 56 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 57 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
(3) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 58).
(4) Remove pi ni on gear mate shaft wi th a dri ft and
hammer (Fi g. 59).
(5) I nstal l and l ubri cate Step Pl ate C-6960-3 (Fi g.
60).
(6) Assembl e Threaded Adapter C-6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(7) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter Di sc C-6960-1 (Fi g. 61) to prevent
adapter from turni ng.
Fig. 58 MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 59 PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
Fig. 60 Step Plate
1 - LOWER SIDE GEAR
3 - STEP PLATE
Fig. 61 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - STEP PLATE
5 - FORCING SCREW
6 - THREAD ADAPTER DISC
DIFFERENTIAL - TRAC-LOK (Continued)
screw to 122 Nm (90 ft. l bs.) maxi mum to compress
Bel l evi l l e spri ngs i n cl utch packs (Fi g. 62).
(9) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 63).
(10) I nsert Turni ng Bar C-6960-2 i nto the pi ni on
mate shaft hol e i n the case (Fi g. 64).
(11) Loosen the Forci ng Screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and the di f-
ferenti al case can be turned usi ng Turni ng Bar.
(12) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(13) Remove pi ni on gears from di fferenti al case.
Threaded Adapter.
(15) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 65).
(16) Remove di fferenti al case from the Hol di ng
Fi xture. Remove si de gear, cl utch pack retai ner and
cl utch pack. Keep pl ates i n correct order duri ng
removal .
CLEANING
components wi th compressed ai r.
INSPECTION
I nspect cl utch pack pl ates for wear, scori ng or dam-
age. Repl ace both cl utch packs i f any one component
i n ei ther pack i s damaged. I nspect si de and pi ni on
gears for cracks chi ps or damage and repl ace as nec-
essary. I nspect di fferenti al case and pi ni on shaft and
repl ace i f worn or damaged.
ASSEMBLY
components wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
Fig. 62 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
Fig. 63 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 64 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
damaged. I nspect si de gears and pi ni ons. Repl ace
any gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Lubri cate each component wi th gear l ubri cant
before assembl y.
(2) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 66).
NOTE: Dished plate is position with the convex side
against the side gear.
(3) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(4) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 67). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
(5) Posi ti on the di fferenti al case on the Hol di ng
Fi xture 6965.
Fig. 65 SIDE GEARS AND CLUTCH DISCS
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 66 CLUTCH PACK
1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
6 - PLATES
Fig. 67 CLUTCH PACK AND LOWER SIDE GEAR
2 - LOWER SIDE GEAR AND CLUTCH DISC PACK
(6) I nstal l l ubri cated Step Pl ate C-6960-3 i n l ower
si de gear (Fi g. 68).
(7) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 68).
(8) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C-6960-1 i nto top si de gear.
screw to sl i ghtl y compress cl utch di sc.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar C-6960-2 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
Threaded Adapter.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove si de beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, Adapters 8353 and Pl ug
C-293-3 (Fi g. 69).
INSTALLATION
NOTE: If differential side bearings or differential
case are replaced, differential side bearing shim
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.
Fig. 68 CLUTCH PACK AND UPPER SIDE GEAR
3 - STEP PLATE
Fig. 69 Differential Bearing Removal
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
CAUTION: Vari-lok plenum must be seated against
the differential case prior to installing the ring gear
side differential bearing.
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-4340 and Handl e C-4171 (Fi g. 70).
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without the
other matched gear.
(2) Mark pi ni on yoke and propel l er shaft for
(3) Di sconnect propel l er shaft from pi ni on yoke
and ti e shaft to underbody.
(4) Remove di fferenti al from axl e housi ng.
jaw.
case.
(7) Dri ve ri ng gear from di fferenti al case wi th a
6958 and remove the pi ni on yoke nut and washer
(Fi g. 72).
Fig. 70 Install Differential Side Bearings
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 71 RING GEAR
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 72 Pinion Yoke Holder
1 - PIPE
2 - PINION YOKE
3 - SPANNER WRENCH
(9) Remove pi ni on yoke from pi ni on shaft wi th
Remover C-452 and Wrench C-3281 (Fi g. 73).
(10) Remove pi ni on gear from housi ng (Fi g. 74).
(12) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(13) Remove the front pi ni on beari ng cup wi th
Remover D-103 and Handl e C-4171 (Fi g. 76).
Fig. 73 Pinion Yoke Remover
1 - FLANGE WRENCH
2 - YOKE
3 - YOKE PULLER
Fig. 74 Pinion Gear
1 - RAWHIDE HAMMER
Fig. 75 Pinion Seal Remover
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 76 Front Pinion Bearing Cup
1 - REMOVER
2 - HANDLE
(14) Remove rear beari ng cup from housi ng (Fi g.
77) wi th Remover C-4307 and Handl e C-4171.
(15) Remove col l apsi bl e prel oad spacer (Fi g. 78).
(16) Remove rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-42 (Fi g.
79).
(17) Remove depth shi ms from the pi ni on gear
shaft and record shi m thi ckness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
Fig. 77 Rear Pinion Bearing Cup
1 - REMOVER
2 - HANDLE
Fig. 78 Collapsible Spacer
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
Fig. 79 Rear Pinion Bearing Puller
1 - PULLER
2 - VISE
3 - ADAPTERS
to outsi de surface of pi ni on beari ng cups.
(2) I nstal l pi ni on rear beari ng cup wi th I nstal l er
C-4308 and Dri ver Handl e C-4171 (Fi g. 80) and ver-
i fy cup i s seated.
(3) I nstal l pi ni on front beari ng cup wi th I nstal l er
D-129 and Handl e C-4171 (Fi g. 81) and veri fy cup i s
seated.
(4) I nstal l pi ni on front beari ng and oi l sl i nger, i f
equi pped.
(Fi g. 82).
(6) I nstal l depth shi m on the pi ni on gear.
(7) I nstal l rear beari ng on the pi ni on gear wi th
Fig. 80 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
1 - HANDLE
2 - INSTALLER
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
i on shaft and i nstal l pi ni on gear i n the housi ng (Fi g.
84).
Wrench 6958 (Fi g. 85).
(10) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
installed.
(12) Usi ng Spanner Wrench 6958 and a torque
wrench set at 380 Nm (280 ft. l bs.), (Fi g. 86) sl owl y
ti ghten the nut i n 6.8 Nm (5 ft. l bs.) i ncrements
unti l the rotati ng torque i s achi eved. Measure the
rotati ng torque frequentl y to avoi d over crushi ng the
col l apsi bl e spacer (Fi g. 87).
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
1 - INSTALLER
2 - PINION YOKE
4 - SPANNER WRENCH
Fig. 86 PINION NUT
1 - SPANNER WRENCH
2 - PIPE
3 - TORQUE WRENCH
(13) Check beari ng rotati ng torque wi th a i nch
pound torque wrench (Fi g. 87). The pi ni on gear rotat-
i ng torque shoul d be:
Ori gi nal Beari ngs: 1 to 2.25 Nm (10 to 20 i n. l bs.).
New Beari ngs: 2.8 to 4 Nm (25 to 35 i n. l bs.).
hol e al i gnment.
ti ghten to 129-142 Nm (95-105 ft. l bs.) (Fi g. 88).
NOTE: If equipped with Veri-Lok differential install
oil feed plenum and side bearing.
(17) I nstal l di fferenti al i n housi ng.
CAUTION: When installing a Vari-lok differential
(Fig. 89), the oil feed tube must point to the bottom
of the housing. If differential is installed with the oil
feed tube pointed toward the top, the anti-rotation
tabs will be damaged.
(18) Veri fy di fferenti al beari ng prel oad, gear mesh
and contact pattern. Refer to Ajustments for procedure.
l ubri cant.
(20) I nstal l the propel l er shaft wi th the reference
marks al i gned.
Fig. 88 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
Fig. 89 VARI-LOK
2 - OIL FEED TUBE
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STANDARD PROCEDURE - PRESSURE
BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . 6
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE FLUID LEVEL SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RED BRAKE WARN INDICATOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - RED BRAKE
WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . 7
ADJUSTABLE PEDAL SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - BRAKE HOSES
AND LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING . . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - ISO FLARING . . . 9
BRAKE PADS / SHOES
DESCRIPTION
DESCRIPTION - FRONT DISC BRAKE
SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION - REAR DISC BRAKE SHOES . 10
OPERATION
OPERATION - FRONT DISC BRAKE SHOES . 10
OPERATION - REAR DISC BRAKE SHOES . . 10
REMOVAL
REMOVAL- FRONT DISC BRAKE SHOES . . . 11
REMOVAL - REAR DISC BRAKE SHOES . . . . 12
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION - REAR DISC BRAKE
SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DISC BRAKE CALIPERS
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER . 14
REMOVAL - REAR DISC BRAKE CALIPER . . 15
DISASSEMBLY
DISASSEMBLY - FRONT DISC BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DISASSEMBLY - REAR DISC BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CLEANING - DISC BRAKE CALIPER . . . . . . . . . 19
INSPECTION - DISC BRAKE CALIPER . . . . . . . 19
ASSEMBLY
ASSEMBLY - FRONT DISC BRAKE CALIPER . 20
ASSEMBLY - REAR DISC BRAKE CALIPER . 21
INSTALLATION
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 23
FLUID RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WJ BRAKES 5 - 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
MASTER CYLINDER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER . . . . . . . . . . . 24
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING PROCEDURE . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
PEDAL
DESCRIPTION
DESCRIPTION - STANDARD PEDAL . . . . . . . 25
DESCRIPTION - ADJUSTABLE PEDALS . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL
REMOVAL - NON-ADJUSTABLE PEDAL . . . . 26
REMOVAL - ADJUSTABLE PEDALS . . . . . . . . 27
INSTALLATION
INSTALLATION - NON-ADJUSTABLE PEDAL . 28
INSTALLATION - ADJUSTABLE PEDALS . . . . 28
PEDAL MOTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
POWER BRAKE BOOSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
ROTORS
DIAGNOSIS AND TESTING - FRONT DISC
BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING - REAR DISC
BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . 32
STANDARD PROCEDURE - DISC ROTOR
MACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL
REMOVAL - FRONT DISC BRAKE ROTOR . . 33
REMOVAL - REAR DISC BRAKE ROTOR . . . 33
INSTALLATION
ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
PARKING BRAKE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIAGNOSIS AND TESTING - PARKING BRAKE . 34
CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE
CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL - REAR PARKING BRAKE
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION - REAR PARKING BRAKE
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
SHOES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
ADJUSTMENTS - PARKING BRAKE SHOE . . . . 40
BRAKES - BASE
DESCRIPTION
Dual pi ston di sc brake cal i pers are used on the
front. Si ngl e pi ston di sc brake cal i pers are used on
the rear. Venti l ated di sc brake rotors are used on the
front and sol i d rotors are used on the rear.
Power brake assi st i s suppl i ed by a vacuum oper-
ated, dual di aphragm power brake booster. The mas-
ter cyl i nder used for al l appl i cati ons has an
al umi num body and nyl on reservoi r wi th si ngl e fi l l er
cap. A fl ui d l evel i ndi cator i s mounted to the si de of
the reservoi r.
The braki ng force of the rear wheel s i s control l ed
by el ectroni c brake di stri buti on (EBD). The EBD
functi ons l i ke a rear proporti oni ng val ve. The EBD
system uses the ABS system to control the sl i p of the
rear wheel s i n parti al braki ng range. The braki ng
force of the rear wheel s i s control l ed el ectroni cal l y by
usi ng the i nl et and outl et val ves l ocated i n the HCU.
Factory i nstal l ed brake l i ni ngs on al l model s con-
si sts of organi c base materi al combi ned wi th metal l i c
parti cl es.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consi st of the brake shoes,
cal i pers, rear park brake drums/rotors, front brake
rotors, brake l i nes, master cyl i nder, booster, HCU
and parki ng brake shoes.
Brake di agnosi s i nvol ves determi ni ng i f the prob-
l em i s rel ated to a mechani cal , hydraul i c, el ectri cal
or vacuum operated component.
The fi rst di agnosi s step i s the prel i mi nary check.
PRELIMINARY BRAKE CHECK
(1) Check condi ti on of ti res and wheel s. Damaged
wheel s and worn, damaged, or underi nfl ated ti res
can cause pul l , shudder, vi brati on, and a condi ti on
si mi l ar to grab.
5 - 2 BRAKES - BASE WJ
(2) I f compl ai nt was based on noi se when braki ng,
check suspensi on components. Jounce front and rear
of vehi cl e and l i sten for noi se that mi ght be caused
by l oose, worn or damaged suspensi on or steeri ng
components.
(3) I nspect brake fl ui d l evel and condi ti on. Note
that the brake reservoi r fl ui d l evel wi l l decrease i n
proporti on to normal l i ni ng wear. Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.
(a) I f fl ui d l evel i s abnormal l y l ow, l ook for evi -
dence of l eaks at cal i pers, brake l i nes, master cyl -
i nder, and HCU.
(b) I f fl ui d appears contami nated, drai n out a
sampl e to exami ne. System wi l l have to be fl ushed
i f fl ui d i s separated i nto l ayers, or contai ns a sub-
stance other than brake fl ui d. The system seal s,
cups, hoses, master cyl i nder, and HCU wi l l al so
have to be repl aced after fl ushi ng. Use cl ean brake
fl ui d to fl ush the system.
(4) Check parki ng brake operati on. Veri fy free
movement and ful l rel ease of cabl es and l ever. Al so
note i f vehi cl e was bei ng operated wi th parki ng
brake parti al l y appl i ed.
(5) Check brake pedal operati on. Veri fy that pedal
does not bi nd and has adequate free pl ay. I f pedal
l acks free pl ay, check pedal and power booster for
bei ng l oose or for bi nd condi ti on. Do not road test
unti l condi ti on i s corrected.
(6) Check booster vacuum check val ve and hose.
(7) I f components checked appear OK, road test
the vehi cl e.
ROAD TESTING
(1) I f compl ai nt i nvol ved l ow brake pedal , pump
pedal and note i f i t comes back up to normal hei ght.
(2) Check brake pedal response wi th transmi ssi on
i n neutral and engi ne runni ng. Pedal shoul d remai n
fi rm under constant foot pressure.
(3) Duri ng road test, make normal and fi rm brake
stops i n 25-40 mph range. Note faul ty brake opera-
ti on such as l ow pedal , hard pedal , fade, pedal pul sa-
ti on, pul l , grab, drag, noi se, etc.
(4) Attempt to stop the vehi cl e wi th the parki ng
brake onl y (do not exceed 25 mph) and note grab,
drag, noi se, etc.
PEDAL FALLS AWAY
A brake pedal that fal l s away under steady foot
pressure i s general l y the resul t of a system l eak. The
l eak poi nt coul d be at a brake l i ne, fi tti ng, hose, or
cal i per. I f l eakage i s severe, fl ui d wi l l be evi dent at
or around the l eaki ng component.
I nternal l eakage (seal by-pass) i n the master cyl i n-
der caused by worn or damaged pi ston cups, may
al so be the probl em cause.
An i nternal l eak i n the ABS system may al so be
the probl em wi th no vi sual fl ui d l eak.
LOW PEDAL
I f a l ow pedal i s experi enced, pump the pedal sev-
eral ti mes. I f the pedal comes back up, the most
l i kel y causes are worn l i ni ngs, rotors, or cal i pers are
not sl i di ng on the sl i de pi ns. The proper course of
acti on i s to i nspect and repl ace al l worn component.
SPONGY PEDAL
A spongy pedal i s most often caused by ai r i n the
system. However substandard brake hoses can cause
a spongy pedal . The proper course of acti on i s to
bl eed the system, and repl ace substandard qual i ty
brake hoses i f suspected.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or hi gh pedal effort may be due to
l i ni ng that i s water soaked, contami nated, gl azed, or
badl y worn. The power booster, check val ve, check
val ve seal /grommet or vacuum l eak coul d al so cause
a hard pedal or hi gh pedal effort.
PEDAL PULSATION
Pedal pul sati on i s caused by components that are
l oose, or beyond tol erance l i mi ts.
The pri mary cause of pul sati on are di sc brake
rotors wi th excessi ve l ateral runout or thi ckness vari -
ati on. Other causes are l oose wheel beari ngs or cal i -
pers and worn, damaged ti res.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the l i ni ng i s i n constant
contact wi th the rotor or drum. Drag can occur at one
wheel , al l wheel s, fronts onl y, or rears onl y.
Drag i s a product of i ncompl ete brake rel ease.
Drag can be mi nor or severe enough to overheat the
l i ni ngs, rotors and park brake drums.
Mi nor drag wi l l usual l y cause sl i ght surface charri ng
of the l i ni ng. I t can al so generate hard spots i n rotors
and park brake drums from the overheat-cool down pro-
cess. I n most cases, the rotors, wheel s and ti res are
qui te warm to the touch after the vehi cl e i s stopped.
Severe drag can char the brake l i ni ng al l the way
through. I t can al so di stort and score rotors to the
poi nt of repl acement. The wheel s, ti res and brake
components wi l l be extremel y hot. I n severe cases,
the l i ni ng may generate smoke as i t chars from over-
heati ng.
WJ BRAKES - BASE 5 - 3
BRAKES - BASE (Continued)
Common causes of brake drag are:
Parki ng brake parti al l y appl i ed.
Loose/worn wheel beari ng.
Sei zed cal i per.
Cal i per bi ndi ng.
Loose cal i per mounti ng.
Mi s-assembl ed components.
Damaged brake l i nes.
I f brake drag occurs at the front, rear or al l
wheel s, the probl em may be rel ated to a bl ocked mas-
ter cyl i nder return port, faul ty power booster (bi nds-
does not rel ease) or the ABS system.
BRAKE FADE
Brake fade i s usual l y a product of overheati ng
caused by brake drag. However, brake overheati ng
and resul ti ng fade can al so be caused by ri di ng the
brake pedal , maki ng repeated hi gh decel erati on stops
i n a short ti me span, or constant braki ng on steep
mountai n roads. Refer to the Brake Drag i nformati on
i n thi s secti on for causes.
BRAKE PULL
Front brake pul l condi ti on coul d resul t from:
Contami nated l i ni ng i n one cal i per
Sei zed cal i per pi ston
Bi ndi ng cal i per
Loose cal i per
Rusty cal i per sl i de surfaces
I mproper brake shoes
Damaged rotor
Wheel al i gnment.
Ti re pressure.
A worn, damaged wheel beari ng or suspensi on compo-
nent are further causes of pul l . A damaged front ti re
(brui sed, pl y separati on) can al so cause pul l .
A common and frequentl y mi sdi agnosed pul l condi -
ti on i s where di recti on of pul l changes after a few
stops. The cause i s a combi nati on of brake drag fol -
l owed by fade at one of the brake uni ts.
As the draggi ng brake overheats, effi ci ency i s so
reduced that fade occurs. Si nce the opposi te brake
uni t i s sti l l functi oni ng normal l y, i ts braki ng effect i s
magni fi ed. Thi s causes pul l to swi tch di recti on i n
favor of the normal l y functi oni ng brake uni t.
An addi ti onal poi nt when di agnosi ng a change i n
pul l condi ti on concerns brake cool down. Remember
that pul l wi l l return to the ori gi nal di recti on, i f the
draggi ng brake uni t i s al l owed to cool down (and i s
not seri ousl y damaged).
REAR BRAKE DRAG OR PULL
Rear drag or pul l may be caused by i mproperl y
adjusted park brake shoes or sei zed parki ng brake
cabl es, contami nated l i ni ng, bent or bi ndi ng shoes or
i mproperl y assembl ed components. Thi s i s parti cu-
l arl y true when onl y one rear wheel i s i nvol ved.
However, when both rear wheel s are affected, the
master cyl i nder or ABS system coul d be at faul t.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Thi s condi ti on i s general l y caused by water soaked
l i ni ng. I f the l i ni ng i s onl y wet, i t can be dri ed by
dri vi ng wi th the brakes very l i ghtl y appl i ed for a
mi l e or two. However, i f the l i ni ng i s both soaked and
di rt contami nated, cl eani ng and or repl acement wi l l
be necessary.
BRAKE LINING CONTAMINATION
Brake l i ni ng contami nati on i s mostl y a product of
l eaki ng cal i pers or worn seal s, dri vi ng through deep
water puddl es, or l i ni ng that has become covered wi th
grease and gri t duri ng repai r. Contami nated l i ni ng
shoul d be repl aced to avoi d further brake probl ems.
WHEEL AND TIRE PROBLEMS
Some condi ti ons attri buted to brake components
may actual l y be caused by a wheel or ti re probl em.
A damaged wheel can cause shudder, vi brati on and
pul l . A worn or damaged ti re can al so cause pul l .
NOTE: Propshaft angle can also cause vibration/
shudder.
Severel y worn ti res wi th very l i ttl e tread l eft can
produce a grab-l i ke condi ti on as the ti re l oses and
recovers tracti on. Fl at-spotted ti res can cause vi bra-
ti on and generate shudder duri ng brake operati on.
Ti re damage such as a severe brui se, cut, pl y separa-
ti on, l ow ai r pressure can cause pul l and vi brati on.
BRAKE NOISES
Some brake noi se i s common on some di sc brakes
duri ng the fi rst few stops after a vehi cl e has been
parked overni ght or stored. Thi s i s pri mari l y due to
the formati on of trace corrosi on (l i ght rust) on metal
surfaces. Thi s l i ght corrosi on i s typi cal l y cl eared from
the metal surfaces after a few brake appl i cati ons
causi ng the noi se to subsi de.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to l i ni ngs that
are wet or contami nated wi th brake fl ui d, grease, or oi l .
Gl azed l i ni ngs and rotors wi th hard spots can al so con-
tri bute to squeak. Di rt and forei gn materi al embedded
i n the brake l i ni ng wi l l al so cause squeak/squeal .
A very l oud squeak or squeal i s frequentl y a si gn of
severel y worn brake l i ni ng. I f the l i ni ng has worn
through to the brake shoes i n spots, metal -to-metal
contact occurs. I f the condi ti on i s al l owed to conti nue,
rotors may become so scored that repl acement i s nec-
essary.
NOTE: The front outer brake shoes are equipped
with a wear indicator. The indicator will produce an
audible noise when it contacts the rotor surface.
BRAKE CHATTER
Brake chatter i s usual l y caused by l oose or worn
components, or gl azed/burnt l i ni ng. Rotors wi th hard
spots can al so contri bute to chatter. Addi ti onal causes
of chatter are out-of-tol erance rotors, brake l i ni ng not
securel y attached to the shoes, l oose wheel beari ngs
and contami nated brake l i ni ng.
THUMP/CLUNK NOISE
Thumpi ng or cl unk noi ses duri ng braki ng are fre-
quentl y not caused by brake components. I n many
cases, such noi ses are caused by l oose or damaged
steeri ng, suspensi on, or engi ne components.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Do not pump the brake pedal at any ti me whi l e
bl eedi ng. Ai r i n the system wi l l be compressed i nto
smal l bubbl es that are di stri buted throughout the
hydraul i c system. Thi s wi l l make addi ti onal bl eedi ng
operati ons necessary.
Do not al l ow the master cyl i nder to run out of fl ui d
duri ng bl eed operati ons. An empty cyl i nder wi l l al l ow
addi ti onal ai r to be drawn i nto the system. Check the
cyl i nder fl ui d l evel frequentl y and add fl ui d as
needed.
Bl eed onl y one brake component at a ti me i n the
fol l owi ng sequence:
(1) Fi l l the master cyl i nder reservoi r wi th brake
fl ui d.
(2) I f cal i pers are overhaul ed, open al l cal i per
bl eed screws. Then cl ose each bl eed screw as fl ui d
starts to dri p from i t. Top off master cyl i nder reser-
voi r once more before proceedi ng.
(3) Attach one end of bl eed hose to bl eed screw
and i nsert opposi te end i n gl ass contai ner parti al l y
fi l l ed wi th brake fl ui d (Fi g. 1). Be sure end of bl eed
hose i s i mmersed i n fl ui d.
(4) Open up bl eeder, then have a hel per press
down the brake pedal . Once the pedal i s down cl ose
the bl eeder. Repeat bl eedi ng unti l fl ui d stream i s
cl ear and free of bubbl es. Then move to the next
wheel .
STANDARD PROCEDURE - PRESSURE
BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Do not pump the brake pedal at any ti me whi l e
bl eedi ng. Ai r i n the system wi l l be compressed i nto
smal l bubbl es that are di stri buted throughout the
hydraul i c system. Thi s wi l l make addi ti onal bl eedi ng
operati ons necessary.
Do not al l ow the master cyl i nder to run out of fl ui d
duri ng bl eed operati ons. An empty cyl i nder wi l l al l ow
addi ti onal ai r to be drawn i nto the system. Check the
cyl i nder fl ui d l evel frequentl y and add fl ui d as
needed.
Bl eed onl y one brake component at a ti me i n the
fol l owi ng sequence:
Fol l ow the manufacturers i nstructi ons careful l y
when usi ng pressure equi pment. Do not exceed the
tank manufacturers pressure recommendati ons. Gen-
eral l y, a tank pressure of 51-67 kPa (15-20 psi ) i s suf-
fi ci ent for bl eedi ng.
Fi l l the bl eeder tank wi th recommended fl ui d and
purge ai r from the tank l i nes before bl eedi ng.
Do not pressure bl eed wi thout a proper master cyl -
i nder adapter. The wrong adapter can l ead to l eak-
age, or drawi ng ai r back i nto the system. Use
adapter provi ded wi th the equi pment or Adapter
6921.
Fig. 1 Bleed Hose Setup
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
SPECIFICATIONS
BRAKE COMPONENTS
SPECIFICATIONS
Front Disc Brake Caliper
Type
Floating
Front Disc Brake Caliper
Piston
48 mm (1.889 in.)
Front Disc Brake Rotor
Type
Ventilated
Diameter
305 mm (12 in.)
Max. Runout
0.05 mm (0.002 in.)
Max. Thickness Variation
0.0127 mm (0.0005 in.)
Min. Thickness
24.5 mm (0.9646 in.)
Rear Disc Brake Caliper
Type
Floating
Rear Disc Brake Caliper
Piston
48 mm (1.889 in.)
Rear Disc Brake Rotor
Type Diameter
Solid
Diameter
305 mm (12 in.)
Max. Runout
0.76 mm (0.003 in.)
Max. Thickness Variation
0.0127 mm (0.0005 in.)
Min. Thickness
8.5 mm (0.335 in.)
Drum Max. Diameter
196 mm (7.7166 in.)
Brake Booster Type Dual Diaphragm
TORQUE CHART
Brake Pedal Support Bolt 23-24 17-25
Brake Pedal Pivot Nut 27-35 20-26
Brake Pedal Bracket
Adjustable pedals
28 21 250
Brake Pedal Bracket To Dash 12 9 105
Brake Booster Mounting Nuts 39 29
Master Cylinder Mounting Nuts 25 18
Master Cylinder Primary Brake Line 16 144
Master Cylinder Secondary Brake Line 16 144
Front Caliper Slide Pins 29-41 21-30
Front Caliper Anchor Bolts 90-115 66-85
Front Caliper Brake Hose Banjo Bolt 31 23
Front Caliper Bleed Screw 16 144
Rear Caliper Slide Pins 29-41 21-30
Rear Caliper Anchor Bolts 90-115 66-85
Rear Caliper Brake Hose Banjo Bolt 31 23
Rear Caliper Bleed Screw 16 144
SPECIAL TOOLS
BASE BRAKES
BRAKE FLUID LEVEL SWITCH
REMOVAL
(1) Remove the wi re connector from the fl ui d l evel
sensor.
(2) From the same si de of the master cyl i nder res-
ervoi r rel ease the sensor l ocki ng taps wi th a smal l
screw dri ver.
(3) Pul l the sensor out of the reservoi r from the
connector si de of the sensor.
INSTALLATION
(1) I nstal l the sensor wi th a new o-ri ng i nto the
reservoi r unti l the l ocki ng tabs are engaged.
(2) I nstal l the wi re connector to the fl ui d l evel sen-
sor.
RED BRAKE WARN INDICATOR
SWITCH
DESCRIPTION
A red warni ng l amp i s used for the servi ce brake
porti on of the hydraul i c system. The l amp i s l ocated
i n the i nstrument cl uster.
OPERATION
The l amp i s turned on momentari l y when the i gni -
ti on swi tch i s turn to the on posi ti on. Thi s i s a sel f
test to veri fy the l amp i s operati onal .
The red warni ng l i ght al erts the dri ver i f the fl ui d
l evel i s l ow or the parki ng brakes are appl i ed. A red
warni ng l amp wi th an amber warni ng l amp may
i ndi cate a el ectroni c brake di stri buti on faul t.
DIAGNOSIS AND TESTING - RED BRAKE
WARNING LAMP
The red warni ng l amp i l l umi nates when the park-
i ng brake i s appl i ed or when the fl ui d l evel i n the
master cyl i nder i s l ow. I t wi l l al so i l l umi nate at start
up as part of a bul b check.
I f the l i ght comes on, fi rst veri fy that the parki ng
brakes are ful l y rel eased. Then check pedal acti on
and fl ui d l evel . I f a probl em i s confi rmed, i nspect the
brake hydraul i c system for l eaks.
A red warni ng l amp wi th a amber warni ng l amp
may i ndi cate a el ectroni c brake di stri buti on faul t.
Installer Caliper Dust Boot 8280
Handle C-4171
Adapter Pressure Bleeder 6921
ADJ USTABLE PEDAL SWITCH
REMOVAL
(1) Remove the steeri ng col umn openi ng cover
(Fi g. 2)(Refer to 23 - BODY/I NSTRUMENT PANEL/
STEERI NG COLUMN OPENI NG COVER - REMOV-
AL).
(2) Di sconnect the el ectri cal connector from the
adjustabl e pedal swi tch.
(3) Remove the swi tch from the steeri ng col umn
openi ng cover by squeezi ng the retai ni ng cl i ps
together and pushi ng the swi tch outwards (Fi g. 3).
INSTALLATION
(1) I nstal l the swi tch to the steeri ng col umn open-
i ng cover by pushi ng the swi tch i nwards seati ng the
retai ni ng cl i ps to the steeri ng col umn openi ng cover
(Fi g. 3).
(2) Reconnect the el ectri cal connector to the
adjustabl e pedal swi tch.
(3) I nstal l the steeri ng col umn openi ng cover (Fi g.
2)(Refer to 23 - BODY/I NSTRUMENT PANEL/
STEERI NG COLUMN OPENI NG COVER - I NSTAL-
LATI ON).
BRAKE LINES
DESCRIPTION
Fl exi bl e rubber hose i s used at both front brakes,
rear brakes and at the rear axl e juncti on bl ock. Dou-
bl e wal l ed steel tubi ng i s used. Doubl e i nverted styl e
and I SO styl e fl ares are used on the brake l i nes.
DIAGNOSIS AND TESTING - BRAKE HOSES
AND LINES
Fl exi bl e rubber hose i s used at both front and rear
brakes and at the rear axl e juncti on bl ock. I nspect
the hoses whenever the brake system i s servi ced, at
every engi ne oi l change, or whenever the vehi cl e i s i n
for servi ce.
I nspect the hoses for surface cracki ng, scuffi ng, or
worn spots. Repl ace any brake hose i mmedi atel y i f
the fabri c casi ng of the hose i s exposed due to cracks
or abrasi ons.
Al so check brake hose i nstal l ati on. Faul ty i nstal l a-
ti on can resul t i n ki nked, twi sted hoses, or contact
wi th the wheel s and ti res or other chassi s compo-
nents. Al l of these condi ti ons can l ead to scuffi ng,
cracki ng and eventual fai l ure.
The steel brake l i nes shoul d be i nspected peri odi -
cal l y for evi dence of corrosi on, twi sts, ki nks, l eaks, or
other damage. Heavi l y corroded l i nes wi l l eventual l y
rust through causi ng l eaks. I n any case, corroded or
damaged brake l i nes shoul d be repl aced.
Factory repl acement brake l i nes and hoses are rec-
ommended to ensure qual i ty, correct l ength and supe-
ri or fati gue l i fe. Care shoul d be taken to make sure
that brake l i ne and hose mati ng surfaces are cl ean
and free from ni cks and burrs. Al so remember that
ri ght and l eft brake hoses are not i nterchangeabl e.
Use new copper gaskets at al l cal i per connecti ons.
Be sure brake l i ne connecti ons are properl y made
(not cross threaded) and ti ghtened to recommended
torque.
Fig. 2 STEERING COLUMN OPENING COVER
REMOVAL/INSTALL
1 - INSTRUMENT PANEL TOP PAD
2 - STEERING COLUMN OPENING COVER
3 - SCREW (3)
Fig. 3 ADJUSTABLE PEDAL SWITCH
1 - RETAINING CLIPS
2 - ELECTRICAL CONNECTION
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE INVERTED
FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
Speci al bendi ng tool s are needed to avoi d ki nki ng
or twi sti ng of metal brake tubes. Speci al fl ari ng tool s
are needed to make a doubl e i nverted fl are or I SO
fl are.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Ream cut edges of tubi ng to ensure proper
fl are.
(3) I nstal l repl acement tube nut on the tube.
(4) I nsert tube i n fl ari ng tool .
(5) Pl ace gauge form over the end of the tube.
(6) Push tubi ng through fl ari ng tool jaws unti l
tube contacts recessed notch i n gauge that matches
tube di ameter.
(7) Ti ghten the tool bar on the tube
(8) I nsert pl ug on gauge i n the tube. Then swi ng
compressi on di sc over gauge and center tapered fl ar-
i ng screw i n recess of compressi on di sc (Fi g. 4).
(9) Ti ghten tool handl e unti l pl ug gauge i s
squarel y seated on jaws of fl ari ng tool . Thi s wi l l start
the i nverted fl are.
(10) Remove the pl ug gauge and compl ete the
i nverted fl are.
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
Speci al bendi ng tool s are needed to avoi d ki nki ng
or twi sti ng of metal brake tubes. Speci al fl ari ng tool s
are needed to make a doubl e i nverted fl are or I SO
fl are.
To make a I SO fl are use Snap-On Fl ari ng Tool
TFM-428 or equi val ent.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Remove any burrs from the i nsi de of the tube.
(3) I nstal l tube nut on the tube.
(4) Posi ti on the tube i n the fl ari ng tool fl ush wi th
the top of the tool bar (Fi g. 5). Then ti ghten the tool
bar on the tube.
(5) I nstal l the correct si ze adaptor on the fl ari ng
tool yoke screw.
(6) Lubri cate the adaptor.
(7) Al i gn the adaptor and yoke screw over the tube
(Fi g. 5).
(8) Turn the yoke screw i n unti l the adaptor i s
squarel y seated on the tool bar.
Fig. 4 Inverted
Fig. 5 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
BRAKE LINES (Continued)
BRAKE PADS / SHOES
DESCRIPTION
DESCRIPTION - FRONT DISC BRAKE SHOES
The cal i pers are twi n pi ston type. The cal i pers are
free to sl i de l ateral l y on the anchor, thi s al l ows con-
ti nuous compensati on for l i ni ng wear.
DESCRIPTION - REAR DISC BRAKE SHOES
The rear di sc brakes consi st of si ngl e pi ston fl oat-
i ng-type cal i pers and sol i d rotors. The rear cal i per i s
mounted on an anchor attached to an adapter
attached the rear axl e tube fl ange. The anchors are
secured to the adapters wi th mounti ng bol ts. The
di sc brake rotor spl ash shi el d i s part of the adaptor.
The di sc brake rotor has a bui l t i n brake drum used
for the parki ng brakes (Fi g. 6). The parki ng brake
shoes are mounted to the adaptor.
OPERATION
OPERATION - FRONT DISC BRAKE SHOES
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi stons. The fl ui d pres-
sure i s exerted equal l y and i n al l di recti ons. Thi s
means pressure exerted agai nst the cal i per pi stons
and wi thi n the cal i per bores wi l l be equal (Fi g. 7).
Fl ui d pressure appl i ed to the pi stons i s transmi t-
ted di rectl y to the i nboard brake shoe. Thi s forces the
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bores forces the cal i per to sl i de i nward on
the sl i de pi ns. Thi s acti on bri ngs the outboard brake
shoe l i ni ng i nto contact wi th the outer surface of the
di sc brake rotor.
Fl ui d pressure acti ng si mul taneousl y on the pi s-
tons and cal i per to produces a strong cl ampi ng
acti on. When suffi ci ent force i s appl i ed, fri cti on wi l l
stop the rotors from turni ng and bri ng the vehi cl e to
a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi stons. Upon rel ease of the pedal , the cal i per and
pi stons return to a rest posi ti on. The brake shoes do
not retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal s control the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal s are defl ected
outward by fl ui d pressure and pi ston movement (Fi g.
8). When the brakes (and fl ui d pressure) are
rel eased, the seal s rel ax and retract the pi stons.
The front outboard brake shoes have wear i ndi ca-
tors.
OPERATION - REAR DISC BRAKE SHOES
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi stons. The fl ui d pres-
sure i s exerted equal l y and i n al l di recti ons. Thi s
means pressure exerted agai nst the cal i per pi stons
and wi thi n the cal i per bores wi l l be equal (Fi g. 7).
Fl ui d pressure appl i ed to the pi stons i s transmi t-
ted di rectl y to the i nboard brake shoe. Thi s forces the
Fig. 6 Rear Disc Brake Rotor
1 - PARKING BRAKE DRUM SURFACE
2 - REAR DISC BRAKE ROTOR
Fig. 7 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bores forces the cal i per to sl i de i nward on
the sl i de pi ns. Thi s acti on bri ngs the outboard brake
shoe l i ni ng i nto contact wi th the outer surface of the
di sc brake rotor.
Fl ui d pressure acti ng si mul taneousl y on the pi s-
tons and cal i per to produces a strong cl ampi ng
acti on. When suffi ci ent force i s appl i ed, fri cti on wi l l
stop the rotors from turni ng and bri ng the vehi cl e to
a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi stons. Upon rel ease of the pedal , the cal i per and
pi stons return to a rest posi ti on. The brake shoes do
not retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal s control the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal s are defl ected
outward by fl ui d pressure and pi ston movement (Fi g.
8). When the brakes (and fl ui d pressure) are
rel eased, the seal s rel ax and retract the pi stons.
The front outboard brake shoes have wear i ndi ca-
tors.
REMOVAL
REMOVAL- FRONT DISC BRAKE SHOES
(3) Drai n smal l amount of fl ui d from master cyl i n-
der brake reservoi r wi th clean sucti on gun.
(4) Bottom cal i per pi stons i nto the cal i per by pry-
i ng the cal i per over (Fi g. 9).
(5) Remove the cal i per support spri ng by pryi ng
the spri ng out of the cal i per (Fi g. 10).
(6) Remove the cal i per sl i de pi n bushi ng caps and
remove the sl i de pi ns (Fi g. 11).
(7) Remove cal i per from the anchor.
Fig. 8 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
Fig. 9 Bottoming Caliper Piston
1 - ROTOR
2 - CALIPER
Fig. 10 Caliper Support Spring
1 - SUPPORT SPRING
2 - CALIPER
BRAKE PADS / SHOES (Continued)
(8) Secure cal i per to nearby suspensi on part wi th
wi re. Do not allow brake hose to support caliper
weight.
(9) Remove the i nboard brake shoe from the cal i -
per (Fi g. 12).
(10) Remove the outboard brake shoe (Fi g. 13)
from the cal i per anchor.
REMOVAL - REAR DISC BRAKE SHOES
(2) Remove rear wheel and ti re assembl y.
der brake reservoi r wi th a clean sucti on gun.
Fig. 11 Caliper Slide
1 - SLIDE PIN
2 - SLIDE PIN
3 - CALIPER
Fig. 12 Inboard Brake Shoe
1 - CALIPER
2 - INBOARD SHOE
Fig. 13 Outboard Brake Shoe
1 - CALIPER ANCHOR
2 - OUTBOARD BRAKE SHOE
1 - CALIPER
2 - CALIPER ANCHOR
(8) Secure cal i per to nearby suspensi on part wi th
wi re. Do not allow brake hose to support caliper
weight.
(9) Remove the i nboard brake shoe from the cal i -
per (Fi g. 17).
(10) Remove outboard brake shoe (Fi g. 18) from
the cal i per anchor.
INSTALLATION
INSTALLATION - FRONT DISC BRAKE SHOES
(1) I nstal l the i nboard brake shoe onto the cal i per
(Fi g. 12).
(2) I nstal l the outboard shoe onto the cal i per
anchor (Fi g. 13).
(3) Lubri cate the sl i de pi ns and sl i de pi n bushi ngs
wi th Dow Corni ng grease G807 or the grease pro-
vi ded wi th the brake shoes.
(4) I nstal l cal i per on the cal i per anchor.
(5) I nstal l the cal i per sl i de pi n and ti ghten to
29-41 Nm (21-30 ft. l bs.).
(6) I nstal l the cal i per sl i de pi n bushi ng caps.
(7) I nstal l the cal i per support spri ng i n the top
end of the cal i per and under the anchor. Then i nstal l
other end i nto the l ower cal i per hol e. Hol d the spri ng
i nto the cal i per hol e wi th your thumb whi l e pryi ng
the end of the spri ng out and down under the anchor
wi th a screw dri ve.
1 - CALIPER
2 - ANCHOR
3 - SUPPORT SPRING
Fig. 16 Caliper Slide Pins
1 - CALIPER
2 - SLIDE PINS
1 - CALIPER
2 - INBOARD SHOE
(8) I nstal l wheel and ti re assembl y.
(10) Pump brake pedal unti l cal i per pi stons and
brake shoes are seated and a fi rm brake pedal i s
obtai ned.
(11) Fi l l brake fl ui d.
INSTALLATION - REAR DISC BRAKE SHOES
(1) I nstal l the i nboard brake shoe onto the cal i per
(Fi g. 17).
(2) I nstal l the outboard brake shoe onto the cal i per
anchor (Fi g. 18).
vi ded wi th the brake shoes.
(4) I nstal l cal i per on the anchor.
29-41 Nm (21-30 ft. l bs.).
(10) Pump brake pedal unti l cal i per pi ston and
brake shoes are seated and a fi rm brake pedal i s
obtai ned.
(11) Fi l l brake fl ui d l evel i f necessary.
DISC BRAKE CALIPERS
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(2) Remove front wheel and ti re assembl y.
der brake reservoi r wi th clean sucti on gun.
Fig. 18 Outboard Brake Shoe
1 - OUTBOARD BRAKE SHOE
2 - CALIPER ANCHOR
3 - ROTOR
1 - ROTOR
2 - CALIPER
(5) Remove brake hose banjo bol t and gasket
washers. Di scard gasket washers.
(9) Remove the i nboard brake shoe (Fi g. 22).
REMOVAL - REAR DISC BRAKE CALIPER
der brake reservoi r wi th a clean sucti on gun.
1 - SUPPORT SPRING
2 - CALIPER
Fig. 21 Slide Pins
1 - SLIDE PIN
2 - SLIDE PIN
3 - CALIPER
1 - CALIPER
2 - INBOARD SHOE
1 - CALIPER
2 - CALIPER ANCHOR
DISC BRAKE CALIPERS (Continued)
(5) Remove brake hose banjo bol t and di scard gas-
ket washers.
(9) Remove the i nboard brake shoe (Fi g. 26).
1 - CALIPER
2 - ANCHOR
3 - SUPPORT SPRING
Fig. 25 Caliper Slide Pins
1 - CALIPER
2 - SLIDE PINS
1 - CALIPER
2 - INBOARD SHOE
DISASSEMBLY
DISASSEMBLY - FRONT DISC BRAKE CALIPER
(1) Drai n the brake fl ui d from cal i per.
(2) C-cl amp a bl ock of wood over one pi ston (Fi g.
27).
(3) Take another pi ece of wood and pad i t wi th
one-i nch thi ckness of shop towel s. Pl ace thi s pi ece i n
the outboard shoe si de of the cal i per i n front of the
other pi ston. Thi s wi l l cushi on and protect cal i per
pi ston duri ng removal (Fi g. 28).
(4) To remove the cal i per pi ston di rect short
bursts of low pressure air wi th a bl ow gun
through the cal i per brake hose port. Use onl y enough
ai r pressure to ease the pi ston out.
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS COULD
RESULT IN PERSONAL INJURY.
(5) Remove the C-cl amp and bl ock of wood from
the cal i per and cl amp i t over the dust boot of the
fi rst pi ston removed. Thi s wi l l seal the empty pi ston
bore.
(6) Move the padded pi ece of wood i n front of the
other pi ston.
(7) Remove the second pi ston usi ng the same pro-
cedure wi th short bursts of low pressure air.
(8) Remove pi ston dust boots wi th a sui tabl e pry
tool (Fi g. 29)and di scard.
Fig. 27 C-Clamp One Piston
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - CALIPER
Fig. 28 Protect Caliper Piston
1 - CALIPER
2 - PADDED BLOCK OF WOOD
3 - C-CLAMP
Fig. 29 Piston Dust Boot Removal
1 - CALIPER
2 - PISTON DUST BOOT
(9) Remove pi ston seal s from cal i per (Fi g. 30) and
di scard.
CAUTION: Do not scratch piston bore while remov-
ing the seals.
(10) Remove cal i per sl i de pi n bushi ngs (Fi g. 31).
(11) Remove cal i per bl eed screw.
DISASSEMBLY - REAR DISC BRAKE CALIPER
(1) Drai n brake fl ui d out of cal i per.
(2) Take a pi ece of wood and pad i t wi th one-i nch
thi ckness of shop towel s. Pl ace thi s pi ece i n the out-
board shoe si de of the cal i per i n front of the pi ston.
Thi s wi l l cushi on and protect cal i per pi ston duri ng
removal (Fi g. 32).
(3) To remove cal i per pi ston di rect short bursts
of low pressure air wi th a bl ow gun through the
cal i per brake hose port (Fi g. 33). Use onl y enough ai r
pressure to ease the pi ston out.
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.
Fig. 30 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
Fig. 31 Caliper Slide Pin Bushings
1 - CALIPER
2 - BUSHING
3 - CALIPER SLIDE PIN
Fig. 32 Padding Caliper Interior
1 - SHOP TOWELS OR CLOTHS
2 - CALIPER
Fig. 33 Caliper Piston Removal
1 - CALIPER PISTON
2 - AIR GUN
3 - PADDING MATERIAL
(4) Remove cal i per pi ston dust boot wi th a sui tabl e
pry tool (Fi g. 34) and di scard.
(5) Remove pi ston seal from the cal i per (Fi g.
35)and di scard.
CAUTION: Do not scratch the piston bore while
removing the seal.
(6) Remove cal i per sl i de pi n bushi ngs (Fi g. 36).
(7) Remove cal i per bl eed screw.
CLEANING - DISC BRAKE CALIPER
Cl ean the cal i per components wi th cl ean brake
fl ui d or brake cl ean onl y. Wi pe the cal i per and pi ston
dry wi th l i nt free towel s or use l ow pressure com-
pressed ai r.
CAUTION: Do not use gasoline, kerosene, paint
thinner, or similar solvents. These products may
leave a residue that could damage the piston and
seal.
INSPECTION - DISC BRAKE CALIPER
The pi ston i s made from a phenol i c resi n (pl asti c
materi al ) and shoul d be smooth and cl ean.
The pi ston must be repl aced i f cracked or scored.
Do not attempt to restore a scored pi ston surface by
sandi ng or pol i shi ng.
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can be lightly pol i shed wi th a brake
hone to remove very mi nor surface i mperfecti ons
(Fi g. 37). The cal i per shoul d be repl aced i f the bore i s
severel y corroded, rusted, scored, or i f pol i shi ng
woul d i ncrease bore di ameter more than 0.025 mm
(0.001 i nch).
Fig. 34 Caliper Piston Dust
1 - PISTON DUST BOOT
2 - CALIPER
Fig. 35 Piston Seal Removal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
Fig. 36 Slide Pin And Bushing
1 - BUSHING
ASSEMBLY
ASSEMBLY - FRONT DISC BRAKE CALIPER
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubri cate cal i per pi stons, pi ston seal s and pi s-
ton bores wi th cl ean brake fl ui d.
(2) I nstal l new pi ston seal s i nto seal groove wi th
fi nger (Fi g. 38).
NOTE: Verify seal is fully seated and not twisted.
(3) I nstal l new dust boot on cal i per pi ston and seat
boot l i p i nto pi ston groove (Fi g. 39).
(4) Stretch boot rearward to strai ghten boot fol ds,
then move boot forward unti l fol ds snap i nto pl ace.
(5) I nstal l pi ston i nto cal i per bore and press pi ston
down to the bottom of the cal i per bore by hand or
wi th hammer handl e (Fi g. 40).
Fig. 37 Polishing Piston Bore
1 - SPECIAL HONE
2 - CALIPER
3 - PISTON BORE
Fig. 38 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
Fig. 39 Dust Boot On Piston
1 - PISTON
2 - DUST BOOT
Fig. 40 Caliper Piston Installation
1 - CALIPER
2 - DUST BOOT
3 - PISTON
(6) Seat dust boot i n cal i per (Fi g. 41) wi th
I nstal l er 8280 and Handl e C-4171.
(7) I nstal l the second pi ston and dust boot.
(8) I nstal l cal i per sl i de pi n bushi ngs i nto the cal i per.
(9) I nstal l cal i per bl eed screw.
ASSEMBLY - REAR DISC BRAKE CALIPER
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubri cate cal i per pi ston, pi ston seal and pi ston
bore wi th cl ean brake fl ui d.
(2) I nstal l new pi ston seal i nto seal groove wi th
fi nger (Fi g. 42).
NOTE: Verify seal is fully seated and not twisted.
(3) I nstal l new dust boot on cal i per pi ston and seat
boot l i p i nto pi ston groove (Fi g. 43).
(4) Stretch boot rearward to strai ghten boot fol ds,
then move boot forward unti l fol ds snap i nto pl ace.
(5) I nstal l pi ston i nto cal i per bore and press pi ston
down to the bottom of the cal i per bore by hand or
wi th hammer handl e (Fi g. 44).
Fig. 41 Seating Dust Boot
1 - HANDLE
2 - CALIPER
3 - DUST BOOT INSTALLER
Fig. 42 Piston Seal Installation
1 - SEAL GROOVE
2 - PISTON SEAL
Fig. 43 Dust Boot On Piston
1 - PISTON
2 - DUST BOOT
Fig. 44 Caliper Piston Installation
1 - PISTON
2 - BOOT
(6) Seat dust boot i n cal i per wi th I nstal l er 8280
and Handl e C-4171 (Fi g. 45).
(7) I nstal l cal i per sl i de pi n bushi ngs i nto the cal i -
per (Fi g. 46).
(8) I nstal l cal i per bl eed screw.
INSTALLATION
INSTALLATION - FRONT DISC BRAKE CALIPER
(1) I nstal l the i nboard brake shoe (Fi g. 22).
vi ded wi th the cal i per.
(3) I nstal l the cal i per on the anchor.
29-41 Nm (21-30 ft. l bs.).
(7) I nstal l brake hose to cal i per wi th new gasket
washers and ti ghten banjo bol t to 31 Nm (23 ft.
l bs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening banjo bolt.
(8) Fi l l and bl eed brake system.
(11) Veri fy brake fl ui d l evel .
INSTALLATION - REAR DISC BRAKE CALIPER
(1) I nstal l the i nboard brake shoe (Fi g. 26).
vi ded wi th the cal i per.
(3) I nstal l the cal i per on the anchor.
29-41 Nm (21-30 ft. l bs.).
(5) I nstal l the cal i per sl i de pi n caps.
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(7) I nstal l brake hose to cal i per wi th a new gasket
washers and ti ghten banjo bol t to 31 Nm (23 ft. l bs.).
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
Fig. 45 Piston Dust Boot Installation
1 - HANDLE
2 - INSTALLER
3 - DUST BOOT
Fig. 46 Slide Pin And Bushing
2 - BUSHING
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder wi th
reservoi r, cal i per seal s, HCU and al l hydraul i c fl ui d
hoses.
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
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, etc.
FLUID RESERVOIR
REMOVAL
(1) Remove reservoi r cap and remove fl ui d wi th a
cleansucti on gun.
(2) Remove the wi re connector from the brake fl ui d
l evel sensor.
(3) I nsert the tool (Fi g. 47) provi ded wi th the res-
ervoi r to rel ease the reservoi r retai ni ng tabs.
(4) Pul l the reservoi r strai ght up out of the cyl i n-
der.
(5) Remove and di scard grommets from the cyl i n-
der body.
INSTALLATION
(1) Lubri cate new grommets wi th cl ean brake
fl ui d. I nstal l new grommets i nto the cyl i nder body.
CAUTION: Do not use tools to install the grommets.
Tools may cut, or tear the grommets. Install the
grommets using finger pressure only.
(2) Start reservoi r i n grommets then press the res-
ervoi r strai ght down to seat the reservoi r i nto the
cyl i nder grommets.
CAUTION: Do not rock the reservoir during installa-
tion.
(3) Veri fy retai ni ng tabs are seated.
(4) I nstal l the wi re connector to the brake fl ui d
l evel sensor.
(5) Fi l l master cyl i nder.
MASTER CYLINDER
DESCRIPTION
The master cyl i nder body i s made of al umi num
and contai ns a pri mary and secondary pi ston assem-
bl y. The cyl i nder body i ncl udi ng the pi ston assem-
bl i es are not servi ceabl e. I f di agnosi s i ndi cates an
i nternal probl em wi th the cyl i nder body, i t must be
repl aced as an assembl y. The master cyl i nder has a
removabl e reservoi r and fl ui d l evel i ndi cator. The res-
ervoi r, reservoi r grommets, reservoi r cap and fl ui d
l evel swi tch are the onl y repl aceabl e parts on the
master cyl i nder.
Fig. 47 Release Tool
1 - RESERVOIR
2 - RELEASE TOOL
3 - RETAINING TABS
FLUID (Continued)
OPERATION
The master cyl i nder bore contai ns a pri mary and
secondary pi ston. The pri mary pi ston suppl i es
hydraul i c pressure to the front brakes. The secondary
pi ston suppl i es hydraul i c pressure to the rear brakes.
The master cyl i nder reservoi r stores reserve brake
fl ui d for the hydraul i c brake ci rcui ts.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
NOTE: Inspect and repair any external fluid leaks
before performing test.
(1) Start engi ne and check booster vacuum hose
connecti ons. A hi ssi ng noi se i ndi cates vacuum l eak.
Correct any vacuum l eak before proceedi ng.
(2) Stop engi ne and shi ft transmi ssi on i nto Neutral .
(3) Pump brake pedal unti l al l vacuum reserve i n
booster i s depl eted.
(4) Press and hol d brake pedal under l i ght foot
pressure. The pedal shoul d hol d fi rm, i f the pedal
fal l s away the master cyl i nder or HCU may be faul ty
(i nternal l eakage).
(5) Start engi ne and note pedal acti on. I t shoul d
fal l away sl i ghtl y under l i ght foot pressure then hol d
fi rm. I f no pedal acti on i s di scerni bl e, power booster,
vacuum suppl y, or vacuum check val ve i s faul ty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebui l d booster vacuum reserve as fol l ows:
Rel ease brake pedal . I ncrease engi ne speed to 1500
rpm, cl ose the throttl e and turn off the engi ne.
(7) Wai t a mi ni mum of 90 seconds and try brake
acti on agai n. Booster shoul d provi de two or more vac-
uum assi sted pedal appl i cati ons. I f vacuum assi st i s
not provi ded, some component of the booster i s faul ty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check val ve
wi th short l ength of hose and T-fi tti ng (Fi g. 48).
(2) Start and run engi ne at curb i dl e speed for one
mi nute.
(3) Observe the vacuum suppl y. I f vacuum suppl y
i s not adequate, repai r vacuum suppl y.
(4) Cl amp hose shut between vacuum source and
check val ve.
(5) Stop engi ne and observe vacuum gauge.
(6) I f vacuum drops more than one i nch HG (33
mi l l i bars) wi thi n 15 seconds, booster di aphragm,
check val ve or check val ve seal /grommet i s faul ty.
POWER BOOSTER CHECK VALVE TEST
(1) Di sconnect vacuum hose from check val ve.
(2) Remove check val ve and val ve seal from booster.
(3) Use a hand operated vacuum pump for test.
(4) Appl y 51-67 kPa (15-20 i n.) vacuum at l arge
end of check val ve (Fi g. 49).
(5) Vacuum shoul d hol d steady. I f gauge on pump
i ndi cates vacuum l oss the check val ve and seal
shoul d be repl aced.
Fig. 48 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 49 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
MASTER CYLINDER (Continued)
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING PROCEDURE
A new master cyl i nder shoul d be bl ed before i nstal -
l ati on on the vehi cl e. Requi red bl eedi ng tool s i ncl ude
bl eed tubes and a wood dowel to stroke the pi stons.
Bl eed tubes can be fabri cated from brake l i ne.
(1) Mount master cyl i nder i n vi se wi th brass jaws.
(2) Attach bl eed tubes to cyl i nder outl et ports.
Then posi ti on each tube end i nto the bottom of the
reservoi r (Fi g. 50).
(3) Fi l l reservoi r wi th fresh brake fl ui d.
(4) Press cyl i nder pi stons i nward wi th wood dowel .
Then rel ease pi stons and al l ow them to return under
spri ng pressure. Conti nue bl eedi ng operati ons unti l
ai r bubbl es are no l onger vi si bl e i n fl ui d.
REMOVAL
(1) Remove the wi re connector from the brake fl ui d
l evel sensor.
(2) Remove brake l i nes from master cyl i nder.
(3) Remove nuts that attach master cyl i nder to
booster studs (Fi g. 51).
(4) Remove master cyl i nder from booster.
INSTALLATION
NOTE: Bleed new master cylinder on bench before
installation, refer to Service Procedures.
(1) Have an assi stant depress the brake pedal
whi l e gui di ng the master cyl i nder on the booster rod
and mounti ng studs.
CAUTION: Do not depress brake pedal too hard and
ensure the booster rod is in the master cylinder pis-
ton or booster/master cylinder damage will occur.
(2) I nstal l master cyl i nder mounti ng nuts and
ti ghten nuts to 25 Nm (18 l b. l bs.).
NOTE: Use original or factory replacement nuts only.
(3) I nstal l brake l i nes and ti ghten to 16 Nm (144
i n. l bs.).
(4) I nstal l fl ui d l evel sensor connector.
PEDAL
DESCRIPTION
DESCRIPTION - STANDARD PEDAL
A suspended-type brake pedal i s used, the pedal
pi vots on a shaft mounted i n the pedal support
bracket. The bracket i s attached to the dash panel .
The brake pedal assembl y and pedal pad are the
onl y servi ceabl e component.
DESCRIPTION - ADJUSTABLE PEDALS
The Adjustabl e Pedal s System (APS) i s desi gned to
enabl e the fore and aft reposi ti oni ng of the brake and
accel erator pedal s. Thi s resul ts i n i mproved ergonom-
i cs i n rel ati on to the steeri ng wheel for tal l er and
shorter dri vers. Bei ng abl e to adjust the pedal posi -
Fig. 50 Master Cylinder Bleeding
1 - BLEEDING TUBES
2 - RESERVOIR
Fig. 51 Master Cylinder Mounting
1 - MOUNTING NUT
2 - SENSOR CONNECTOR
3 - MOUNTING NUT
4 - BRAKE LINES
MASTER CYLINDER (Continued)
ti ons al so al l ows the dri ver to set steeri ng wheel ti l t
and seat posi ti on to the most comfortabl e posi ti on.
The posi ti on of the brake and accel erator pedal s can
be adjusted wi thout compromi si ng safety or comfort
i n actuati ng the pedal s. Reposi ti oni ng the pedal s
does not change the effort requi red for actuati on.
Change of pedal posi ti on i s accompl i shed by means
of a motor dri ven screw. Operati ng the adjustabl e
pedal swi tch acti vates the pedal dri ve motor. The
pedal dri ve motor turns a screw that changes the
posi ti on of the brake and accel erator pedal s. The
pedal can be moved rearward (cl oser to the dri ver) or
forward (away from dri ver). The brake pedal i s
moved on i ts dri ve screw to a posi ti on where the
dri ver feel s most comfortabl e (Fi g. 52).
The accel erator pedal i s moved at the same ti me
and the same di stance as the brake pedal . The accel -
erator pedal adjustment screw i s turned by a fl exi bl e
shaft sl aved off the brake adjustment screw.
Nei ther the pedal dri ve motor nor dri ve mecha-
ni sm are subject to the mechani cal stress of brake or
accel erator appl i cati on.
SYSTEM FEATURES:
Range of Adjustment: The pedal s may be
adjusted up to 3 i n. (75 mm)
Pedal Adjustment Speed: 0.5 i n./sec (12.5
mm/sec)
Pedal Adjustment I nhi bi tors: Pedal adjust-
ment i s i nhi bi ted when the vehi cl e i s i n reverse or
when crui se control i s acti vated.
Memory: An opti onal memory feature i s avai l -
abl e. Thi s al l ows stori ng of one or two preferred
pedal posi ti ons i n the Adjustabl e Pedal Modul e
(APM). A preferred posi ti on can be stored and
recal l ed usi ng the door-mounted swi tches. A stored
pedal posi ti on can be recal l ed (but not stored)
usi ng the Remote Keyl ess Entry (RKE).
Adjustabl e Pedal Feedback Message: The El ec-
troni c Vehi cl e I nformati on Center (EVI C) wi l l di spl ay
a message when the APS i s di sabl ed. i e: Adjustabl e
Pedal Di sabl ed - Crui se Control Engaged or Adjust-
abl e Pedal Di sabl ed - Vehi cl e i n Reverse.
Damage Preventi on: Foot pressure or debri s
can stal l pedal adjustment. I n order to avoi d dam-
age to system components duri ng pedal adjust-
ment, the APM wi l l moni tor pedal posi ti on sensor
vol tage. I f the APM does not detect expected vol t-
age change wi thi n 1.5 seconds, i t wi l l cut power to
the adjustabl e pedal motor.
OPERATION
The brake pedal i s attached to the booster push
rod. When the pedal i s depressed, the pri mary
booster push rod i s depressed whi ch moves the
booster secondary rod. The booster secondary rod
depresses the master cyl i nder pi ston.
REMOVAL
REMOVAL - NON-ADJUSTABLE PEDAL
(1) Remove retai ner cl i p that hol ds booster to
pedal pi n (Fi g. 53).
Fig. 52 ADJUSTABLE PEDALS ASSEMBLY
1 - HARNESS
2 - ADJUSTABLE PEDAL BRACKET
3 - CABLE
4 - ACCELERATOR PEDAL
5 - BRAKE PEDAL
6 - ADJUSTABLE PEDAL MOTOR
7 - BRAKE LIGHT SWITCH
8 - ADJUSTABLE PEDALS MODULE
Fig. 53 Push Rod Retainer Clip
1 - RETAINER CLIP
2 - PUSH ROD
3 - PEDAL PIN
PEDAL (Continued)
(2) Remove nut from pedal shaft.
(3) Sl i de pedal shaft out and remove brake pedal .
(4) Remove pedal bushi ngs (Fi g. 54) i f they are to
be repl aced.
REMOVAL - ADJUSTABLE PEDALS
NOTE: If possible put the pedals in the full forward
position.
(1) Di sconnect the negati ve battery cabl e.
(2) Remove the cl uster bezel (Refer to 23 - BODY/
I NSTRUMENT PANEL/CLUSTER BEZEL - REMOV-
AL).
(Refer to 23 - BODY/I NSTRUMENT PANEL/STEER-
I NG COLUMN OPENI NG COVER - REMOVAL).
(4) Di sconnect the modul e el ectri cal connector.
(5) Remove the brake l i ght swi tch.
(6) Di sconnect the booster rod cl i p (Fi g. 53).
(7) Di sconnect the accel erator cabl e from the
pedal .
(8) Lock the steeri ng wheel i nto pl ace.
(9) Remove the l ower steeri ng shaft pi nch bol t
(Fi g. 56).
(10) Separate the l ower shaft coupl er and push for-
ward (Fi g. 56).
(11) Remove the two pedal bracket upper nuts
(Fi g. 55).
(12) Remove the brake booster nuts (Fi g. 56).
(13) Remove the accel erator pedal nuts (Fi g. 57).
(14) Remove the I CU mounti ng bracket nuts and
bol ts and move the I CU and booster forward thi s wi l l
al l ow enough cl earance to remove the adjustabl e
pedal bracket from over the booster push rod.
(15) Remove the pedal from the vehi cl e (Fi g. 56).
(16) Transfer the modul e i f needed.
Fig. 54 Pedal Bushings
1 - BUSHING
2 - BUSHING
3 - SHAFT NUT
4 - PEDAL SHAFT
Fig. 55 UPPER MOUNTING NUTS
1 - UPPER MOUNTING STUDS
2 - ACCELERATOR MOUNTING STUDS
3 - UPPER MOUNTING NUT
4 - MOTOR
5 - ADJUSTABLE PEDAL BRACKET
Fig. 56 ADJUSTABLE PEDAL BRACKET
1 - BRAKE LIGHT SWITCH
2 - STEERING COLUMN
4 - ADJUSTABLE PEDALS MOUNTING BRACKET
5 - BRAKE PEDAL
6 - MOTOR MOUNTING BRACKET
7 - BRAKE BOOSTER MOUNTING NUTS
(4)
PEDAL (Continued)
INSTALLATION
INSTALLATION - NON-ADJUSTABLE PEDAL
(1) Lubri cate bushi ngs, pedal shaft and pedal pi n
wi th Mopar mul ti -mi l eage grease.
(2) I nstal l bushi ngs i nto pedal .
(3) Posi ti on pedal i n bracket and i nstal l pedal
shaft i n support and through pedal .
(4) I nstal l new nut on pedal shaft and ti ghten to
27 Nm (20 ft. l bs.).
NOTE: Pedal shaft nut should not be reused.
(5) I nstal l booster push rod on pedal pi n and
i nstal l retai ner cl i p on pedal pi n.
(6) Check and adjust stop l amp swi tch i f necessary.
INSTALLATION - ADJUSTABLE PEDALS
(1) I nstal l the pedal to the vehi cl e (Fi g. 56).
(2) Reposi ti on the I CU and booster, I nstal l the
I CU mounti ng bracket nuts and bol ts.
28 N
(3) I nstal l the brake booster nuts. Ti ghten to 28
Nm ( 21 ft. l bs.). (Fi g. 56).
(4) I nstal l the pedal bracket upper nuts. Ti ghten
to 12 Nm ( 9 ft. l bs.). (Fi g. 56).
(5) I nstal l the accel erator pedal nuts. Ti ghten to
28 Nm ( 21 ft. l bs.). (Fi g. 57).
(6) I nstal l the l ower steeri ng shaft coupl er over the
shaft (Fi g. 56).
(7) I nstal l the l ower steeri ng shaft pi nch bol t (Fi g.
56).
(8) Unl ock the steeri ng wheel .
(9) Reconnect the accel erator cabl e to the pedal
(Fi g. 56).
(10) Reconnect the booster rod cl i p (Fi g. 56).
(11) I nstal l the brake l i ght swi tch.
(12) Reconnect the modul e el ectri cal connector.
(13) I nstal l the steeri ng col umn openi ng cover
I NG COLUMN OPENI NG COVER - I NSTALLA-
TI ON).
(14) I nstal l the cl uster bezel (Refer to 23 - BODY/
I NSTRUMENT PANEL/CLUSTER BEZEL -
I NSTALLATI ON).
(15) Reconnect the negati ve battery cabl e.
PEDAL MOTOR
REMOVAL
AL).
(4) Remove the two mounti ng screws (Fi g. 58).
(5) Di sconnect the el ectri cal connector (Fi g. 58).
(6) Remove the adjustabl e pedal motor (Fi g. 58).
INSTALLATION
(1) I nstal l the adjustabl e pedal motor (Fi g. 58).
(2) Reconnect the el ectri cal connector (Fi g. 58).
(3) I nstal l the two mounti ng screws (Fi g. 58).
TI ON).
Fig. 57 ACCELERATOR MOUNTING BRACKET
1 - ACCELERATOR MOUNTING NUTS
2 - ADJUSTABLE PEDALS BRACKET
Fig. 58 ADJUSTABLE PEDALS MOTOR
1 - ELECTRICAL CONNECTOR
2 - PEDALS MOTOR
3 - MOUNTING SCREWS HOLES
PEDAL (Continued)
I NSTALLATI ON).
POWER BRAKE BOOSTER
DESCRIPTION
The booster assembl y consi sts of a housi ng di vi ded
i nto separate chambers by two i nternal di aphragms.
The outer edge of each di aphragm i s attached to the
booster housi ng.
Two push rods are used i n the booster. The pri -
mary push rod connects the booster to the brake
pedal . The secondary push rod connects the booster
to the master cyl i nder to stroke the cyl i nder pi stons.
OPERATION
The atmospheri c i nl et val ve i s opened and cl osed
by the pri mary push rod. Booster vacuum suppl y i s
through a hose attached to an i ntake mani fol d fi tti ng
at one end and to the booster check val ve at the
other. The vacuum check val ve i n the booster housi ng
i s a one-way devi ce that prevents vacuum l eak back.
Power assi st i s generated by uti l i zi ng the pressure
di fferenti al between normal atmospheri c pressure
and a vacuum. The vacuum needed for booster oper-
ati on i s taken di rectl y from the engi ne i ntake mani -
fol d. The entry poi nt for atmospheri c pressure i s
through a fi l ter and i nl et val ve at the rear of the
housi ng (Fi g. 59) .
The chamber areas forward of the booster di a-
phragms are exposed to vacuum from the i ntake
mani fol d. The chamber areas to the rear of the di a-
phragms, are exposed to normal atmospheri c pres-
sure of 101.3 ki l opascal s (14.7 pounds/square i n.).
Brake pedal appl i cati on causes the pri mary push
rod to open the atmospheri c i nl et val ve. Thi s exposes
the area behi nd the di aphragms to atmospheri c pres-
sure. The resul ti ng pressure di fferenti al provi des the
extra appl y force for power assi st.
The booster check val ve, check val ve grommet and
booster seal s are servi ceabl e.
PEDAL MOTOR (Continued)
Fig. 59 Power Brake BoosterTypical
1 - VACUUM CHECK VALVE
2 - FRONT DIAPHRAGM
3 - REAR DIAPHRAGM
4 - HOUSING
5 - SEAL
6 - AIR FILTER
7 - PRIMARY PUSH ROD (TO BRAKE PEDAL)
8 - ATMOSPHERIC INLET VALVE ASSEMBLY
9 - BOOSTER MOUNTING STUDS (4)
10 - SECONDARY PUSH ROD (TO MASTER CYLINDER)
11 - MASTER CYLINDER MOUNTING STUD (2)
12 - SPRING
POWER BRAKE BOOSTER (Continued)
REMOVAL
(1) Remove the master cyl i nder.
(2) Di sconnect vacuum hose at booster check val ve.
(3) Remove retai ner cl i p (Fi g. 60) that hol ds
booster push rod on pedal pi n. Then sl i de push rod
off pi n.
(4) Remove four nuts (Fi g. 61) that attach booster
to dash panel .
(5) I n engi ne compartment, sl i de booster forward,
ti l t i t upward sl i ghtl y, and remove i t from engi ne
compartment.
INSTALLATION
(1) Check condi ti on of grommet that secures check
val ve i n booster. Repl ace grommet i f cut, torn, or
l oose.
(2) I nstal l new booster dash seal .
(3) Al i gn and posi ti on booster on engi ne compart-
ment si de of dash panel .
(4) I nsi de passenger compartment:
(a) Lubri cate pedal pi n Mopar mul ti -mi l eage
grease.
(b) I nstal l booster attachi ng nuts on studs.
Ti ghten attachi ng nuts to 39 Nm (29 ft. l bs.).
(c) Sl i de booster push rod on pedal pi n. Then
secure rod to pi n wi th retai ner cl i p.
(5) I n engi ne compartment, attach vacuum hose to
booster check val ve.
(6) I nstal l the master cyl i nder wi th new gasket
and nuts.
CAUTION: The master cylinder installation proce-
dure must be perform as written or damage to the
booster/master cylinder may occur.
ROTORS
DIAGNOSIS AND TESTING - FRONT DISC
BRAKE ROTOR
ROTOR MINIMUM THICKNESS
Rotor mi ni mum usabl e thi ckness i s 24.5 mm (0.964
i n.). Do not resurface a rotor i f machi ni ng woul d
cause thi ckness to fal l bel ow thi s l i mi t.
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f refi ni shi ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
FRONT ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Fig. 60 Retainer Clip
1 - RETAINER CLIP
2 - PUSH ROD
3 - PEDAL PIN
Fig. 61 Power Brake Booster Mounting
1 - BOOSTER
2 - DASH PANEL
POWER BRAKE BOOSTER (Continued)
Measure rotor thi ckness a mi ni mum of si x poi nts
around the rotor face. Posi ti on the mi crometer approx-
i matel y 19 mm (3/4 i n.) from the rotor outer ci rcumfer-
ence for each measurement (Fi g. 62).
Thi ckness shoul d not vary by more than 0.0127 mm
(0.0005 i n.) from poi nt to poi nt on the rotor. Refi ni sh or
repl ace the rotor i f necessary.
NOTE: A hub mounted on-vehicle lathe is recom-
mended. This type of lathe trues the rotor to the vehi-
cles hub/bearing.
CAUTION: For vehicles equipped with the Quadra-
Drive System, consisting of the NV-247 transfer case
and a Vari-Lok differential in the front and rear axles,
the following steps must be done prior to the use of a
hub mounted on-vehicle brake lathe. Disconnect the
driveshaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT - REMOVAL)
from the respective axle on which the brake rotors are
being machined. Temporarily remove both brake cali-
pers (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL) from the axle
while disc rotor machining is in process. Both steps
will prevent unnecessary loads to the hub mounted
on-vehicle lathe and speed machining times. Install a
thread lock material to the driveshaft attaching bolts
when reinstalling (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION).
Front rotors and hub/beari ngs are matched mounted
for mi ni mum l ateral runout. Before removi ng the rotor,
mark the rotor and hub/beari ng to mai ntai n ori gi nal
ori entati on.
FRONT ROTOR LATERAL RUNOUT
Check rotor l ateral runout whenever pedal pul sati on,
or rapi d, uneven brake l i ni ng wear has occurred.
The rotor must be securel y cl amped to the hub to
ensure an accurate runout measurement. Secure the
rotor wi th a mi ni mum of 3 l ug nuts and l arge di ameter
fl at washers on each stud.
Use a di al i ndi cator to check l ateral runout (Fi g. 63).
Maxi mum al l owabl e rotor l ateral runout i s 0.05 mm
(0.002 i n.).
DIAGNOSIS AND TESTING - REAR DISC
BRAKE ROTOR
ROTOR MINIMUM THICKNESS
Mi ni mum usabl e thi ckness of the rear di sc brake
rotor i s 8.5 mm (0.335 i n.). The thi ckness speci fi cati on
i s l ocated on the center secti on of the rotor.
Never resurface a rotor i f machi ni ng woul d cause
thi ckness to fal l bel ow thi s l i mi t.
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f refi ni shi ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
REAR ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul sa-
ti on, noi se and shudder.
Measure rotor thi ckness at a mi ni mum of si x poi nts
around the rotor face. Posi ti on the mi crometer approxi -
matel y 19 mm (3/4 i n.) from the rotor outer ci rcumfer-
ence for each measurement (Fi g. 62).
Thi ckness shoul d not vary by more than 0.0127 mm
(0.0005 i n.) from poi nt to poi nt on the rotor. Refi ni sh or
repl ace the rotor i f necessary.
REAR ROTOR LATERAL RUNOUT
Check rotor l ateral runout whenever di agnosi s i ndi -
cates pedal pul sati on and rapi d, uneven brake l i ni ng
wear.
The rotor must be securel y cl amped to the hub to
ensure an accurate runout measurement. Secure the
rotor wi th the wheel nuts and 4 or 5 l arge di ameter fl at
washers on each stud.
Use a di al i ndi cator to check l ateral runout (Fi g. 63).
Maxi mum al l owabl e l ateral runout i s 0.76 mm (0.003 i n.).
Fig. 62 Measuring Rotor Thickness Variation
1 - MICROMETER
2 - ROTOR
Fig. 63 Checking Rotor Lateral Runout
1 - DIAL INDICATOR
ROTORS (Continued)
2002 WJ Service Manual
Publication No. 81-370-02064
02WJ5-32 June, 2002
STANDARD PROCEDURE - DISC ROTOR
MACHINING
CAUTION: For vehicles equipped with the Quadra-
Drive System, consisting of the NV-247 transfer case
and a Vari-Lok differential in the front and rear axles,
the following steps must be done prior to the use of a
hub mounted on-vehicle brake lathe. Disconnect the
driveshaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT - REMOVAL)
from the respective axle on which the brake rotors are
being machined. Temporarily remove both brake cali-
pers (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - REMOVAL) from the axle
while disc rotor machining is in process. Both steps
will prevent unnecessary loads to the hub mounted
on-vehicle lathe and speed machining times. Install a
thread lock material to the driveshaft attaching bolts
when reinstalling (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION).
NOTE: A hub mounted on-vehicle lathe is recom-
mended. This type of lathe trues the rotor to the vehi-
cles hub/bearing.
The di sc brake rotor can be machi ned i f scored or
worn. The l athe must machi ne both si des of the rotor
si mul taneousl y wi th dual cutter heads. The rotor
mounti ng surface must be cl ean before pl aci ng on the
l athe. Equi pment capabl e of machi ni ng onl y one si de at
a ti me may produce a tapered rotor.
CAUTION: Brake rotors that do not meet minimum
thickness specifications before or after machining
must be replaced.
REMOVAL
REMOVAL - FRONT DISC BRAKE ROTOR
NOTE: Front rotors and hub/bearings are matched
mounted for minimum lateral runout. Before removing
the rotor, mark the rotor and hub/bearing to maintain
original orientation.
(3) Remove the cal i per anchor bol ts (Fi g. 64) and
remove the cal i per and anchor as an assembl y from the
steeri ng knuckl e.
(4) Secure cal i per anchor assembl y to nearby suspen-
si on part wi th a wi re. Do not allow brake hose to
support caliper weight.
(5) Mark the rotor and hub/beari ng to mai ntai n ori g-
i nal ori entati on. Remove retai ners securi ng rotor to hub
studs.
(6) Remove rotor from hub/beari ng.
REMOVAL - REAR DISC BRAKE ROTOR
(3) Remove the cal i per anchor bol ts (Fi g. 65).
(4) Remove cal i per and anchor as an assembl y.
(5) Secure cal i per anchor assembl y to nearby suspen-
si on part wi th wi re. Do not allow brake hose to sup-
port caliper weight.
(6) Remove retai ners securi ng rotor to axl e studs.
(7) Remove rotor off axl e studs.
Fig. 64 Caliper Anchor Bolts
1 - KNUCKLE
2 - ANCHOR
3 - ANCHOR BOLTS
4 - ROTOR
Fig. 65 Caliper Anchor Bolts
1 - ROTOR
2 - ANCHOR
3 - ANCHOR BOLTS
ROTORS (Continued)
02WJ5-33 June, 2002
INSTALLATION
INSTALLATION - FRONT DISC BRAKE ROTOR
NOTE: If a new rotor is installed it must be match
mounted to the hub/bearing.
(1) I nstal l rotor on hub studs i n i ts ori gi nal l oca-
ti on.
(2) I nstal l the cal i per anchor assembl y on the
knuckl e. I nstal l anchor bol ts and ti ghten to 90-115
Nm (66-85 ft. l bs.).
(5) Pump brake pedal to seat cal i per pi stons and
brake shoes. Do not move vehi cl e unti l fi rm brake
pedal i s obtai ned.
INSTALLATION - REAR DISC BRAKE ROTOR
(1) I nstal l rotor on axl e studs.
(2) I nstal l the cal i per anchor assembl y.
(3) I nstal l anchor bol ts and ti ghten to 90-115 Nm
(66-85 ft. l bs.).
(6) Pump brake pedal unti l cal i per pi stons and
brake shoes are seated.
PARKING BRAKE
OPERATION
The parki ng brakes operated by a automati c ten-
si oner mechani sm bui l t i nto the hand l ever and cabl e
system. The front cabl e i s connected to the hand
l ever and the equal i zer. The rear cabl es attached to
the equal i zer and the parki ng brake shoe actuator.
A set of drum type brake shoes are used for park-
i ng brakes. The shoes are mounted to the rear di sc
brake adaptor. The parki ng brake drum i s i ntegrated
i nto the rear di sc brake rotor.
Parki ng brake cabl e adjustment i s control l ed by an
automati c tensi oner mechani sm. The onl y adjust-
ment i f necessary i s to the park brake shoes i f the
l i ni ngs are worn.
DIAGNOSIS AND TESTING - PARKING BRAKE
NOTE: Parking brake adjustment is controlled by an
automatic cable tensioner and does not require
adjustment. The only adjustment that may be nec-
essary would be to the park brake shoes if they are
worn.
The parki ng brake swi tch i s i n ci rcui t wi th the red
warni ng l amp i n the dash. The swi tch wi l l cause the
l amp to i l l umi nate onl y when the parki ng brakes are
appl i ed. I f the l amp remai ns on after parki ng brake
rel ease, the swi tch or wi res are faul ty.
I f the red l amp comes on a faul t has occurred i n
the front or rear brake hydraul i c system.
I f the red warni ng l amp and yel l ow warni ng l amp
come on, the el ectroni c brake di stri buti on may be at
faul t.
I n most cases, the actual cause of an i mproperl y
functi oni ng parki ng brake (too l oose/too ti ght/wont
hol d), can be traced to a parki ng brake component.
NOTE: The leading cause of improper parking brake
operation, is excessive clearance between the park-
ing brake shoes and the shoe braking surface.
Excessive clearance is a result of lining and/or
drum wear, drum surface machined oversize.
Excessi ve parki ng brake l ever travel (someti mes
descri bed as a l oose l ever or too l oose condi ti on), i s
the resul t of worn brake shoes, i mproper brake shoe
adjustment, or i mproperl y assembl ed brake parts.
A too l oose condi ti on can al so be caused by i noper-
ati ve or i mproperl y assembl ed parki ng brake shoe
parts.
A condi ti on where the parki ng brakes do not hol d,
wi l l most probabl y be due to a wheel brake compo-
nent.
I tems to l ook for when di agnosi ng a parki ng brake
probl em, are:
Brake shoe wear
Drum surface (i n rear rotor) machi ned oversi ze
Front cabl e not secured to l ever
Rear cabl e not attached to actuator
Rear cabl e sei zed
Parki ng brake l ever not seated
Parki ng brake l ever bi nd
ROTORS (Continued)
CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE CABLE
(1) Remove center consol e,(Refer to 23 - BODY/I N-
TERI OR/FLOOR CONSOLE - REMOVAL).
(2) Li ft up rear seat and carpet coveri ng the park-
i ng brake cabl es.
(3) Pl ace a screw dri ver through the front cabl e
eyel et (Fi g. 66) and pry back on the front cabl e.
(4) Have an assi stant pry down the l ock out spri ng
through the hol e i n the si de of the park brake l ever
(Fi g. 67) wi th a smal l screw dri ver. Then sl owl y
rel ease the front cabl e.
NOTE: Their should be slack in the cable if the lock
out spring is engaged.
(5) Di sengage front cabl e end from the equal i zer
(Fi g. 68).
(6) Di sengage front cabl e end from the parki ng
brake l ever.
(7) Remove the front carpet,(Refer to 23 - BODY/
I NTERI OR/CARPETS AND FLOOR MATS -
REMOVAL).
(8) Remove front cabl e retai ner nuts (Fi g. 69) from
the fl oor pan.
Fig. 66 Front Cable Eyelet
1 - REAR CABLES
2 - FRONT CABLE EYELET
3 - FRONT CABLE
4 - EQUALIZER
Fig. 67 Lock Out Spring
1 - LOCK OUT SPRING
Fig. 68 Cable Equalizer
1 - EQUALIZER
2 - FRONT CABLE
Fig. 69 Front Parking Brake Cable
1 - RETAINER NUT
2 - FLOOR PAN
3 - FRONT CABLE
(9) Compress the cabl e retai ners wi th a 13 mm
wrench (Fi g. 70). Remove the cabl e from parki ng
brake l ever bracket and equal i zer bracket.
REMOVAL - REAR PARKING BRAKE CABLES
(1) Remove center consol e, (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - REMOVAL).
i ng brake cabl es.
(5) Di sengage rear cabl es ends from the equal i zer.
(6) Compress the cabl e retai ners wi th a 13 mm
wrench (Fi g. 73) and remove the cabl e from equal i zer
bracket.
Fig. 70 Brake Lever Bracket
1 - FRONT CABLE
2 - WRENCH
Fig. 71 Front Cable Eyelet
1 - REAR CABLES
3 - FRONT CABLE
4 - EQUALIZER
1 - LOCK OUT SPRING
Fig. 73 Cable Retainers
1 - CABLE RETAINER
2 - WRENCH
3 - FRONT CABLE
4 - REAR CABLES
CABLES (Continued)
(9) Remove the brake cal i pers, cal i per anchors and
rotors.
(10) Remove the ABS sensor wi ri ng harness (Fi g.
74)from the rear brake cabl es.
(11) Remove the cabl e retai ner bol ts (Fi g. 74) from
the rear spri ng pads.
(12) Pul l the cabl es out of the upper suspensi on
arm brackets.
(13) Push the cabl e i n and l i ft up the end of cabl e
wi th a smal l screw dri ver to di sengage the cabl e from
the parki ng brake actuator (Fi g. 75).
(14) Remove the cabl e from the vehi cl e.
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE
(1) I nstal l thecabl e i nto the parki ng brake l ever
bracket and equal i zer bracket.
(2) I nstal l the front cabl e to the fl oor pan and
i nstal l retai ner nuts.
(3) Engage the front cabl e ends to the parki ng
brake l ever and equal i zer.
(4) I nstal l the front carpet, (Refer to 23 - BODY/
I NTERI OR/CARPETS AND FLOOR MATS -
I NSTALLATI ON).
(5) Pul l on the l ever to rel ease the l ock out spri ng.
(6) I nstal l the center consol e, (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - I NSTALLATI ON).
(7) Fol d down the rear carpet cover and rear seat.
INSTALLATION - REAR PARKING BRAKE
CABLES
(1) I nstal l the cabl es through the cal i per anchor
mount. Then push the end of cabl e strand i n to
engage the cabl e end to the parki ng brake actuator.
(2) Feed the other end of the cabl es through the
body and i nto the equal i zer bracket (Fi g. 76).
Fig. 74 Left Rear Parking Brake Cable
1 - CABLE BRACKET
3 - PARKING BRAKE CABLE
4 - CABLE RETAINER
5 - ABS SENSOR WIRING
Fig. 75 Parking Brake
1 - CABLE END
2 - SCREW DRIVER
3 - PARKING BRAKE ACTUATOR
4 - BRAKE SHOES
Fig. 76 Equalizer Bracket
1 - EQUALIZER
2 - RIGHT REAR CABLE
3 - LEFT REAR CABLE
4 - FRONT CABLE
CABLES (Continued)
(3) Push the cabl es i nto the upper suspensi on arm
brackets.
(4) I nstal l the cabl e retai ner bol ts to the rear
spri ng pads.
(5) I nstal l the ABS sensor wi ri ng harness to the
rear brake cabl es.
(6) I nstal l the rotors, cal i per anchors and brake
cal i pers.
(9) Engage the cabl e ends i nto the parki ng brake
equal i zer.
(10) Pul l on the l ever to rel ease the l ock out
spri ng.
(11) I nstal l center consol e, (Refer to 23 - BODY/I N-
TERI OR/FLOOR CONSOLE - I NSTALLATI ON).
(13) Veri fy parki ng brake operati on.
LEVER
REMOVAL
(1) Remove center consol e,(Refer to 23 - BODY/I N-
TERI OR/FLOOR CONSOLE - REMOVAL).
i ng brake cabl es.
(5) Di sconnect parki ng brake swi tch wi ri ng con-
nector.
(6) Di sengage front cabl e end from parki ng brake
l ever.
(7) Compress the cabl e retai ner wi th a 13 mm
wrench (Fi g. 79) and remove the cabl e from the park-
i ng brake l ever bracket.
Fig. 77 FRONT CABLE
1 - REAR CABLES
3 - FRONT CABLE
4 - EQUALIZER
1 - LOCK OUT SPRING
Fig. 79 Parking Brake Lever Bracket
1 - FRONT CABLE
2 - WRENCH
CABLES (Continued)
(8) Remove the park brake l ever mounti ng nuts
and consol e bracket (Fi g. 80).
(9) Li ft the l ever assembl y off the mounti ng studs
and pul l the front cabl e out of the l ever bracket.
INSTALLATION
(1) I nstal l the l ever assembl y on the mounti ng
studs whi l e feedi ng the front cabl e i nto the l ever
bracket.
(2) I nstal l the consol e bracket (Fi g. 80) and mount-
i ng nuts.
(3) Engage the front cabl e end to the l ever.
(4) Connect parki ng brake swi tch wi re connector.
(5) Pul l on the l ever to rel ease the l ock out spri ng.
(6) I nstal l center consol e,(Refer to 23 - BODY/I N-
TERI OR/FLOOR CONSOLE - I NSTALLATI ON).
SHOES
REMOVAL
(1) Lock out park brake l ever (Fi g. 81).
(2) Rai se vehi cl e.
(4) Remove cal i per and anchor as an assembl y.
(5) Remove rubber access pl ug from back of rear
di sc brake spl ash shi el d.
(6) I f necessary retract parki ng brake shoes wi th
brake adjuster tool (Fi g. 82). Posi ti on tool at top of
star wheel and rotate wheel .
(7) Remove rotor from axl e hub fl ange.
(8) Remove the l ower shoe to shoe spri ng/adjuster
spri ng wi th needl e nose pl i ers (Fi g. 83).
(9) Remove the upper shoe to shoe spri ng/return
spri ng wi th brake pl i ers (Fi g. 84).
(10) Remove shoe hol d-down cl i ps and pi ns (Fi g.
85). Cl i p i s hel d i n pl ace by pi n whi ch fi ts i n cl i p
notch. To remove cl i p, fi rst push cl i p ends together
and sl i de cl i p unti l head of pi n cl ears narrow part of
notch. Then remove cl i p and pi n.
(11) Remove shoes and adjuster.
INSTALLATION
(1) I nstal l shoes on spl ash shi el d wi th hol d down
cl i ps and pi ns. Be sure shoes are properl y engaged i n
the park brake actuator.
(2) Lubri cate and i nstal l adjuster screw assembl y.
Be sure notched ends of screw assembl y are properl y
seated on shoes and that star wheel i s al i gned wi th
access hol e i n shi el d.
Fig. 80 Parking Brake Lever Mounting
1 - MOUNTING NUT
2 - PARK BRAKE LEVER
1 - LOCK OUT SPRING
Fig. 82 Retracting Parking Brake Shoes
1 - ACCESS HOLE
2 - BRAKE ADJUSTING TOOL
3 - SPLASH SHIELD
LEVER (Continued)
(3) I nstal l l ower shoe to shoe spri ng/adjuster
spri ng. Needl e nose pl i ers can be used to connect
spri ng to each shoe.
(4) I nstal l the upper shoe to shoe spri ng/return
spri ng wi th brake pl i ers (Fi g. 83).
(5) I nstal l rotor and cal i per anchor assembl y.
(6) I nstal l anchor bol ts and ti ghten to 90-115 Nm
(66-85 ft. l bs.).
(7) Actuate park brake l ever to unl ock the park
brake system.
(8) Adjust the parki ng brake shoes (Fi g. 82).
(10) Lower vehi cl e and veri fy correct parki ng
brake operati on.
ADJUSTMENTS - PARKING BRAKE SHOE
(2) Secure rotor wi th two wheel nuts.
(3) Remove rubber access pl ug from back of spl ash
shi el d.
(4) I nsert brake tool through access hol e i n spl ash
shi el d (Fi g. 86). Posi ti on tool at bottom of star wheel .
(5) Rotate star wheel upward di recti on to expand
shoes (whi l e faci ng front of vehi cl e).
(6) Expand shoes unti l l i ght drag i s experi enced.
Then back off adjuster screw onl y enough to el i mi -
nate drag.
(7) I nstal l pl ug i n spl ash shi el d access hol e.
Fig. 83 Lower Spring
1 - REAR SHOE
2 - NEEDLENOSE PLIERS
3 - ADJUSTER SCREW
4 - LOWER SPRING
Fig. 84 Upper Spring
1 - BRAKE PLIERS
2 - REAR SHOE
3 - UPPER SPRING
Fig. 85 Hold-Down Clip And Pin
1 - HOLD-DOWN CLIP
2 - HOLD-DOWN PIN
Fig. 86 Park Brake Shoe Adjustment
1 - ACCESS HOLE
2 - BRAKE ADJUSTING TOOL
3 - SPLASH SHIELD
SHOES (Continued)
BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 42
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 42
ELECTRIC BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FRONT WHEEL SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
G-SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
REAR WHEEL SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
BRAKES - ABS
DESCRIPTION
The purpose of the anti l ock system i s to prevent
wheel l ockup duri ng peri ods of hi gh wheel sl i p. Pre-
venti ng l ockup hel ps mai ntai n vehi cl e braki ng acti on
and steeri ng control .
The hydraul i c system i s a three channel desi gn.
The front brakes are control l ed i ndi vi dual l y and the
rear brakes i n tandem.
The ABS el ectri cal system i s separate from other
vehi cl e el ectri cal ci rcui ts. A separate control l er oper-
ates the system.
OPERATION
The anti l ock CAB acti vates the system whenever
sensor si gnal s i ndi cate peri ods of hi gh wheel sl i p.
Hi gh wheel sl i p can be descri bed as the poi nt where
wheel rotati on begi ns approachi ng 20 to 30 percent of
actual vehi cl e speed duri ng braki ng. Peri ods of hi gh
wheel sl i p occur when brake stops i nvol ve hi gh pedal
pressure and rate of vehi cl e decel erati on.
Battery vol tage i s suppl i ed to the CAB i gni ti on ter-
mi nal when the i gni ti on swi tch i s turned to Run posi -
ti on. The CAB performs a system i ni ti al i zati on
procedure at thi s poi nt. I ni ti al i zati on consi sts of a
stati c and dynami c sel f check of system el ectri cal
components.
The stati c check occurs after the i gni ti on swi tch i s
turned to Run posi ti on. The dynami c check occurs
when vehi cl e road speed reaches approxi matel y 30
kph (18 mph). Duri ng the dynami c check, the CAB
bri efl y cycl es the pump and sol enoi ds to veri fy oper-
ati on.
I f an ABS component exhi bi ts a faul t duri ng i ni -
ti al i zati on, the CAB i l l umi nates the amber warni ng
l i ght and regi sters a faul t code i n the mi croprocessor
memory.
ANTILOCK BRAKING
The anti l ock system prevents l ockup duri ng hi gh
sl i p condi ti ons by modul ati ng fl ui d appl y pressure to
the wheel brake uni ts.
Brake fl ui d appl y pressure i s modul ated accordi ng
to wheel speed, degree of sl i p and rate of decel era-
ti on. A sensor at each wheel converts wheel speed
i nto el ectri cal si gnal s. These si gnal s are transmi tted
to the CAB for processi ng and determi nati on of
wheel sl i p and decel erati on rate.
The ABS system has three fl ui d pressure control
channel s. The front brakes are control l ed separatel y
and the rear brakes i n tandem. A speed sensor i nput
si gnal i ndi cati ng a hi gh sl i p condi ti on acti vates the
CAB anti l ock program.
Two sol enoi d val ves are used i n each anti l ock con-
trol channel . The val ves are al l l ocated wi thi n the
HCU val ve body and work i n pai rs to ei ther i ncrease,
hol d, or decrease appl y pressure as needed i n the
i ndi vi dual control channel s.
The sol enoi d val ves are not stati c duri ng anti l ock
braki ng. They are cycl ed conti nuousl y to modul ate
pressure. Sol enoi d cycl e ti me i n anti l ock mode can be
measured i n mi l l i seconds.
WJ BRAKES - ABS 5 - 41
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES
The ABS brake system performs several sel f-tests
every ti me the i gni ti on swi tch i s turned on and the
vehi cl e i s dri ven. The CAB moni tors the systems
i nput and output ci rcui ts to veri fy the system i s oper-
ati ng correctl y. I f the on board di agnosti c system
senses that a ci rcui t i s mal functi oni ng the system
wi l l set a troubl e code i n i ts memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Electrical section. For test proce-
dures refer to the Chassis Diagnostic Manual.
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM
ABS system bl eedi ng requi res conventi onal bl eed-
i ng methods pl us use of the DRB scan tool . The pro-
cedure i nvol ves performi ng a base brake bl eedi ng,
fol l owed by use of the scan tool to cycl e and bl eed the
HCU pump and sol enoi ds. A second base brake bl eed-
i ng procedure i s then requi red to remove any ai r
remai ni ng i n the system.
(1) Perform base brake bl eedi ng. (Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(2) Connect scan tool to the Data Li nk Connector.
(3) Sel ect ANTI LOCK BRAKES, fol l owed by MI S-
CELLANEOUS, then ABS BRAKES. Fol l ow the
i nstructi ons di spl ayed. When scan tool di spl ays TEST
COMPLETE, di sconnect scan tool and proceed.
(4) Perform base brake bl eedi ng a second ti me.
(Refer to 5 - BRAKES - STANDARD PROCEDURE)
OR (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(5) Top off master cyl i nder fl ui d l evel and veri fy
proper brake operati on before movi ng vehi cl e.
SPECIFICATIONS
TORQUE CHART
G-Sensor Bolt 5.6 50
Hydraulic Control Unit/Controller
Antilock Brakes
Mounting Bolts
12 9 125
Antilock Brakes
Brake Lines
16 144
Antilock Brakes
CAB Screws
1.8 16
Wheel Speed Sensors
Front Sensor Bolt
12-14 106-124
Wheel Speed Sensors
Rear Sensor Bolt
12-14 106-124
5 - 42 BRAKES - ABS WJ
BRAKES - ABS (Continued)
ELECTRIC BRAKE
DESCRIPTION
The el ectroni c brake di stri buti on (EBD) functi ons
l i ke a rear proporti oni ng val ve. The EBD system uses
the ABS system to control the sl i p of the rear wheel s
i n parti al braki ng range. The braki ng force of the
rear wheel s i s control l ed el ectroni cal l y by usi ng the
i nl et and outl et val ves l ocated i n the HCU.
OPERATION
Upon entry i nto EBD the i nl et val ve for the rear
brake ci rcui t i s swi tched on so that the fl ui d suppl y
from the master cyl i nder i s shut off. I n order to
decrease the rear brake pressure the outl et val ve for
the rear brake ci rcui t i s pul sed. Thi s al l ows fl ui d to
enter the l ow pressure accumul ator (LPA) i n the
HCU resul ti ng i n a drop i n fl ui d pressure to the rear
brakes. I n order to i ncrease the rear brake pressure
the outl et val ve i s swi tched off and the i nl et val ve i s
pul sed. Thi s i ncreases the pressure to the rear
brakes. Thi s wi l l conti nue unti l the requi red sl i p di f-
ference i s obtai ned. At the end of EBD braki ng (no
brake appl i cati on) the fl ui d i n the LPA drai ns back to
the master cyl i nder by swi tchi ng on the outl et val ve
and drai ni ng through the i nl et val ve check val ve. At
the same ti me the i nl et val ve i s swi tched on to pre-
vent a hydraul i c short ci rci ut i n case of another
brake appl i cati on.
The EBD wi l l remai n functi onal duri ng many ABS
faul t modes. I f the red and amber warni ng l amps are
i l l umi nated the EBD may have a faul t.
FRONT WHEEL SPEED
SENSOR
DESCRIPTION
A wheel speed sensor i s used at each wheel . The
front sensors are mounted to the steeri ng knuckl es.
The rear sensors are mounted at the outboard end of
the axl e. Tone wheel s are mounted to the outboard
ends of the front and rear axl e shafts. The gear type
tone wheel serves as the tri gger mechani sm for each
sensor.
OPERATION
The sensors convert wheel speed i nto a smal l di gi -
tal si gnal . The CAB sends 12 vol ts to the sensors.
The sensor has an i nternal magneto resi stance
bri dge that al ters the vol tage and amperage of the
si gnal ci rcui t. Thi s vol tage and amperage i s changed
by magneti c i nducti on when the toothed tone wheel
passes the wheel speed sensor. Thi s di gi tal si gnal i s
sent to the CAB. The CAB measures the vol tage and
amperage of the di gi tal si gnal for each wheel .
REMOVAL
(2) Remove the front wheel sensor mounti ng bol t
(Fi g. 1).
(3) Remove the sensor from the steeri ng knuckl e.
(4) Di sengage the sensor wi re from the brackets
(Fi g. 1)on the steeri ng knuckl e.
(5) Di sconnect the sensor from the sensor harness
(Fi g. 2)and (Fi g. 3).
(6) Remove the sensor and wi re.
INSTALLATION
(1) I nstal l the sensor on the steeri ng knuckl e.
(2) Appl y Mopar Lock N Seal or Locti te 242 to
the sensor mounti ng bol t. Use new sensor bol t i f ori g-
i nal bol t i s worn or damaged.
(3) I nstal l the sensor mounti ng bol t and ti ghten
bol t to 12-14 Nm (106-124 i n. l bs.).
(4) Engage the grommets on the sensor wi re to the
steeri ng knuckl e brackets.
(5) Connect the sensor wi re to the harness connec-
tor.
(6) Check the sensor wi re routi ng. Be sure the
wi re i s cl ear of al l chassi s components and i s not
twi sted or ki nked at any spot.
(7) Remove the support and l ower vehi cl e.
Fig. 1 Sensor Location
1 - BRACKET
2 - BRACKET
3 - WHEEL SPEED SENSOR
4 - MOUNTING BOLT
G-SWITCH
DESCRIPTION
The G-swi tch (Fi g. 4) i s l ocated under the rear
seat. The swi tch has di recti onal arrow and must be
mounted wi th the arrow poi nti ng towards the front
of the vehi cl e.
OPERATION
The swi tch i s moni tored by the CAB at al l ti mes.
The swi tch contai ns three mercury swi tches whi ch
moni tor vehi cl e decel erati on rates (G-force). Sudden
changes i n decel erati on rates tri gger the swi tch,
sendi ng a si gnal to the CAB.
REMOVAL
(1) Fol d the rear seat bottom assembl y up for
access to the swi tch.
(2) Li ft up the carpeti ng and di sconnect the swi tch
harness (Fi g. 5).
(3) Remove the swi tch mounti ng bol ts and remove
the swi tch.
INSTALLATION
CAUTION: The mercury switch (inside the
G-Switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig. 6).
(1) Note the posi ti on of the l ocati ng arrow on the
swi tch. Posi ti on the swi tch so the arrow faces for-
ward.
(2) I nstal l the swi tch and ti ghten the mounti ng
bol ts to 5.6 Nm (50 i n. l bs.).
Fig. 2 Left Sensor Connector
1 - LEFT FRONT WHEEL SPEED SENSOR CONNECTOR
2 - ENGINE EXHAUST PIPE
3 - LEFT FRONT FRAME RAIL
4 - FRONT DRIVESHAFT
Fig. 3 Right Sensor Connector
1 - RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
2 - ENGINE EXHAUST Y-PIPE
3 - RIGHT FRONT FRAME RAIL
4 - RIGHT LOWER SUSPENSION ARM
Fig. 4 G-Switch
1 - SWITCH PART NUMBER
2 - ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
FRONT WHEEL SPEED SENSOR (Continued)
(3) Connect the harness to the swi tch. Be sure the
harness connector i s fi rml y seated.
(4) Pl ace the carpet i n posi ti on and fol d the rear
seat back down.
REAR WHEEL SPEED SENSOR
DESCRIPTION
A wheel speed sensor i s used at each wheel . The
front sensors are mounted to the steeri ng knuckl es.
The rear sensors are mounted at the outboard end of
the axl e. Tone wheel s are mounted to the outboard
ends of the front and rear axl e shafts. The gear type
tone wheel serves as the tri gger mechani sm for each
sensor.
OPERATION
The sensors convert wheel speed i nto a smal l di gi -
tal si gnal . The CAB sends 12 vol ts to the sensors.
The sensor has an i nternal magneto resi stance
bri dge that al ters the vol tage and amperage of the
si gnal ci rcui t. Thi s vol tage and amperage i s changed
by magneti c i nducti on when the toothed tone wheel
passes the wheel speed sensor. Thi s di gi tal si gnal i s
sent to the CAB. The CAB measures the vol tage and
amperage of the di gi tal si gnal for each wheel .
REMOVAL
(1) Rai se and fol d the rear seat forward. Then
move the carpeti ng asi de for access to the rear sensor
connectors.
(2) Di sconnect the rear sensor wi re at the harness
connectors (Fi g. 7).
(3) Push the sensor wi res and grommets through
the fl oorpan hol es.
(5) Di sengage the sensor wi re from the axl e and
the chassi s brackets and from the brake l i ne retai n-
ers.
(6) Remove the sensor mounti ng bol t from the rear
brake backi ng pl ate. (Fi g. 8).
(7) Remove the sensor from the backi ng pl ate.
Fig. 5 G-Switch Mounting
1 - MOUNTING BOLTS
2 - CONNECTOR
3 - G-SWITCH
Fig. 6 G-Switch
1 - SWITCH PART NUMBER
2 - ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
Fig. 7 Rear Sensor Connector
1 - RIGHT REAR WHEEL SPEED SENSOR CONNECTOR
2 - LEFT REAR WHEEL SPEED SENSOR CONNECTOR
3 - G-SWITCH SENSOR
4 - PARKING BRAKE CABLES
G-SWITCH (Continued)
INSTALLATION
(1) I nsert the sensor through the backi ng pl ate
(Fi g. 9).
(2) Appl y Mopar Lock N Seal or Locti te 242 to
the ori gi nal sensor bol t. Use a new bol t i f the ori gi nal
i s worn or damaged.
(3) Ti ghten the sensor bol t to 12-14 Nm (106-124
i n. l bs.).
(4) Secure the sensor wi re i n the brackets and the
retai ners on the rear brake l i nes. Veri fy that the sen-
sor wi re i s secure and cl ear of the rotati ng compo-
nents.
(5) Route the sensor wi res to the rear seat area.
(6) Feed the sensor wi res the through fl oorpan
access hol e and seat the sensor grommets i nto the
fl oorpan.
(8) Fol d the rear seat and carpet forward for
access to the sensor wi res and connectors.
(9) Connect the sensor wi res to the harness con-
nectors.
(10) Reposi ti on the carpet and fol d the rear seat
down.
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consi sts of a val ve body, pump motor,
and wi re harness.
OPERATION
Accumul ators i n the val ve body store extra fl ui d
rel eased to the system for ABS mode operati on. The
pump i s used to cl ear the accumul ator of brake fl ui d
and i s operated by a DC type motor. The motor i s
control l ed by the CAB.
The val ves modul ate brake pressure duri ng
anti l ock braki ng and are control l ed by the CAB.
The HCU provi des three channel pressure control
to the front and rear brakes. One channel control s
the rear wheel brakes i n tandem. The two remai ni ng
channel s control the front wheel brakes i ndi vi dual l y.
Duri ng anti l ock braki ng, the sol enoi d val ves are
opened and cl osed as needed. The val ves are not
stati c. They are cycl ed rapi dl y and conti nuousl y to
modul ate pressure and control wheel sl i p and decel -
erati on.
Duri ng normal braki ng, the HCU sol enoi d val ves
and pump are not acti vated. The master cyl i nder and
power booster operate the same as a vehi cl e wi thout
an ABS brake system.
Duri ng anti l ock braki ng, sol enoi d val ve pressure
modul ati on occurs i n three stages, pressure i ncrease,
pressure hol d, and pressure decrease. The val ves are
al l contai ned i n the val ve body porti on of the HCU.
PRESSURE DECREASE
The outl et val ve i s opened and the i nl et val ve i s
cl osed duri ng the pressure decrease cycl e.
A pressure decrease cycl e i s i ni ti ated when speed
sensor si gnal s i ndi cate hi gh wheel sl i p at one or
more wheel s. At thi s poi nt, the CAB cl oses the i nl et
then opens the outl et val ve, whi ch al so opens the
return ci rcui t to the accumul ators. Fl ui d pressure i s
al l owed to bl eed off (decrease) as needed to prevent
wheel l ock.
Once the peri od of hi gh wheel sl i p has ended, the
CAB cl oses the outl et val ve and begi ns a pressure
i ncrease or hol d cycl e as needed.
Fig. 8 Sensor Mounting Bolt
2 - MOUNTING BOLT
Fig. 9 Wheel Speed Sensor
2 - BACKING PLATE
REAR WHEEL SPEED SENSOR (Continued)
PRESSURE HOLD
Both sol enoi d val ves are cl osed i n the pressure
hol d cycl e. Fl ui d appl y pressure i n the control chan-
nel i s mai ntai ned at a constant rate. The CAB mai n-
tai ns the hol d cycl e unti l sensor i nputs i ndi cate a
pressure change i s necessary.
PRESSURE INCREASE
The i nl et val ve i s open and the outl et val ve i s
cl osed duri ng the pressure i ncrease cycl e. The pres-
sure i ncrease cycl e i s used to counteract unequal
wheel speeds. Thi s cycl e control s re-appl i cati on of
fl ui d appl y pressure due to changi ng road surfaces or
wheel speed.
REMOVAL
(1) Remove the negati ve battery cabl e from the
battery.
(2) Remove the ai r cl eaner housi ng,(Refer to 9 -
ENGI NE/AI R I NTAKE SYSTEM/AI R CLEANER
HOUSI NG - REMOVAL).
(3) Pul l the CAB harness connector rel ease up and
remove connector (Fi g. 10).
(4) Remove the brake l i nes from the HCU.
(5) Remove the HCU/CAB si de mounti ng bol t and
the two rear mounti ng bol ts. (Fi g. 11).
(6) Remove the HCU/CAB assembl y from the vehi -
cl e.
INSTALLATION
(1) I nstal l HCU/CAB assembl y i nto the mounti ng
bracket and ti ghten mounti ng bol ts to 12 Nm (9 ft.
l bs.).
(2) I nstal l the brake l i nes to the HCU and ti ghten
to 16 Nm (12 ft. l bs.).
(3) I nstal l CAB harness connector and push down
connector rel ease.
(4) I nstal l ai r cl eaner housi ng,(Refer to 9 -
HOUSI NG - I NSTALLATI ON).
(5) I nstal l negati ve battery cabl e to the battery.
(6) Bl eed base and ABS brake systems,(Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
Fig. 10 CAB Connector Release
1 - CONNECTOR RELEASE
2 - CAB
Fig. 11 HCU/CAB Assembly
1 - SIDE MOUNTING BOLT
2 - REAR MOUNTING BOLTS
HCU (HYDRAULIC CONTROL UNIT) (Continued)
COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 4.7L
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - COOLING SYSTEM
ROUTING 4.7L ENGINE. . . . . . . . . . . . . . . . . . 1
DESCRIPTIONCOOLING SYSTEM 4.0L
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTIONCOOLING SYSTEM
ROUTING 4.0L ENGINE. . . . . . . . . . . . . . . . . . 1
DESCRIPTIONHOSE CLAMPS . . . . . . . . . . . 1
OPERATION
OPERATIONCOOLING SYSTEM . . . . . . . . . 2
OPERATIONHOSE CLAMPS . . . . . . . . . . . . 2
DIAGNOSIS AND TESTINGON-BOARD
DIAGNOSTICS (OBD) . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTINGPRELIMINARY
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIAGNOSIS CHART . . . . . . . . . . . . . 5
SYSTEM LEAKS . . . . . . . . . . . . . . . . . . . . . . 10
SYSTEM DEAERATION . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE
STANDARD PROCEDUREDRAINING
COOLING SYSTEM 4.7L ENGINE . . . . . . . . . 12
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 4.7L ENGINE . . . . . . . . . 12
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM - 4.0L ENGINE . . . . . . . . 13
COOLING SYSTEM - 4.0L ENGINE . . . . . . . . 13
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT. . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE - COOLING
SYSTEM - REVERSE FLUSHING. . . . . . . . . . 14
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 55
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 4. 7L
ENGINE
The cool i ng system consi sts of the fol l owi ng i tems:
Hydraul i c cool i ng fan and fan dri ve assembl y
Radi ator
Power steeri ng oi l cool er
Radi ator pressure cap
Thermostat
Cool ant reserve/overfl ow system
Transmi ssi on oi l cool er (i f equi pped wi th an
automati c transmi ssi on)
Cool ant
Water pump
Hoses and hose cl amps
DESCRIPTION - COOLING SYSTEM ROUTING
4. 7L ENGINE
For cool i ng system routi ng refer to (Fi g. 1).
DESCRIPTION COOLING SYSTEM 4. 0L
ENGINE
The cool i ng system consi sts of:
A radi ator
Mechani cal Cool i ng Fan
Thermal vi scous fan dri ve-Low di sengaged
Fan shroud (Fi g. 2)
Radi ator pressure cap
Thermostat
Cool ant reserve/overfl ow system
Transmi ssi on oi l cool er (i f equi pped wi th an
automati c transmi ssi on)
Cool ant
Water pump
Hoses and hose cl amps
Accessory dri ve bel t
DESCRIPTION COOLING SYSTEM ROUTING
4. 0L ENGINE
For cool i ng system routi ng refer to (Fi g. 3).
DESCRIPTION HOSE CLAMPS
The cool i ng system uti l i zes both worm dri ve and
spri ng type hose cl amps. I f a spri ng type cl amp
WJ COOLING 7 - 1
repl acement i s necessary, repl ace wi th the ori gi nal
Mopar equi pment spri ng type cl amp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 4).
OPERATION
OPERATION COOLING SYSTEM
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e. I t al so
mai ntai ns normal operati ng temperature and pre-
vents overheati ng.
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant throughout the system.
OPERATION HOSE CLAMPS
The worm type hose cl amp uses a speci fi ed torque
val ue to mai ntai n proper tensi on on a hose connec-
ti on.
Fig. 1 Engine Cooling System 4.7L Engine
1 - LH CYL. HEAD
2 - AIR BLEED
3 - THERMOSTAT LOCATION
4 - RH CYL. HEAD
5 - RH BANK CYL. BLOCK
6 - LH BANK CYL. BLOCK
7 - COOLANT TEMP. SENSOR
7 - 2 COOLING WJ
COOLING (Continued)
The spri ng type hose cl amp appl i es constant ten-
si on on a hose connecti on. To remove a spri ng type
hose cl amp, onl y use constant tensi on cl amp pl i ers
desi gned to compress the hose cl amp.
DIAGNOSIS AND TESTING ON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The powertrai n control modul e (PCM) has been
programmed to moni tor certai n cool i ng system com-
ponents:
I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
I f an open or shorted condi ti on has devel oped i n
the rel ay ci rcui t control l i ng the el ectri c radi ator fan
or fan control sol enoi d ci rcui t control i ng the hydrau-
l i c fan, a Di agnosti c Troubl e Code (DTC) can be set.
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cated an actual probl em, a DTC
i s stored. The DTC wi l l be stored i n the PCM mem-
ory for eventual di spl ay to the servi ce techni ci an.
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTCs and to obtai n cool i ng system data,
TI ON).
ERASING TROUBLE CODES
After the probl em has been repai red, use the DRB
scan tool to erase a DTC. Refer to the appropri ate
Powertrai n Di agnosti c Procedures servi ce i nforma-
ti on for operati on of the DRB scan tool .
DIAGNOSIS AND TESTING PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
PROLONGED I DLE
VERY HI GH AMBI ENT TEMPERATURE
Fig. 2 Cooling Module with Electric Fan
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
Fig. 3 Engine Cooling System4.0L Engine
Typical
1 - HEATER CORE
2 - TO COOLANT RESERVE/OVERFLOW TANK
3 - THERMOSTAT HOUSING
4 - RADIATOR
5 - WATER PUMP
WJ COOLING 7 - 3
COOLING (Continued)
SLI GHT TAI L WI ND AT I DLE
SLOW TRAFFI C
TRAFFI C JAMS
HI GH SPEED
STEEP GRADES
Dri vi ng techni ques that avoi d overheati ng are:
I dl e wi th A/C off when temperature gauge i s at
end of normal range.
I ncrease engi ne speed for more ai r fl ow i s recom-
mended.
(1) TRAI LER TOWI NG:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
(2) AI R CONDI TI ONI NG; ADD-ON OR AFTER
MARKET:
A maxi mum cool i ng package shoul d have been
ordered wi th vehi cl e i f add-on or after market A/C i s
i nstal l ed. I f not, maxi mum cool i ng system compo-
nents shoul d be i nstal l ed for model i nvol ved per
manufacturers speci fi cati ons.
(3) RECENT SERVI CE OR ACCI DENT REPAI R:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
Engi ne adjustments (i ncorrect ti mi ng)
Sl i ppi ng engi ne accessory dri ve bel t(s)
Brakes (possi bl y draggi ng)
Changed parts. I ncorrect water pump, or pump
rotati ng i n wrong di recti on due to bel t not correctl y
routed
Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a qui ck-reference
onl y. Refer to the group text for i nformati on.
Fig. 4 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
7 - 4 COOLING WJ
COOLING (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CHART
COOLING SYSTEM DIAGNOSIS CHART
TEMPERATURE GAUGE
READS LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?
1. Refer to (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for On-Board
Diagnostics and DTC information. Replace
thermostat if necessary.
2. Is the temperature sending unit
connected?
2. Check the temperature sensor connector.
(Refer to 7 - COOLING/ENGINE/ENGINE
COOLANT TEMP SENSOR -
DESCRIPTION). Repair connector if
necessary.
3. Is the temperature gauge
operating OK?
3. Check gauge operation. Repair as
necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.
4. Check coolant level in the coolant
reserve/overflow tank and the radiator.
Inspect system for leaks. Repair leaks as
necessary.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as necessary.
(Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND
TESTING)
TEMPERATURE GAUGE
READS HIGH OR THE
COOLANT LAMP
ILLUMINATES.
COOLANT MAY OR MAY
NOT BE LOST OR
LEAKING FROM THE
COOLING SYSTEM
1. Trailer is being towed, a steep hill
is being climbed, vehicle is operated
in slow moving traffic, or engine is
being idled with very high ambient
(outside) temperatures and the air
conditioning is on. Higher altitudes
could aggravate these conditions.
1. This may be a temporary condition and
repair is not necessary. Turn off the air
conditioning and attempt to drive the vehicle
without any of the previous conditions.
Observe the temperature gauge. The gauge
should return to the normal range. If the
gauge does not return to the normal range,
determine the cause for overheating and
repair.
2. Is the temperature gauge reading
correctly?
2. Check gauge. (Refer to Group 8J -
INSTRUMENT CLUSTER). Repair as
necessary.
3. Is the temperature warning
illuminating unnecessarily?
3. Check warning lamp operation. (Refer to
Group 8J - INSTRUMENT CLUSTER).Repair
as necessary.
4. Coolant low in coolant reserve/
overflow tank and radiator?
4. Check for coolant leaks and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer to
the following Step 6.
5. Tighten cap
WJ COOLING 7 - 5
COOLING (Continued)
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and cap seals.
(Refer to 7 - COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS AND
TESTING).
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. Coolant level low in radiator but
not in coolant reserve/overflow tank.
This means the radiator is not
drawing coolant from the coolant
reserve/overflow tank as the engine
cools
7. (a) Check condition of radiator cap and
cap seals. (Refer to 7 - COOLING/ENGINE/
RADIATOR PRESSURE CAP - DIAGNOSIS
AND TESTING).
(b) Check condition of radiator filler neck. If
neck is bent or damaged, replace radiator.
(c) Check condition of the hose from the
radiator to the coolant tank. It should fit tight
at both ends without any kinks or tears.
Replace hose if necessary.
(d) Check coolant reserve/overflow tank and
tanks hoses for blockage. Repair as
necessary.
8. Incorrect coolant concentration 8. Check coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DESCRIPTION) for
correct coolant/water mixture ratio.
9. Coolant not flowing through
system
9. Check for coolant flow at radiator filler
neck with some coolant removed, engine
warm and thermostat open. Coolant should
be observed flowing through radiator. If flow
is not observed, determine area of
obstruction and repair as necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.
10. Remove insects and debris. (Refer to 7 -
COOLING/ENGINE/RADIATOR -
CLEANING).
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or replaced.
12. Aftermarket A/C installed without
proper radiator.
12. Install proper radiator.
13. Fuel or ignition system
problems.
13. Refer to FUEL and /or IGNITION
CONTROL for diagnosis.
14. Dragging brakes. 14. Check and correct as necessary. (Refer
to 5 - BRAKES - DIAGNOSIS AND
TESTING) for correct procedures.
15. Bug screen or cardboard is
being used, reducing airflow.
15. Remove bug screen or cardboard.
16. Thermostat partially or
completely shut.
16. Check thermostat operation and replaces
necessary. (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT -
7 - 6 COOLING WJ
COOLING (Continued)
17. Viscous fan drive not operating
properly.
17. Check fan drive operation and replace as
FAN DRIVE VISCOUS CLUTCH -
18. Cylinder head gasket leaking. 18. Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS AND
TESTING). For repair, (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
19. Heater core leaking. 19. Check heater core for leaks. (Refer to 24
- HEATING & AIR CONDITIONING/
PLUMBING/HEATER CORE - REMOVAL).
Repair as necessary.
20. Hydraulic fan speed too low or
inopertive.
20. Check for
DTC code.
Check fan operation speeds.
Refer to fan speed operation table.
Low power steering pump output. Refer to
power steering pump diagnosis - 4.7L engine.
TEMPERATURE GAUGE
READING IS
INCONSISTENT
(FLUCTUATES, CYCLES
OR IS ERRATIC)
1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.
1. A normal condition. No correction is
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
2. Check operation of gauge and repair if
necessary. Refer to Group 8J, Instrument
cluster.
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running)
necessary. Gauge should return to normal
range after vehicle is driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.
necessary. The gauge should return to
normal range after a few minutes of engine
operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open late).
5. Check and correct coolant leaks. (Refer to
7 - COOLING - DIAGNOSIS AND TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a thermostat
to open late.
6. (a) Check for cylinder head gasket leaks.
TESTING).
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from the
exhaust system. Repair as necessary.
WJ COOLING 7 - 7
COOLING (Continued)
7. Water pump impeller loose on
shaft.
7. Check water pump and replace as
WATER PUMP - DIAGNOSIS AND
TESTING).
8. Loose accessory drive belt. (water
pump slipping)
8. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND
TESTING). Check and correct as necessary.
9. Air leak on the suction side of the
water pump allows air to build up in
cooling system causing thermostat
to open late.
9. Locate leak and repair as necessary.
PRESSURE CAP IS
BLOWING OFF STEAM
AND/OR COOLANT TO
COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE
ABOVE NORMAL BUT
NOT HIGH. COOLANT
LEVEL MAY BE HIGH IN
COOLANT RESERVE/
OVERFLOW TANK
1. Pressure relief valve in radiator
cap is defective.
1. Check condition of radiator cap and cap
seals. (Refer to 7 - COOLING/ENGINE/
RADIATOR PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as necessary.
COOLANT LOSS TO THE
GROUND WITHOUT
PRESSURE CAP
BLOWOFF. GAUGE
READING HIGH OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.
1. Pressure test and repair as necessary.
TESTING).
DETONATION OR
PRE-IGNITION (NOT
CAUSED BY IGNITION
SYSTEM). GAUGE MAY
OR MAY NOT BE
READING HIGH
1. Engine overheating. 1. Check reason for overheating and repair
as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.
2. Check coolant concentration. (Refer to 7 -
COOLING/ENGINE/COOLANT -
DESCRIPTION) and adjust ratio as required.
HOSE OR HOSES
COLLAPSE WHILE
ENGINE IS RUNNING
1. Vacuum created in cooling system
on engine cool-down is not being
relieved through coolant reserve/
overflow system.
1. (a) Radiator cap relief valve stuck. (Refer
to 7 - COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS AND
TESTING). Replace if necessary
(b) Hose between coolant reserve/overflow
tank and radiator is kinked. Repair as
necessary.
(c) Vent at coolant reserve/overflow tank is
plugged. Clean vent and repair as necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for blockage and
repair as necessary.
7 - 8 COOLING WJ
COOLING (Continued)
NOISY VISCOUS
FAN/DRIVE
1. Fan blades loose - 4.0L. 1. Replace fan blade assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN -
REMOVAL)
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact and
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or clean debris
or insects from radiator or A/C condenser.
4. Thermal viscous fan drive has
defective bearing - 4.0L
4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL).
INADEQUATE HEATER
PERFORMANCE.
1.Thermostat failed in open position
2. Has a Diagnostic trouble Code
(DTC) been set?
2. (Refer to 25 - EMISSIONS CONTROL -
DESCRIPTION) for correct procedures and
replace thermostat if necessary
3. Coolant level low 3. (Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
4. Obstructions in heater hose/
fittings
4. Remove heater hoses at both ends and
check for obstructions
5. Heater hose kinked 5. Locate kinked area and repair as
necessary
6. Water pump is not pumping water
to/through the heater core. When
the engine is fully warmed up, both
heater hoses should be hot to the
touch. If only one of the hoses is
hot, the water pump may not be
operating correctly or the heater
core may be plugged. Accessory
drive belt may be slipping causing
poor water pump operation.
6. (Refer to 7 - COOLING/ENGINE/WATER
PUMP - DIAGNOSIS AND TESTING). If a
slipping belt is detected, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE
BELTS - REMOVAL). If heater core
obstruction is detected, (Refer to 7 -
COOLING - STANDARD PROCEDURE) for
cooling system reverse flushing.
STEAM IS COMING
FROM THE FRONT OF
VEHICLE NEAR THE
GRILL AREA WHEN
WEATHER IS WET,
ENGINE IS WARMED UP
AND RUNNING, AND
VEHICLE IS
STATIONARY.
TEMPERATURE GAUGE
IS IN NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the radiator.
When the moisture contacts the hot
radiator, steam may be emitted. This
usually occurs in cold weather with
no fan or airflow to blow it away.
1. Occasional steam emitting from this area
is normal. No repair is necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
1. (Refer to 7 - COOLING/ENGINE/
COOLANT - DESCRIPTION) for coolant
concentration information. Adjust coolant
mixture as necessary.
WJ COOLING 7 - 9
COOLING (Continued)
COOLANT LEVEL
CHANGES IN COOLANT
RESERVE/OVERFLOW
TANK. TEMPERATURE
GAUGE IS IN NORMAL
RANGE
1. Level changes are to be expected
as coolant volume fluctuates with
engine temperature. If the level in
the tank was between the FULL and
ADD marks at normal operating
temperature, the level should return
to within that range after operation
at elevated temperatures.
1. A normal condition. No repair is necessary.
FAN RUNS ALL THE
TIME
1. Fan control sensors inoperative. 1. Check for DTCs. Verify sensor readings.
2. Fan control solenoid stuck on. 2. Check fan operation speeds. Refer to fan
speed operation table.
3. Fan control solenoid harness
damaged.
3. Check for DTC 1499. Repair as required.
4. Transmission temperature too
high.
4. Check for transmission over temp. DTC.
5. Engine coolant temperature too
high.
5. (a) Check coolant level. Correct level as
required.
(b) Thermostat stuck. Replace thermostat.
(c) Water pump failed. Replace water pump.
(d) Coolant flow restricted. Clean radiator.
(e) Air flow over radiator obstructed.Remove
obstruction.
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAKS
ULTRAVIOLET LIGHT METHOD
A l eak detecti on addi ti ve i s avai l abl e through the
parts department that can be added to cool i ng sys-
tem. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). Pour one ounce of addi ti ve i nto
cool i ng system. Pl ace heater control uni t i n HEAT
posi ti on. Start and operate engi ne unti l radi ator
upper hose i s warm to touch. Ai m the commerci al l y
avai l abl e bl ack l i ght tool at components to be
checked. I f l eaks are present, bl ack l i ght wi l l cause
addi ti ve to gl ow a bri ght green col or.
The bl ack l i ght can be used i n conjuncti on wi th a
pressure tester to determi ne i f any external l eaks
exi st (Fi g. 5).
PRESSURE TESTER METHOD
The engi ne shoul d be at normal operati ng temper-
ature. Recheck the system col d i f cause of cool ant
l oss i s not l ocated duri ng the warm engi ne exami na-
ti on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Fig. 5 Leak Detection Using Black LightTypical
1 - TYPICAL BLACK LIGHT TOOL
7 - 10 COOLING WJ
COOLING (Continued)
Careful l y remove radi ator pressure cap from fi l l er
neck and check cool ant l evel . Push down on cap to
di sengage i t from stop tabs. Wi pe i nsi de of fi l l er neck
and exami ne l ower i nsi de seal i ng seat for ni cks,
cracks, pai nt, di rt and sol der resi due. I nspect radi a-
tor-to- reserve/overfl ow tank hose for i nternal
obstructi ons. I nsert a wi re through the hose to be
sure i t i s not obstructed.
I nspect cams on outsi de of fi l l er neck. I f cams are
damaged, seati ng of pressure cap val ve and tester
seal wi l l be affected.
Attach pressure tester (7700 or an equi val ent) to
radi ator fi l l er neck (Fi g. 6).
Operate tester pump to appl y 103.4 kPa (15 psi )
pressure to system. I f hoses enl arge excessi vel y or
bul ges whi l e testi ng, repl ace as necessary. Observe
gauge poi nter and determi ne condi ti on of cool i ng sys-
tem accordi ng to fol l owi ng cri teri a:
Holds Steady: I f poi nter remai ns steady for two
mi nutes, seri ous cool ant l eaks are not present i n sys-
tem. However, there coul d be an i nternal l eak that
does not appear wi th normal system test pressure. I f
i t i s certai n that cool ant i s bei ng l ost and l eaks can-
not be detected, i nspect for i nteri or l eakage or per-
form I nternal Leakage Test.
Drops Slowly: I ndi cates a smal l l eak or seepage
i s occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect radi ator,
hoses, gasket edges and heater. Seal smal l l eak hol es
wi th a Seal er Lubri cant (or equi val ent). Repai r l eak
hol es and i nspect system agai n wi th pressure
appl i ed.
Drops Quickly: I ndi cates that seri ous l eakage i s
occurri ng. Exami ne system for external l eakage. I f
l eaks are not vi si bl e, i nspect for i nternal l eakage.
Large radi ator l eak hol es shoul d be repai red by a
reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . I f cool ant i s present i n
the pan, i t wi l l drai n fi rst because i t i s heavi er than
oi l . An al ternati ve method i s to operate engi ne for a
short peri od to churn the oi l . After thi s i s done,
remove engi ne di psti ck and i nspect for water gl ob-
ul es. Al so i nspect transmi ssi on di psti ck for water
gl obul es and transmi ssi on fl ui d cool er for l eakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engi ne wi thout pressure cap on radi ator
unti l thermostat opens. Attach a Pressure Tester to
fi l l er neck. I f pressure bui l ds up qui ckl y i t i ndi cates a
combusti on l eak exi sts. Thi s i s usual l y the resul t of a
cyl i nder head gasket l eak or crack i n engi ne. Repai r
as necessary.
I f there i s not an i mmedi ate pressure i ncrease,
pump the Pressure Tester. Do thi s unti l i ndi cated
pressure i s wi thi n system range of 110 kPa (16 psi ).
Fl uctuati on of gauge poi nter i ndi cates compressi on or
combusti on l eakage i nto cool i ng system.
Because the vehi cl e i s equi pped wi th a catal yti c
converter, do not remove spark pl ug cabl es or short
out cyl i nders to i sol ate compressi on l eak.
I f the needl e on di al of pressure tester does not
fl uctuate, race engi ne a few ti mes to check for an
abnormal amount of cool ant or steam. Thi s woul d be
emi tti ng from exhaust pi pe. Cool ant or steam from
exhaust pi pe may i ndi cate a faul ty cyl i nder head gas-
ket, cracked engi ne cyl i nder bl ock or cyl i nder head.
A conveni ent check for exhaust gas l eakage i nto
cool i ng system i s provi ded by a commerci al l y avai l -
abl e Bl ock Leak Check tool . Fol l ow manufacturers
i nstructi ons when usi ng thi s product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow thermostat
removal . (Refer to 7 - COOLI NG/ENGI NE/ENGI NE
COOLANT THERMOSTAT - REMOVAL). Remove
Fig. 6 Pressure Testing Cooling SystemTypical
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
WJ COOLING 7 - 11
COOLING (Continued)
accessory dri ve bel t (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - REMOVAL).
Add cool ant to radi ator to bri ng l evel to wi thi n 6.3
mm (1/4 i n) of top of thermostat housi ng.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engi ne and accel erate rapi dl y three ti mes, to
approxi matel y 3000 rpm whi l e observi ng cool ant. I f
i nternal engi ne combusti on gases are l eaki ng i nto
cool i ng system, bubbl es wi l l appear i n cool ant. I f bub-
bl es do not appear, i nternal combusti on gas l eakage
i s not present.
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
As the engi ne operates, any ai r trapped i n cool i ng
system gathers under the radi ator cap. The next ti me
the engi ne i s operated, thermal expansi on of cool ant
wi l l push any trapped ai r past radi ator cap i nto the
cool ant reserve/overfl ow tank. Here i t escapes to the
atmosphere i nto the tank. When the engi ne cool s
down the cool ant, i t wi l l be drawn from the reserve/
overfl ow tank i nto the radi ator to repl ace any
removed ai r.
STANDARD PROCEDURE
STANDARD PROCEDURE DRAINING COOLING
SYSTEM 4. 7L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS (Fig. 7) OR LOOSEN THE
RADIATOR DRAINCOCK WITH SYSTEM HOT AND
UNDER PRESSURE. SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(1) DO NOT remove radi ator cap fi rst. Wi th engi ne
col d, rai se vehi cl e on a hoi st and l ocate radi ator
drai ncock.
NOTE: Radiator draincock is located on the left/
lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner. Open drai ncock
and drai n cool ant from radi ator. Thi s wi l l empty the
cool ant reserve/overfl ow tank. The cool ant does not
have to be removed from the tank unl ess the system
i s bei ng refi l l ed wi th a fresh mi xture. When tank i s
empty, remove radi ator cap and conti nue drai ni ng
cool i ng system.
COOLING SYSTEM 4. 7L ENGINE
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s) (i f removed).
CAUTION: Failure to purge air from the cooling sys-
tem can result in an overheating condition and
severe engine damage.
(2) Remove the cool i ng system bl eed pl ug from the
radi ator upper hose i nl et housi ng. (Fi g. 8)Fi l l system
usi ng a 50/50 mi xture of ethyl ene-gl ycol anti freeze
and l ow mi neral content water, unti l cool ant begai ns
comi ng out of the cool i ng system bl eed hol e. I nstal l
the cool i ng system bl eed pl ug. Fi l l radi ator to top and
i nstal l radi ator cap. Add suffi ci ent cool ant to the
reserve/overfl ow tank to rai se l evel to FULL mark.
(3) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th radi ator cap i n pl ace.
(4) After engi ne has reached normal operati ng
temperature, shut engi ne off and al l ow i t to cool .
When engi ne i s cool i ng down, cool ant wi l l be drawn
i nto the radi ator from the reserve/overfl ow tank.
(5) Add cool ant to reserve/overfl ow tank as neces-
sary. Only add coolant to the reserve/overflow
tank when the engine is cold. Coolant level in a
warm engine will be higher due to thermal
expansion. To purge the cool i ng system of al l ai r,
thi s heat up/cool down cycl e (addi ng cool ant to col d
engi ne) must be performed three ti mes. Add neces-
sary cool ant to rai se tank l evel to the FULL mark
after each cool down peri od.
Fig. 7 Drain Plug4.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
7 - 12 COOLING WJ
COOLING (Continued)
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM - 4. 0L ENGINE
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(1) DO NOT remove radi ator cap fi rst. Wi th engi ne
col d, rai se vehi cl e on a hoi st and l ocate radi ator
drai ncock.
NOTE: Radiator draincock is located on the right/
lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner. Open drai ncock
and drai n cool ant from radi ator. Thi s wi l l empty the
cool ant reserve/overfl ow tank. The cool ant does not
have to be removed from the tank unl ess the system
i s bei ng refi l l ed wi th a fresh mi xture. When tank i s
empty, remove radi ator cap and conti nue drai ni ng
cool i ng system.
To drai n the engi ne of cool ant, remove the cyl i nder
bl ock drai n pl ug l ocated on the si de of cyl i nder bl ock
(Fi g. 9).
COOLING SYSTEM - 4. 0L ENGINE
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s) (i f removed).
(2) Fi l l system usi ng a 50/50 mi xture of ethyl ene-
gl ycol anti freeze and l ow mi neral content water. Fi l l
radi ator to top and i nstal l radi ator cap. Add suffi -
ci ent cool ant to the reserve/overfl ow tank to rai se
l evel to FULL mark.
(3) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th radi ator cap i n pl ace.
(4) After engi ne has reached normal operati ng
temperature, shut engi ne off and al l ow i t to cool .
When engi ne i s cool i ng down, cool ant wi l l be drawn
i nto the radi ator from the reserve/overfl ow tank.
(5) Add cool ant to reserve/overfl ow tank as neces-
sary. Only add coolant to the reserve/overflow
tank when the engine is cold. Coolant level in a
warm engine will be higher due to thermal
expansion. To purge the cool i ng system of al l ai r,
thi s heat up/cool down cycl e (addi ng cool ant to col d
engi ne) must be performed three ti mes. Add neces-
sary cool ant to rai se tank l evel to the FULL mark
after each cool down peri od.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
Fig. 8 Cooling System Bleed Plug - 4.7L
1 - COOLING SYSTEM BLEED PLUG
Fig. 9 Drain Plug4.0L Engine
1 - COOLANT TEMPERATURE SENSOR
2 - BLOCK DRAIN PLUG
WJ COOLING 7 - 13
COOLING (Continued)
STANDARD PROCEDURE - COOLING SYSTEM -
REVERSE FLUSHING
CAUTION: The cooling system normally operates at
97-to-124 kPa (14-to -18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
CHEMICAL CLEANING
I f vi sual i nspecti on i ndi cates the formati on of
sl udge or scal y deposi ts, use a radi ator cl eaner
(Mopar Radi ator Kl een or equi val ent) before fl ushi ng.
Thi s wi l l soften scal e and other deposi ts and ai d the
fl ushi ng operati on.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
CAUTION: The cooling system normally operates at
97-to-124 kPa (14- to-18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Al l ow the radi ator to fi l l wi th water. When radi ator
i s fi l l ed, appl y ai r i n short bl asts al l owi ng radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
cool i ng tube passages. For more i nformati on, refer to
operati ng i nstructi ons suppl i ed wi th fl ushi ng equi p-
ment. Have radi ator cl eaned more extensi vel y by a
radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE). Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water suppl y hose and ai r suppl y hose
to the fl ushi ng gun. Al l ow the engi ne to fi l l wi th
water. When the engi ne i s fi l l ed, appl y ai r i n short
bl asts, al l owi ng the system to fi l l between ai r bl asts.
Conti nue unti l cl ean water fl ows through the l ead
away hose. For more i nformati on, refer to operati ng
i nstructi ons suppl i ed wi th fl ushi ng equi pment.
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng (Refer to 7 - COOLI NG/ENGI NE/EN-
GI NE COOLANT THERMOSTAT - REMOVAL).
I nstal l the thermostat and housi ng wi th a repl ace-
ment gasket (Refer to 7 - COOLI NG/ENGI NE/EN-
GI NE COOLANT THERMOSTAT -
I NSTALLATI ON). Connect the radi ator hoses. Refi l l
the cool i ng system wi th the correct anti freeze/water
mi xture (Refer to 7 - COOLI NG - STANDARD PRO-
CEDURE).
SPECIFICATIONS
TORQUE
DESCRIPTION Nm Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
Mounting
BracketBolt
4.0L 28 250
4.7L 41 30
Automatic Belt Tensioner
Pulley
Bolt
(4.7L) 61 45
Block HeaterBolt
7 - 14 COOLING WJ
COOLING (Continued)
Lbs. Lbs.
4.0L 4 32
4.7L 2 17
Fan Blade Assy. to Viscous
Drive
Bolts 4.0L 23 200
Generator MountingBolts
4.0L
57 42
Radiator Upper Isolator to
CrossmemberNuts 3 20
Radiator Upper Isolator to
Radiator
Nuts 4 36
Radiator BraceBolts 10 90
Thermostat HousingBolts
4.0L 22 16
4.7L 13 115
Upper Radiator Crossmember
to
BodyBolts 10 90
Water PumpBolts
4.0L 23 17
4.7L 54 40
Water Pump Pulley to Water
Pump
Bolts 4.0L 28 250
High Pressure Inlet Hose to
Hydraulic Fan Drive1/2 inch
Fitting
49 36
High Pressure Outlet Hose to
Steering Gear3/8 inch
Fitting
29 21.5
Fan Shroud to Radiator
Mounting Bolts
6 50
SPECIAL TOOLS
COOLING
Pliers 6094
Pressure Tester 7700A
WJ COOLING 7 - 15
COOLING (Continued)
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONERS
REMOVAL
REMOVAL4.7L ENGINE . . . . . . . . . . . . . . . 16
REMOVAL4.0L ENGINE . . . . . . . . . . . . . . . 16
INSTALLATION
INSTALLATION4.7L ENGINE . . . . . . . . . . . 16
DRIVE BELTS - 4.0L
DIAGNOSIS AND TESTING SERPENTINE
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL4.0L ENGINE . . . . . . . . . . . . . . . . . 19
INSTALLATION4.0L ENGINE . . . . . . . . . . . . . 19
DRIVE BELTS - 4.7L
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL - 4.7L ENGINE . . . . . . . . . . . . . . . . . 22
INSTALLATION - 4.7L ENGINE . . . . . . . . . . . . . 23
BELT TENSIONERS
REMOVAL
REMOVAL 4. 7L ENGINE
(1) Remove accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(2) Remove tensi oner assembl y from engi ne front
cover (Fi g. 1).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY
(EXCEPT FOR PULLEY ON TENSIONER).
(3) Remove pul l ey bol t. Remove pul l ey from ten-
si oner.
REMOVAL).
(2) Remove tensi oner assembl y from mounti ng
bracket (Fi g. 2).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY.
INSTALLATION
INSTALLATION 4. 7L ENGINE
(1) I nstal l pul l ey and pul l ey bol t to tensi oner.
Ti ghten bol t to 61 Nm (45 ft. l bs.) torque.
(2) An i ndexi ng sl ot i s l ocated on back of tensi oner.
Al i gn thi s sl ot to the head of the bol t on the front
cover. I nstal l the mounti ng bol t. Ti ghten bol t to 41
Nm (30 ft. l bs.).
Fig. 1 Automatic Belt Tensioner
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 Nm (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
7 - 16 ACCESSORY DRIVE WJ
(3) I nstal l dri ve bel t (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(4) Check bel t i ndexi ng marks (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
(1) I nstal l tensi oner assembl y to mounti ng
bracket, al i gn the two dowel s on the tensi oner wi th
the mounti ng bracket and hand start the bol t.
Ti ghten bol t to 28 Nm (250 i n. l bs.).
CAUTION: To prevent damage to coil case, coil
mounting bolts must be torqued.
(2) I nstal l dri ve bel t. (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(3) Check bel t i ndexi ng marks (Refer to 7 - COOL-
LATI ON).
DRIVE BELTS - 4.0L
DRIVE BELT
When di agnosi ng serpenti ne dri ve bel ts, smal l
cracks that run across ri bbed surface of bel t from ri b
to ri b (Fi g. 3), are consi dered normal . These are not a
reason to repl ace bel t. However, cracks runni ng al ong
a ri b (not across) are not normal . Any bel t wi th
cracks runni ng al ong a ri b must be repl aced (Fi g. 3).
Al so repl ace bel t i f i t has excessi ve wear, frayed cords
or severe gl azi ng.
Refer to SERPENTI NE DRI VE BELT DI AGNOSI S
CHART for further bel t di agnosi s.
Fig. 2 Automatic Belt Tensioner
1 - IDLER PULLEY TIGHTEN TO 47 Nm (35 FT. LBS.)
2 - AUTOMATIC BELT TENSIONER
3 - GENERATOR MOUNTING BRACKET
Fig. 3 Serpentine Accessory Drive Belt Wear
Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
WJ ACCESSORY DRIVE 7 - 17
BELT TENSIONERS (Continued)
SERPENTINE DRIVE BELT DIAGNOSIS CHART
RIB CHUNKING (ONE OR MORE
RIBS HAS SEPARATED FROM
BELT BODY)
1. Foreign objects imbedded in pulley
grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage. 2. Replace belt.
RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).
2. Abrasive environment. 2. Clean pulley(s). Replace belt if
necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove tips. 4. Replace pulley.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT
CRACKING (CRACKS BETWEEN
TWO RIBS)
1. Belt has mistracked from pulley
groove.
1. Replace belt.
2. Pulley groove tip has worn away
rubber to tensile member.
2. Replace belt.
BELT SLIPS 1. Belt slipping because of insufficient
tension.
1. Replace automatic belt tensioner.
2. Belt routed 2. Verify belt routing.
incorrectly
3. Incorrect belt. 3. Replace belt.
4. Belt or pulley subjected to
substance (belt dressing, oil ethylene
glycol) that has reduced friction.
4. Replace belt and clean pulleys.
5. Driven component bearing failure. 5. Replace faulty component
bearing.
6. Belt glazed and hardened from
heat and excessive slippage.
6. Replace belt.
GROOVE JUMPING (BELT
DOES NOT MAINTAIN CORRECT
POSITION ON PULLEY)
1. Belt tension either too high or too
low.
incorrectly.
4. Pulley(s) not within design
tolerance.
4. Replace pulley(s).
5. Foreign object(s) in grooves. 5. Remove foreign objects from
grooves.
6. Pulley misalignment. 6. Check and replace.
7. Belt cord line is broken. 7. Replace belt.
DRIVE BELTS - 4.0L (Continued)
BELT BROKEN (NOTE: IDENTIFY
AND CORRECT PROBLEM
BEFORE NEW BELT IS
INSTALLED)
1. Excessive tension. 1. Replace belt and automatic belt
tensioner.
3. Tensile member damaged during
belt installation.
3. Replace belt.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.
NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE
IS HEARD OR FELT WHILE
DRIVE BELT IS IN OPERATION)
1. Belt slippage. 1. Replace belt or automatic belt
tensioner.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on. (Fi g. 4).
si oner.
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 4).
Fig. 4 Belt Routing4.0L
1 - GENERATOR
2 - IDLER
3 - POWER STEERING
4 - A/C
5 - CRANKSHAFT
6 - WATER PUMP
7 - TENSIONER
8 - ACCESSORY DRIVE BELT
(2) I nstal l new bel t (Fi g. 4). Route the bel t around
al l pul l eys except the i dl er pul l ey. Rotate the ten-
si oner arm unti l i t contacts i ts stop posi ti on. Route
the bel t around the i dl er and sl owl y l et the tensi oner
rotate i nto the bel t. Make sure the bel t i s seated onto
al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator (Fi g. 5). On 4.0L Engi nes, the i ndi ca-
tor mark must be between the mi ni mum and maxi -
mum marks. I f the measurement exceedes thi s
speci fi cati on repl ace the serpenti ne accessory dri ve
bel t.
DRIVE BELTS - 4.7L
DRIVE BELT
When di agnosi ng serpenti ne dri ve bel ts, smal l
cracks that run across ri bbed surface of bel t from ri b
to ri b (Fi g. 6), are consi dered normal . These are not a
reason to repl ace bel t. However, cracks runni ng al ong
a ri b (not across) are not normal . Any bel t wi th
cracks runni ng al ong a ri b must be repl aced (Fi g. 6).
Al so repl ace bel t i f i t has excessi ve wear, frayed cords
or severe gl azi ng.
Refer to SERPENTI NE DRI VE BELT DI AGNOSI S
CHART for further bel t di agnosi s.
Fig. 5 Accessory Drive Belt Wear Indicator
1 - INDICATOR MARK
2 - MINIMUM TENSION MARK
3 - MAXIMUM TENSION MARK
Fig. 6 Serpentine Accessory Drive Belt Wear
Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
SERPENTINE DRIVE BELT DIAGNOSIS CHART
RIB CHUNKING (ONE OR MORE
RIBS HAS SEPARATED FROM
BELT BODY)
1. Foreign objects imbedded in pulley
grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage. 2. Replace belt.
RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).
2. Abrasive environment. 2. Clean pulley(s). Replace belt if
necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove tips. 4. Replace pulley.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT
CRACKING (CRACKS BETWEEN
TWO RIBS)
1. Belt has mistracked from pulley
groove.
1. Replace belt.
2. Pulley groove tip has worn away
rubber to tensile member.
2. Replace belt.
BELT SLIPS 1. Belt slipping because of insufficient
tension.
incorrectly
4. Belt or pulley subjected to
substance (belt dressing, oil ethylene
glycol) that has reduced friction.
4. Replace belt and clean pulleys.
5. Driven component bearing failure. 5. Replace faulty component
bearing.
6. Belt glazed and hardened from
heat and excessive slippage.
6. Replace belt.
GROOVE JUMPING (BELT
DOES NOT MAINTAIN CORRECT
POSITION ON PULLEY)
1. Belt tension either too high or too
low.
incorrectly.
4. Pulley(s) not within design
tolerance.
4. Replace pulley(s).
5. Foreign object(s) in grooves. 5. Remove foreign objects from
grooves.
6. Pulley misalignment. 6. Check and replace.
7. Belt cord line is broken. 7. Replace belt.
BELT BROKEN (NOTE: IDENTIFY
AND CORRECT PROBLEM
BEFORE NEW BELT IS
INSTALLED)
1. Excessive tension. 1. Replace belt and automatic belt
tensioner.
3. Tensile member damaged during
belt installation.
3. Replace belt.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.
NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE
IS HEARD OR FELT WHILE
DRIVE BELT IS IN OPERATION)
1. Belt slippage. 1. Replace belt or automatic belt
tensioner.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
REMOVAL - 4. 7L ENGINE
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
si oner.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on. (Fi g. 7).
Fig. 7 Belt Routing - 4.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
INSTALLATION - 4. 7L ENGINE
si oner.
(1) Check condi ti on of al l pul l eys.
rotating in the wrong direction (Fig. 7).
(2) I nstal l new bel t (Fi g. 7). Route the bel t around
al l pul l eys except the i dl er pul l ey. Rotate the ten-
si oner arm unti l i t contacts i ts stop posi ti on. Route
the bel t around the i dl er and sl owl y l et the tensi oner
rotate i nto the bel t. Make sure the bel t i s seated onto
al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator (Fi g. 8). On 4.7L Engi nes the gap
between the tang and the housi ng stop ( measure-
ment A ) must not exceed 24 mm (.94 i nches).
Fig. 8 Accessory Drive Belt Wear Indicator
1 - AUTOMATIC TENSIONER ASSEMBLY
ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION
DESCRIPTION - ENGINE COOLANT . . . . . . . 25
DESCRIPTION - HOAT COOLANT . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
COOLANT LEVEL SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
RADIATOR FAN - 4.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
RADIATOR FAN - 4.0L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE BLOCK HEATER
DESCRIPTION
DESCRIPTION4.7L ENGINE . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSIS AND TESTINGENGINE BLOCK
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL
REMOVAL4.7L ENGINE . . . . . . . . . . . . . . . 33
REMOVAL4.0L ENGINE . . . . . . . . . . . . . . . 34
INSTALLATION
ENGINE COOLANT TEMP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL
REMOVAL4.0L ENGINE . . . . . . . . . . . . . . . 35
REMOVAL4.7L ENGINE . . . . . . . . . . . . . . . 36
INSTALLATION
ENGINE COOLANT THERMOSTAT
DESCRIPTION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTINGTHERMOSTAT . . . 37
REMOVAL
REMOVAL4.0L ENGINE . . . . . . . . . . . . . . . 38
REMOVAL4.7L ENGINE . . . . . . . . . . . . . . . 38
INSTALLATION
FAN DRIVE VISCOUS CLUTCH - 4.0L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIAGNOSIS AND TESTINGVISCOUS FAN
DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
PWM FAN CONTROL MODULE - 4.0L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
RADIATOR - 4.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
RADIATOR - 4.0L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
RADIATOR FAN MOTOR
DIAGNOSIS AND TESTINGELECTRIC
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . 47
WATER PUMP - 4.7L
DESCRIPTION
DESCRIPTIONWATER PUMP . . . . . . . . . . . 47
DESCRIPTIONWATER PUMP BYPASS . . . . 47
OPERATION
OPERATIONWATER PUMP . . . . . . . . . . . . 47
OPERATIONWATER PUMP BYPASS . . . . . 48
DIAGNOSIS AND TESTINGWATER PUMP . . . 48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
WATER PUMP - 4.0L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
DIAGNOSIS AND TESTINGWATER PUMP . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7 - 24 ENGINE WJ
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
RADIATOR PRESSURE CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DIAGNOSIS AND TESTINGRADIATOR
PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . 53
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 54
WATER PUMP INLET TUBE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
COOLANT
DESCRIPTION
ETHYLENE-GLYCOL MIXTURES
ene-glycol.
mi xture depends upon the cl i mate and vehi cl e oper-
ati ng condi ti ons. The recommended mi xture of 50/50
ethyl ene-gl ycol and water wi l l provi de protecti on
agai nst freezi ng to -37 deg. C (-35 deg. F). The anti -
freeze concentrati on must always be a mi ni mum of
44 percent, year-round i n al l cl i mates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maxi mum protecti on agai nst freezi ng i s provi ded
wi th a 68 percent anti freeze concentrati on, whi ch
prevents freezi ng down to -67.7 deg. C (-90 deg. F). A
hi gher percentage wi l l freeze at a warmer tempera-
ture. Al so, a hi gher percentage of anti freeze can
cause the engi ne to overheat because the speci fi c
heat of anti freeze i s l ower than that of water.
Use of 100 percent ethyl ene-gl ycol wi l l cause for-
mati on of addi ti ve deposi ts i n the system, as the cor-
rosi on i nhi bi ti ve addi ti ves i n ethyl ene-gl ycol requi re
the presence of water to di ssol ve. The deposi ts act as
i nsul ati on, causi ng temperatures to ri se to as hi gh as
149 deg. C (300) deg. F). Thi s temperature i s hot
enough to mel t pl asti c and soften sol der. The
i ncreased temperature can resul t i n engi ne detona-
ti on. I n addi ti on, 100 percent ethyl ene-gl ycol freezes
at 22 deg. C (-8 deg. F ).
PROPYLENE-GLYCOL MIXTURES
I ts overal l effecti ve temperature range i s smal l er
than that of ethyl ene-gl ycol . The freeze poi nt of 50/50
propyl ene-gl ycol and water i s -32 deg. C (-26 deg. F).
5 deg. C hi gher than ethyl ene-gl ycol s freeze poi nt.
The boi l i ng poi nt (protecti on agai nst summer boi l -
over) of propyl ene-gl ycol i s 125 deg. C (257 deg. F )
at 96.5 kPa (14 psi ), compared to 128 deg. C (263
deg. F) for ethyl ene-gl ycol . Use of propyl ene-gl ycol
can resul t i n boi l -over or freeze-up on a cool i ng sys-
tem desi gned for ethyl ene-gl ycol . Propyl ene gl ycol
al so has poorer heat transfer characteri sti cs than
ethyl ene gl ycol . Thi s can i ncrease cyl i nder head tem-
peratures under certai n condi ti ons.
Propyl ene-gl ycol /ethyl ene-gl ycol Mi xtures can
cause the destabi l i zati on of vari ous corrosi on i nhi bi -
tors, causi ng damage to the vari ous cool i ng system
components. Al so, once ethyl ene-gl ycol and propy-
l ene-gl ycol based cool ants are mi xed i n the vehi cl e,
conventi onal methods of determi ni ng freeze poi nt wi l l
not be accurate. Both the refracti ve i ndex and spe-
ci fi c gravi ty di ffer between ethyl ene gl ycol and propy-
l ene gl ycol .
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. 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. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
WJ ENGINE 7 - 25
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
mi xed wi th 50% Ethyl ene Gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37C (-35F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
CAUTION: Mopar Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149C
(300F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22C (-8F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37C (-34F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7C (-90F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
ene-glycol.
COOLANT SELECTION AND ADDITIVES
OPERATION
Cool ant fl ows through the engi ne bl ock absorbi ng
the heat from the engi ne, then fl ows to the radi ator
where the cool i ng fi ns i n the radi ator transfers the
heat from the cool ant to the atmosphere. Duri ng col d
weather the ethyl ene-gl ycol cool ant prevents water
present i n the cool i ng system from freezi ng wi thi n
temperatures i ndi cated by mi xture rati o of cool ant to
water.
COOLANT LEVEL SENSOR
REMOVAL
(1) Open Hood.
(2) Di sconnect el ectri cal connector from cool ant
l evel sensor.
(3) Pul l cool ant l evel sensor out of cool ant recovery
pressure contai ner.
INSTALLATION
NOTE: Make sure the coolant level sensor fully
seats into the rubber grommet. Failure to do so
may cause inaccurate coolant level readings and
leaks.
7 - 26 ENGINE WJ
COOLANT (Continued)
(1) Posi ti on sensor i nto the cool ant recovery pres-
sure contai ner (Fi g. 1).
(2) Connect the cool ant l evel sensor el ectri cal con-
nector (Fi g. 2).
(3) Cl ose hood.
COOLANT RECOVERY PRESS
CONTAINER
DESCRIPTION
Thi s system works al ong wi th the radi ator pres-
sure cap. Thi s i s done by usi ng thermal expansi on
and contracti on of the cool ant to keep the cool ant
free of trapped ai r. I t provi des:
A vol ume for cool ant expansi on and contracti on.
A conveni ent and safe method for checki ng/ad-
justi ng cool ant l evel at atmospheri c pressure. Thi s i s
done wi thout removi ng the radi ator pressure cap.
Some reserve cool ant to the radi ator to cover
mi nor l eaks and evaporati on or boi l i ng l osses.
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
The cool ant reservoi r/overfl ow system has a radi a-
tor mounted pressuri zed cap, an overfl ow tube and a
pl asti c cool ant reservoi r/overfl ow tank (Fi g. 3)
mounted to the ri ght i nner fender.
RADIATOR FAN - 4.7L
DESCRIPTION
The hydraul i c fan (Fi g. 4) used on vehi cl es
equi pped the 4.7L engi ne, repl aces both the el ectri c
fan and the engi ne dri ven mechani cal fan. The
hydraul i c cool i ng fan i s i ntegral to the fan shroud
and i s l ocated between the radi ator and the engi ne.
The power steeri ng pump suppl i es the hydraul i c
fl ui d and pressure to rotate the cool i ng fan bl ade,
whi l e the el ectri cal part of the fan i s control l ed by
the JTEC.
The hydraul i c fan dri ve (motor) consi sts of the
three major fol l owi ng components:
Steeri ng fl ow control val ve
Fig. 1 COOLANT LEVEL SENSOR ELECTRICAL
CONNECTOR
Fig. 2 COOLANT LEVEL SENSOR REMOVAL/
INSTALLATION
Fig. 3 Coolant Reservoir / Overflow Tank
1 - COOLANT OVERFLOW HOSE
2 - COOLANT RESERVOIR/OVERFLOW TANK
3 - COOLANT LEVEL SENSOR
4 - BOLT
WJ ENGINE 7 - 27
COOLANT LEVEL SENSOR (Continued)
Fan control val ve
Two stage G-rotor hydraul i c dri ve
The hydraul i c fan and dri ve i s not servi ceabl e.
Therefore any fai l ure of the fan bl ade, hydraul i c fan
dri ve or fan shroud requi res repl acement of the fan
modul e because the fan bl ade and hydraul i c fan dri ve
are matched and bal anced as a system and servi ci ng
ei ther separatel y woul d di srupt thi s bal ance.
For hydraul i c fl ui d routi ng i nformati on refer to
(Fi g. 5).
CAUTION: Do not attempt to service the hydraulic
cooling fan or fan drive separately replace the cooling
module as an assembly. Failure to do so may cause
severe damage to the hydraulic cooling fan assembly.
OPERATION
The hydraul i c radi ator cool i ng fan used on the
Grand Cherokee wi th the 4.7L engi ne repl aces both
the el ectri c fan and the engi ne dri ven mechani cal
fan. The use of thi s hydraul i c fan provi des the 4.7L
equi pped Grand Cherokee wi th heavy trai l er tow
capabi l i ty whi l e at the same ti me reduci ng unneces-
sary power drai n on both the engi ne and the vehi cl es
el ectri cal system.
HYDRAULIC FAN STRATEGY
The hydraul i c radi ator cool i ng fan i s control l ed by
the JTEC. A PWM (Pul se Wi th Modul ated) si gnal
from the JTEC control s the fan from 0 to 100% of the
avai l abl e fan speed. There are four i nputs to the
JTEC that determi ne what speed percentage of fan i s
requi red by the vehi cl e. These i nputs are:
Engi ne Cool ant Temperature
Transmi ssi on Oi l Temperature
Battery Temperature
A/C System Pressure
By moni tori ng these four parameters, the JTEC
can determi ne i f cool i ng ai rfl ow i s requi red. I f ai rfl ow
i s requi red, the JTEC wi l l sl owl y ramp up (speed up)
the fan speed unti l the parameter(s) are under con-
trol . Once the temperature or pressure i s reduced to
wi thi n operati ng parameters the fan wi l l ramp up,
ramp down, or hol d i ts speed to mai ntai n the temper-
ature / pressure requi rements.
NOTE: Even if the JTEC is not requesting fan on
operation the fan blade will usually spin between
100 and 500 RPM when the vehicle is at idle. This is
due to a controlled minimum oil flow requirement
through the fan drive motor.
ACTIVATING THE HYDRAULIC FAN WITH THE DRB
Under the Engi ne Systems test headi ng, there i s a
subheadi ng. Hydraul i c fan sol enoi d test, that has
the sel ecti ons, on /off. Acti vati ng the fan wi th the
DRB wi l l run the fan at 100% duty cycl e, whi ch wi l l
hel p troubl eshoot any system probl ems, and al so hel p
wi th the deaerati on procedure.
NOTE: Engine must be running to activate the fan
with the DRB.
RADIATOR COOLING FAN HYDRAULIC FLUID PATH
Hydraul i c fl ui d i s pumped through the power
steeri ng pump, from the pump the fl ui d travel s
though a hi gh pressure del i very l i ne to the fan dri ve
motor. As fl ui d i s di verted through the G-rotors, rota-
ti onal moti on i s created as fl ui d moves from the hi gh-
pressure (i nl et) si de of the motor to the l ow-pressure
(outl et) si de. Fl ui d exi ti ng the dri ve motor i s di vi ded
i nto two paths. Path one conti nues through a hi gh
pressure del i very l i ne to the vehi cl es steeri ng gear to
provi de steeri ng assi st. and path two sends fl ui d
back to the power steeri ng pump through a l ow pres-
sure l i ne. Fl ui d exi ts the steeri ng gear under l ow
pressure and travel s through a l ow pressure l i ne to
the power steeri ng fl ui d cool er to be cool ed before
bei ng returned back the the power steeri ng fl ui d res-
ervoi r (Fi g. 5).
Fig. 4 HYDRAULIC RADIATOR COOLING FAN AND
FAN DRIVE
1 - POWER STEERING FLUID COOLER
2 - RADIATOR
3 - HIGH PRESSURE LINE FROM STEERING GEAR PUMP TO
HYDRAULIC FAN MOTOR
4 - HYDRAULIC FAN MOTOR
5 - HIGH PRESSURE LINE FROM HYDRAULIC FAN MOTOR TO
STEERING GEAR
6 - FAN SHROUD
7 - 28 ENGINE WJ
RADIATOR FAN - 4.7L (Continued)
NOTE: There is a steering flow control valve located
in the fan drive motor. This valve operates like the
flow control valve found in the typical power steer-
ing pump. Because of the design of the valve steer-
ing assist can not be effected by the radiator
cooling fan even during fan drive failure.
REMOVAL
(1) Rai se vehi cl e on hoi st.
(2) Drai n cool i ng system.(Refer to 7 - COOLI NG -
STANDARD PROCEDURE)
NOTE: The hydraulic fan drive is driven by the
power steering pump. When removing lines or
hoses from fan drive assembly use a drain pan to
catch any power steering fluid that may exit the fan
drive or the lines and hoses.
NOTE: When ever the high pressure line fittings are
removed from the hydraulic fan drive the O-rings
must be replaced.
(3) Di sconnect two hi gh pressure l i nes at hydraul i c
fan dri ve (Fi g. 6). Remove and di scard o-ri ngs from
l i ne fi tti ngs.
(4) Di sconnect l ow pressure return hose at hydrau-
l i c fan dri ve (Fi g. 6).
NOTE: The lower mounting bolts can only be
accessed from under vehicle.
(5) Remove two l ower mounti ng bol ts from the
shroud (Fi g. 8).
(7) Di sconnect the el ectri cal connector for the fan
control sol enoi d.
(8) Di sconnect the radi ator upper hose at the radi -
ator and posi ti on out of the way.
(9) Di sconnect the power steeri ng gear outl et hose
and fl ui d return hose at the cool er (Fi g. 7).
Fig. 5 HYDRAULIC FAN FLUID FLOW CIRCUIT
1 - POWER STEERING RESERVOIR
2 - POWER STEERING PUMP
3 - HYDRAULIC FAN DRIVE ASSEMBLY
4 - FAN BLADE
5 - HYDRAULIC FAN CONTROL SOLENOID
6 - POWER STEERING OIL COOLER
7 - STEERING GEAR
WJ ENGINE 7 - 29
(10) Remove two upper mounti ng bol ts from the
shroud (Fi g. 8).
(11) Remove the shroud and fan dri ve from vehi -
cl e.
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSTALLATION
CAUTION: There is an external ground wire con-
nected to the hydraulic fan drive located at the elec-
trical connector on the fan assembly. This ground
MUST remain connected at all times. Failure to
ensure ground wire is connected when engine is
operating can cause severe damage to the JTEC
module.
(1) Posi ti on fan dri ve and shroud i n vehi cl e.
(2) I nstal l fan shroud upper mounti ng bol ts. Do
not ti ghten at thi s ti me.
(3) I nstal l radi ator upper hose onto radi ator.
(4) Connect power steeri ng cool er hoses.
(6) I nstal l fan shroud l ower mounti ng bol ts.
Ti ghten to 6 Nm (50 i n. l bs.).
Fig. 6 HYDRAULIC LINES/HOSES AND ELECTRICAL
CONNECTOR
1 - LOW PRESSURE RETURN HOSE
2 - HIGH PRESSURE LINE (OUTLET)
3 - HIGH PRESSURE LINE (INLET)
4 - HYDRAULIC FAN DRIVE
Fig. 7 POWER STEERING GEAR OUTLET AND
RETURN HOSES
1 - POWER STEERING COOLER RETURN HOSE
2 - POWER STEERING COOLER SUPPLY HOSE
Fig. 8 FAN SHROUD MOUNTING BOLT LOCATIONS
1 - FAN SHROUD UPPER MOUNTING BOLT LOCATIONS
2 - FAN SHROUD LOWER MOUNTING BOLT LOCATIONS
7 - 30 ENGINE WJ
NOTE: When ever the high pressure line fittings are
removed from the hydraulic fan drive the o-rings
located on the fittings must be replaced.
(7) Lubri cate the o-ri ngs on the fi tti ngs wi th power
steeri ng fl ui d then connect i nl et and outl et hi gh pres-
sure l i nes to fan dri ve (Fi g. 9). Ti ghten i nl et l i ne to
49 Nm (36 ft. l bs.) ti ghten outl et l i ne to 29 Nm (21.5
ft. l bs.).
(8) Connect l ow pressure return hose to fan dri ve
(Fi g. 9).
(10) I nstal l radi ator upper hose.
(11) Connect el ectri cal connector for hydraul i c fan
control sol enoi d.
(12) Ti ghten fan shroud upper mounti ng bol ts to 6
Nm (50 i n. l bs.).
(13) Refi l l cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE).
CAUTION: Do not run engine with power steering
fluid below the full mark in the reservoir. Sever
damage to the hydraulic cooling fan or the engine
can occur.
(14) Refi l l power steeri ng fl ui d reservoi r and bl eed
ai r from steeri ng system (Refer to 19 - STEERI NG/
PUMP - STANDARD PROCEDURE).
(15) Run engi ne and check for l eaks.
RADIATOR FAN - 4.0L
DESCRIPTION
The radi ator cool i ng fan used on the 4.0L engi ne i s
an hybri d fan desi gn. The hybri d fan system consi st
of a l ow speed vi scous dri ven mechani cal fan and a
el ectri cal fan (Fi g. 10).
REMOVAL
(2) The thermal vi scous fan dri ve/fan bl ade assem-
bl y i s attached (threaded) to water pump hub shaft.
Remove fan bl ade/vi scous fan dri ve assembl y from
water pump by turni ng mounti ng nut countercl ock-
wi se as vi ewed from front (Fi g. 11). Threads on vi s-
cous fan dri ve are RIGHT HAND.
(3) Do not attempt to remove fan/vi scous fan dri ve
assembl y from vehi cl e at thi s ti me.
(4) Do not unbol t fan bl ade assembl y from vi scous
fan dri ve at thi s ti me.
(5) Remove fan shroud-to-upper crossmember nuts.
(6) Remove fan shroud and fan bl ade/vi scous fan
dri ve assembl y as a compl ete uni t from vehi cl e.
Fig. 9 HYDRAULIC LINES/HOSES AND ELECTRICAL
CONNECTOR
1 - LOW PRESSURE RETURN HOSE
2 - HIGH PRESSURE LINE (OUTLET)
3 - HIGH PRESSURE LINE (INLET)
4 - HYDRAULIC FAN DRIVE
Fig. 10 Radiator Cooling Fan
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
WJ ENGINE 7 - 31
(7) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace vi scous fan dri ve i n hori zon-
tal posi ti on. I f stored hori zontal l y, si l i cone fl ui d i n
the vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
CAUTION: Do not remove water pump pulley-to-wa-
ter pump bolts. This pulley is under belt tension.
(8) Remove four bol ts securi ng fan bl ade assembl y
to vi scous fan dri ve .
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan bl ade assembl y from vi scous fan
dri ve uni t (four bol ts).
(2) Lay fan on a fl at surface wi th l eadi ng edge fac-
i ng down. Wi th ti p of bl ade touchi ng fl at surface,
repl ace fan i f cl earance between opposi te bl ade and
surface i s greater than 2.0 mm (.090 i nch). Rocki ng
moti on of opposi te bl ades shoul d not exceed 2.0 mm
(.090 i nch). Test al l bl ades i n thi s manner.
(3) I nspect fan assembl y for cracks, bends, l oose
ri vets or broken wel ds. Repl ace fan i f any damage i s
found.
INSTALLATION
(1) Assembl e fan bl ade to vi scous fan dri ve.
Ti ghten mounti ng bol ts to 27 Nm (20 ft. l bs.) torque.
(2) Thread the fan and fan dri ve onto the water
pump pul l ey.
CAUTION: When installing a serpentine accessory
rotating in the wrong direction. (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
for correct belt routing.
ENGINE BLOCK HEATER
DESCRIPTION
DESCRIPTION 4. 7L ENGINE
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An opti onal engi ne bl ock heater (Fi g. 12) i s avai l -
abl e wi th al l model s. The heater i s equi pped wi th a
power cord. The cord i s attached to an engi ne com-
partment component wi th ti e-straps. The heater
warms the engi ne provi di ng easi er engi ne starti ng
and faster warm-up i n l ow temperatures. The heater
i s mounted i n a core hol e of the engi ne cyl i nder bl ock
i n pl ace of a freeze pl ug wi th the heati ng el ement
i mmersed i n engi ne cool ant.
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
Fig. 11 Fan and Viscous Fan Drive
1 - FAN AND FAN DRIVE
2 - WATER PUMP PULLEY
7 - 32 ENGINE WJ
An opti onal engi ne bl ock heater (Fi g. 13) i s avai l -
abl e wi th al l model s. The heater i s equi pped wi th a
power cord. The cord i s attached to an engi ne com-
partment component wi th ti e-straps. The heater
warms the engi ne provi di ng easi er engi ne starti ng
and faster warm-up i n l ow temperatures. The heater
i s mounted i n a core hol e of the engi ne cyl i nder bl ock
i n pl ace of a freeze pl ug wi th the heati ng el ement
i mmersed i n engi ne cool ant.
OPERATION
Connecti ng the power cord to a grounded 110-120
vol t AC el ectri cal outl et wi th a grounded, three wi re
extensi on cord acti vates the heati ng el ement warm-
i ng the engi ne cool ant.
DIAGNOSIS AND TESTING ENGINE BLOCK
HEATER
I f the uni t does not operate (Fi g. 14) (Fi g. 15), pos-
si bl e causes can be ei ther the power cord or the
heater el ement. Test the power cord for conti nui ty
wi th a 110-vol t vol tmeter or 110-vol t test l i ght. Test
heater el ement conti nui ty wi th an ohmmeter or a
12-vol t test l i ght.
CAUTION: To prevent damage, the power cord must
be secured in its retainer clips and away from any
components that may cause abrasion or damage,
such as linkages, exhaust components, etc.
REMOVAL
(2) Drai n cool ant from radi ator (Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
Fig. 12 Engine Block Heater4.7L
1 - ENGINE BLOCK HEATER
Fig. 13 Block Heater
Fig. 14 Engine Block Heater 4.0L Engine
WJ ENGINE 7 - 33
ENGINE BLOCK HEATER (Continued)
(4) Remove engi ne cyl i nder bl ock drai n pl ug(s)
l ocated on the si des of cyl i nder bl ock above the oi l
pan rai l (Fi g. 16).
(5) Remove power cord from bl ock heater.
(6) Loosen screw at center of bl ock heater. Remove
heater assembl y (Fi g. 17).
(4) Remove engi ne cyl i nder bl ock drai n pl ug(s)
l ocated on the si des of cyl i nder bl ock above the oi l
pan rai l (Fi g. 18).
(5) Remove power cord from bl ock heater.
(6) Loosen screw at center of bl ock heater. Remove
heater assembl y (Fi g. 19).
INSTALLATION
(1) Thoroughl y cl ean cyl i nder bl ock core hol e and
bl ock heater seat.
(2) I nsert bl ock heater assembl y wi th el ement l oop
poi nti ng at twel ve ocl ock (Fi g. 17).
(3) Wi th bl ock heater ful l y seated, ti ghten center
screw to 2 Nm (17 i n. l bs.) torque.
(5) Start and warm the engi ne. Check for l eaks.
(1) Thoroughl y cl ean cyl i nder bl ock core hol e and
bl ock heater seat.
Fig. 15 Engine Block Heater 4.7L Engine
Fig. 16 Drain Plug - 4.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
Fig. 17 Engine Block Heater - 4.7L
7 - 34 ENGINE WJ
(2) I nsert bl ock heater assembl y wi th el ement l oop
poi nti ng at twel ve ocl ock (Fi g. 19).
(3) Wi th bl ock heater ful l y seated, ti ghten center
screw to 2 Nm (17 i n. l bs.) torque.
ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The Engi ne Cool ant Temperature (ECT) sensor i s
used to sense engi ne cool ant temperature. The sensor
protrudes i nto an engi ne water jacket.
The ECT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as engi ne cool ant
temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
At key-on, the Powertrai n Control Modul e (PCM)
sends out a regul ated 5 vol t si gnal to the ECT sensor.
The PCM then moni tors the si gnal as i t passes
through the ECT sensor to the sensor ground (sensor
return).
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
The PCM uses i nputs from the ECT sensor for the
fol l owi ng cal cul ati ons:
for engi ne cool ant temperature gauge operati on
through CCD or PCI (J1850) communi cati ons
I njector pul se-wi dth
Spark-advance curves
ASD rel ay shut-down ti mes
I dl e Ai r Control (I AC) motor key-on steps
Pul se-wi dth pri me-shot duri ng cranki ng
O2 sensor cl osed l oop ti mes
Purge sol enoi d on/off ti mes
EGR sol enoi d on/off ti mes (i f equi pped)
Leak Detecti on Pump operati on (i f equi pped)
Radi ator fan rel ay on/off ti mes (i f equi pped)
Target i dl e speed
REMOVAL
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE ENGINE COOLANT TEMPERATURE (ECT)
SENSOR. REFER TO GROUP 7, COOLING.
(1) Parti al l y drai n cool i ng system. (Refer to 7 -
Fig. 18 Drain Plug
1 - COOLANT TEMPERATURE SENSOR
2 - BLOCK DRAIN PLUG
Fig. 19 Engine Block Heater
WJ ENGINE 7 - 35
(2) Di sconnect el ectri cal connector from ECT sen-
sor (Fi g. 20).
(3) Remove sensor from thermostat housi ng.
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE ENGINE COOLANT TEMPERATURE (ECT)
SENSOR. REFER TO GROUP 7, COOLING.
The ECT sensor i s l ocated near the front of the
i ntake mani fol d (Fi g. 21).
(1) Parti al l y drai n cool i ng system. (Refer to 7 -
(2) Di sconnect el ectri cal connector from ECT sen-
sor.
(3) Remove sensor from i ntake mani fol d.
INSTALLATION
(1) I nstal l sensor.
(2) Ti ghten to 11 Nm (8 ft. l bs.) torque.
(3) Connect el ectri cal connector to sensor.
(4) Repl ace any l ost engi ne cool ant. (Refer to 7 -
(1) I nstal l sensor.
(2) Ti ghten to 11 Nm (8 ft. l bs.) torque.
(4) Repl ace any l ost engi ne cool ant. (Refer to 7 -
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195F (90C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm up and overal l
temperature control . On the 4.7L engi ne the thermo-
stat i s desi gned to bl ock the fl ow of the cool ant
bypass journal by 50% i nstead of compl etel y bl ocki ng
the fl ow. Thi s desi gn control s cool ant temperature
more accuratel y (Fi g. 22).
Fig. 20 Engine Coolant Temperature Sensor
2 - ENGINE COOLANT TEMPERATURE SENSOR
Fig. 21 Engine Coolant Temperature Sensor
1 - ECT SENSOR
2 - MOUNTING BOLTS (2)
3 - MAP SENSOR
4 - INTAKE MANIFOLD
7 - 36 ENGINE WJ
ENGINE COOLANT TEMP SENSOR (Continued)
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warmup ti me, unrel i -
abl e warmup performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195F (90C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm up and overal l
temperature control . (Fi g. 23).
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warmup ti me, unrel i -
abl e warmup performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
OPERATION
The wax pel l et i s l ocated i n a seal ed contai ner at
the spri ng end of the thermostat. When heated, the
pel l et expands, overcomi ng cl osi ng spri ng tensi on
and water pump pressure to force the val ve to open.
DIAGNOSIS AND TESTING THERMOSTAT
ON-BOARD DIAGNOSTICS
Al l model s are equi pped wi th On-Board Di agnos-
ti cs for certai n cool i ng system components.I f the pow-
ertrai n control modul e (PCM) detects l ow engi ne
cool ant temperature, i t wi l l record a Di agnosti c Trou-
bl e Code (DTC). For other DTC numbers, (Refer to 25
- EMI SSI ONS CONTROL - DESCRI PTI ON).
The DTC can al so be accessed through the DRB
scan tool .
Fig. 22 Thermostat
1 - FROM HEATER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
Fig. 23 Thermostat and Housing
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
5 - SHORT BOLT
WJ ENGINE 7 - 37
ENGINE COOLANT THERMOSTAT (Continued)
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusabl e cool ant. I f the sol uti on i s
cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
(1) Drai n the cool ant from the radi ator unti l the
l evel i s bel ow the thermostat housi ng (Refer to 7 -
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 52). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
is necessary, use only an original equipment clamp
with matching number or letter.
(2) Remove radi ator upper hose and heater hose at
thermostat housi ng.
(3) Di sconnect wi ri ng connector at engi ne cool ant
temperature sensor.
(4) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng, gasket and thermostat (Fi g. 24).
Di scard ol d gasket.
(5) Cl ean the gasket mati ng surfaces.
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
Do not waste reusabl e cool ant. I f sol uti on i s cl ean,
drai n cool ant i nto a cl ean contai ner for reuse.
I f thermostat i s bei ng repl aced, be sure that
repl acement i s speci fi ed thermostat for vehi cl e model
and engi ne type.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Drai n cool i ng system (Refer to 7 - COOLI NG -
(4) Remove spl ash shi el d.
(5) Remove l ower radi ator hose cl amp and l ower
radi ator hose at thermostat housi ng.
(6) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng and thermostat (Fi g. 25).
INSTALLATION
(1) I nstal l the repl acement thermostat so that the
pel l et, whi ch i s enci rcl ed by a coi l spri ng, faces the
engi ne. Al l thermostats are marked on the outer
fl ange to i ndi cate the proper i nstal l ed posi ti on.
(a) Observe the recess groove i n the engi ne cyl -
i nder head (Fi g. 26).
(b) Posi ti on thermostat i n groove wi th arrow and
ai r bl eed hol e on outer fl ange poi nti ng up.
(2) I nstal l repl acement gasket and thermostat
housi ng.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess,
may result in a cracked housing.
(3) Ti ghten the housi ng bol ts to 22 Nm (16 ft. l bs.)
torque.
(4) I nstal l hoses to thermostat housi ng.
Fig. 24 Thermostat
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
5 - SHORT BOLT
7 - 38 ENGINE WJ
(5) I nstal l el ectri cal connector to cool ant tempera-
ture sensor.
(6) Be sure that the radi ator drai ncock i s ti ghtl y
cl osed. Fi l l the cool i ng system to the correct l evel
wi th the requi red cool ant mi xture (Refer to 7 -
(1) Cl ean mati ng areas of ti mi ng chai n cover and
thermostat housi ng.
(2) I nstal l thermostat (spri ng si de down) i nto
recessed machi ned groove on ti mi ng chai n cover (Fi g.
25).
(3) Posi ti on thermostat housi ng on ti mi ng chai n
cover.
(4) I nstal l two housi ng-to-ti mi ng chai n cover bol ts.
Ti ghten bol ts to 13 Nm (115 i n. l bs.) torque.
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
in timimg chain cover. If not, it may result in a
cracked housing, damaged timing chain cover
threads or coolant leaks.
(5) I nstal l l ower radi ator hose on thermostat hous-
i ng.
(6) I nstal l spl ash shi el d.
(8) Fi l l cool i ng system (Refer to 7 - COOLI NG -
(9) Connect negati ve battery cabl e to battery.
Fig. 25 Thermostat and Thermostat Housing
2 - THERMOSTAT LOCATION
3 - THERMOSTAT AND GASKET
Fig. 26 Thermostat Recess
1 - GROOVE
WJ ENGINE 7 - 39
FAN DRIVE VISCOUS CLUTCH
- 4.0L
DESCRIPTION
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
The thermal vi scous fan dri ve (Fi g. 27) i s a si l i -
cone-fl ui d-fi l l ed coupl i ng used to connect the fan
bl ades to the water pump shaft. The coupl i ng al l ows
the fan to be dri ven i n a normal manner. Thi s i s
done at l ow engi ne speeds whi l e l i mi ti ng the top
speed of the fan to a predetermi ned maxi mum l evel
at hi gher engi ne speeds.
An el ectri cal cool i ng fan l ocated i n the fan shroud
ai ds i n l ow speed cool i ng, I t i s desi gned to augment
the vi scous fan, However, i t does not repl ace the vi s-
cous fan.
OPERATION
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t (Fi g. 27).
Thi s spri ng coi l reacts to the temperature of the radi -
ator di scharge ai r. I t engages the vi scous fan dri ve
for hi gher fan speed i f the ai r temperature from the
radi ator ri ses above a certai n poi nt. Unti l addi ti onal
engi ne cool i ng i s necessary, the fan will remain at
a reduced rpm regardless of engine speed. Nor-
mally less than three hundred (300) rpm.
Onl y when suffi ci ent heat i s present, wi l l the vi s-
cous fan dri ve engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
DIAGNOSIS AND TESTING VISCOUS FAN
DRIVE
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18 to
105C (0 to 220 F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght (ti mi ng l i ght i s to be used as a strobe
l i ght).
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
Fig. 27 Viscous Fan Drive
1 - VISCOUS FAN DRIVE
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
7 - 40 ENGINE WJ
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 93 C (200 F).
Fan dri ve engagement shoul d have started to occur
at between 91 to 96 C (195 to 205 F). Engage-
ment i s di sti ngui shabl e by a defi ni te increase i n fan
fl ow noi se (roari ng). The ti mi ng l i ght al so wi l l i ndi -
cate an i ncrease i n the speed of the fan.
(7) When the ai r temperature reaches 93 C (200
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 62 to
85 C (145 to 185 F). A defi ni te decrease of fan
fl ow noi se (roari ng) shoul d be noti ced. I f not, repl ace
the defecti ve vi scous fan dri ve uni t.
PWM FAN CONTROL MODULE -
4.0L
DESCRIPTION
The pul se wi dth modul ated (PWM) radi ator cool i ng
fan rel ay i s l ocated behi nd the front bumper fasci a
bel ow the ri ght headl amp.
OPERATION
The PWM rel ay i s used to control the speed of the
el ectri c radi ator cool i ng fan. I t al l ows for mul ti pl e fan
speeds. Thi s al l ows for i mproved fan noi se and A/C
performance, better engi ne cool i ng, and addi ti onal
vehi cl e power.
PWM rel ay operati on i s control l ed by the Power-
trai n Control Modul e (PCM). To operate the PWM
rel ay, the PCM l ooks at i nputs from:
Engi ne cool ant temperature
Ambi ent temperature from the body control l er
Vehi cl e speed
Transmi ssi on oi l temperature
A/C swi tch posi ti on (A/C request)
REMOVAL
The Pul se Wi dth Modul ated (PWM) cool i ng fan
rel ay i s l ocated bel ow the ri ght headl amp behi nd the
bumper fasci a (Fi g. 28).
(1) Remove front bumper and gri l l assembl y.
(2) Remove 1 support bol t near front of reservoi r
(Fi g. 28).
(3) Remove 2 reservoi r mounti ng bol ts.
(4) Remove reservoi r from vehi cl e to gai n access to
vacuum hose (Fi g. 29). Di sconnect vacuum hose from
reservoi r fi tti ng at rear of reservoi r.
(5) Di sconnect el ectri cal connector at rel ay (Fi g.
30).
(6) Remove 2 rel ay mounti ng bol ts (Fi g. 30) and
remove rel ay.
Fig. 28 Radiator Cooling Fan Relay Location
1 - RADIATOR FAN RELAY
2 - VACUUM RESERVOIR
3 - BOLT
4 - RIGHT FRONT FENDER
Fig. 29 Vacuum Reservoir Removal/Installation
1 - VACUUM HOSE
2 - RADIATOR
WJ ENGINE 7 - 41
FAN DRIVE VISCOUS CLUTCH - 4.0L (Continued)
INSTALLATION
(1) Posi ti on rel ay to body and i nstal l 2 bol ts.
Ti ghten bol ts to 3 Nm (25 i n. l bs.) torque.
(2) Connect el ectri cal connector to rel ay.
(3) Connect vacuum hose to reservoi r.
(4) I nstal l reservoi r and ti ghten 2 bol ts to 3 Nm
(25 i n. l bs.) torque.
(5) I nstal l front bumper and gri l l assembl y.
RADIATOR - 4.7L
DESCRIPTION
Al l vehi cl es are equi pped wi th a cross fl ow type
radi ator wi th pl asti c si de tanks (Fi g. 31).
Pl asti c tanks, whi l e stronger than brass, are sub-
ject to damage by i mpact, such as from tool s or
wrenches. Handl e radi ator wi th care.
REMOVAL
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.
reuse.
tongue of constant tension clamps (Fig. 33). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 34). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
To prevent overheating, these seals must be
installed to their original positions.
(1) Di sconnect the negati ve battery cabl e at bat-
tery.
(3) Remove the front gri l l (Refer to 23 - BODY/EX-
TERI OR/GRI LLE - REMOVAL).
Fig. 30 Radiator Cooling Fan Relay Removal/
Installation
Fig. 31 Cross Flow Radiator - Typical
1 - RADIATOR
7 - 42 ENGINE WJ
PWM FAN CONTROL MODULE - 4.0L (Continued)
(4) Remove two radi ator mounti ng bol ts.
(5) Di sconnect both transmi ssi on cool er l i nes from
radi ator.
(6) Di sconnect el ectri cal connector for the fan con-
trol sol enoi d.
(7) Di sconnect the power steeri ng cool er l i ne from
cool er and fi l ter.
(8) Di sconnect the radi ator upper and l ower hoses.
(9) Di sconnect the overfl ow hose from radi ator.
(10) Remove the ai r i nl et duct at the gri l l .
(11) The l ower part of radi ator i s equi pped wi th
two al i gnment dowel pi ns (Fi g. 35). They are l ocated
on the bottom of radi ator tank and fi t i nto rubber
grommets. These rubber grommets are pressed i nto
the radi ator l ower crossmember.
WARNING: THE AIR CONDITIONING SYSTEM (IF
EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN, HEATING AND AIR CONDI-
TIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.
NOTE: The radiator and radiator cooling fan can be
removed as an assembly. It is not necessary to
remove the cooling fan before removing or install-
ing the radiator.
(12) Di sconnect the two hi gh pressure fl ui d l i nes
at the hydraul i c fan dri ve.
(13) Di sconnect the l ow pressure return hose at
the hydraul i c fan dri ve.
(14) Gentl y l i ft up and remove radi ator from vehi -
cl e. Be careful not to scrape the radi ator fi ns agai nst
any other component. Al so be careful not to di sturb
the ai r condi ti oni ng condenser (i f equi pped).
CLEANING
Cl ean radi ator fi ns Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
Fig. 32 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 33 Clamp Number/Letter Location - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
Fig. 34 Air Seals - Typical
1 - AIR DAM
2 - RADIATOR
3 - AIR DAM
4 - A/C CONDENSER
5 - AIR SEAL
WJ ENGINE 7 - 43
RADIATOR - 4.7L (Continued)
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
INSPECTION
The radi ator cool i ng fi ns shoul d be checked for
damage or deteri orati on. I nspect cool i ng fi ns to make
sure they are not bent or crushed, these areas resul t
i n reduced heat exchange causi ng the cool i ng system
to operate at hi gher temperatures. I nspect the pl asti c
end tanks for cracks, damage or l eaks.
I nspect the radi ator neck for damage or di storti on.
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals (Fig. 39) are
properly fastened to their original positions. These
are used at the top, bottom and sides of the radia-
tor and A/C condenser. To prevent overheating,
these seals must be installed to their original posi-
tions.
(1) Equi pped wi th ai r condi ti oni ng: Gentl y l ower
the radi ator and fan shroud i nto the vehi cl e. Gui de
the two radi ator al i gnment dowel s through the hol es
i n the rubber ai r seal s fi rst and then through the A/C
support brackets (Fi g. 40). Conti nue to gui de the
al i gnment dowel s i nto the rubber grommets l ocated
i n l ower radi ator crossmember. The hol es i n the
L-shaped brackets (l ocated on bottom of A/C con-
denser) must be posi ti oned between bottom of rubber
ai r seal s and top of rubber grommets.
(2) Connect the radi ator upper and l ower hoses
and hose cl amps to radi ator.
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(3) I nstal l cool ant reserve/overfl ow tank hose at
radi ator.
(4) Connect both transmi ssi on cool er l i nes at the
radi ator.
(5) I nstal l both radi ator mounti ng bol ts.
(6) I nstal l ai r i nl et duct at gri l l .
(7) Attach el ectri c connector for hydraul i c fan con-
trol sol enoi d.
(8) I nstal l the gri l l (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - I NSTALLATI ON).
(9) Connect the two hi gh pressure l i nes to the
hydraul i c fan dri ve. Ti ghten
1
2 i n. pressure l i ne fi t-
ti ng to 49 Nm (36 ft. l bs.). and the 3/8 i n. pressure
l i ne fi tti ng to 29 Nm (21.5 ft. l bs.).
(10) Connect the l ow pressure hose to the hydrau-
l i c fan dri ve. Posi ti on the spri ng cl amp.
(11) Connect the power steeri ng fi l ter hoses to the
fi l ter. I nstal l new hose cl amps.
(12) Rotate the fan bl ades (by hand) and check for
i nterference at fan shroud.
(14) Refi l l the power steeri ng reservoi r and bl eed
ai r from system (Refer to 19 - STEERI NG/PUMP -
(15) Connect battery cabl e at battery.
(16) Start and warm engi ne. Check for l eaks.
RADIATOR - 4.0L
DESCRIPTION
Al l vehi cl es are equi pped wi th a cross fl ow type
radi ator wi th pl asti c si de tanks (Fi g. 36).
Pl asti c tanks, whi l e stronger than brass, are sub-
ject to damage by i mpact, such as from tool s or
wrenches. Handl e radi ator wi th care.
REMOVAL
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.
Fig. 35 Radiator Alignment Dowels - Typical
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
7 - 44 ENGINE WJ
reuse.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 39). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
To prevent overheating, these seals must be
installed to their original positions.
(1) Di sconnect the negati ve battery cabl e at bat-
tery.
(3) Do not attempt to remove fan/vi scous fan dri ve
assembl y from vehi cl e at thi s ti me.
(4) Remove the front gri l l (Refer to 23 - BODY/EX-
TERI OR/GRI LLE - REMOVAL).
(5) Remove two radi ator mounti ng bol ts (Fi g. 41).
(6) Di sconnect both transmi ssi on cool er l i nes from
radi ator.
(7) Di sconnect el ectri c fan connector, then di scon-
nect connector harness from shroud (Fi g. 41).
(8) Di sconnect the radi ator upper and l ower hoses
(Fi g. 41).
Fig. 36 Cross Flow Radiator - Typical
1 - RADIATOR
2 - HOSE CLAMP
Fig. 38 Clamp Number/Letter Location - Typical
3 - TYPICAL HOSE
WJ ENGINE 7 - 45
(9) Di sconnect the overfl ow hose from radi ator
(Fi g. 41).
(10) Remove the ai r i nl et duct at the gri l l .
(11) The l ower part of radi ator i s equi pped wi th
two al i gnment dowel pi ns (Fi g. 40). They are l ocated
on the bottom of radi ator tank and fi t i nto rubber
grommets. These rubber grommets are pressed i nto
the radi ator l ower crossmember.
WARNING: THE AIR CONDITIONING SYSTEM (IF
EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN GROUP 24, HEATING AND
AIR CONDITIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.
(12) I f equi pped wi th an auxi l i ary automati c trans-
mi ssi on oi l cool er, use cauti on when removi ng radi a-
tor. The oi l cool er l i nes are routed through a rubber
ai r seal on the ri ght si de of radi ator. Do not cut or
tear thi s seal .
(13) Gentl y l i ft up and remove radi ator from vehi -
cl e. Be careful not to scrape the radi ator fi ns agai nst
any other component. Al so be careful not to di sturb
the ai r condi ti oni ng condenser (i f equi pped).
CLEANING
Cl ean radi ator fi ns Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
Fig. 39 Air Seals - Typical
1 - AIR DAM
2 - RADIATOR
3 - AIR DAM
4 - A/C CONDENSER
5 - AIR SEAL
Fig. 40 Radiator Alignment Dowels
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
Fig. 41 Radiator, Shroud and Electric Fan
1 - RADIATOR/SHROUD/FAN ASSEMBLY
2 - OVER FLOW HOSE
3 - ELECTRIC FAN CONNECTOR
4 - RADIATOR MOUNTING BOLT(S)
5 - CLAMP
7 - 46 ENGINE WJ
INSPECTION
The radi ator cool i ng fi ns shoul d be checked for
damage or deteri orati on. I nspect cool i ng fi ns to make
sure they are not bent or crushed, these areas resul t
i n reduced heat exchange causi ng the cool i ng system
to operate at hi gher temperatures. I nspect the pl asti c
end tanks for cracks, damage or l eaks.
I nspect the radi ator neck for damage or di storti on.
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals (Fig. 39) are
properly fastened to their original positions. These
are used at the top, bottom and sides of the radia-
tor and A/C condenser. To prevent overheating,
these seals must be installed to their original posi-
tions.
(1) Equi pped wi th ai r condi ti oni ng: Gentl y l ower
the radi ator i nto the vehi cl e. Gui de the two radi ator
al i gnment dowel s through the hol es i n the rubber ai r
seal s fi rst and then through the A/C support brackets
(Fi g. 40). Conti nue to gui de the al i gnment dowel s
i nto the rubber grommets l ocated i n l ower radi ator
crossmember. The hol es i n the L-shaped brackets
(l ocated on bottom of A/C condenser) must be posi -
ti oned between bottom of rubber ai r seal s and top of
rubber grommets.
(2) Connect the radi ator upper and l ower hoses
and hose cl amps to radi ator (Fi g. 41).
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(3) I nstal l cool ant reserve/overfl ow tank hose at
radi ator (Fi g. 41).
(4) Connect both transmi ssi on cool er l i nes at the
radi ator (Fi g. 41).
(5) I nstal l both radi ator mounti ng bol ts (Fi g. 41).
(6) I nstal l ai r i nl et duct at gri l l .
(7) Attach el ectri c fan harness to shroud, then con-
nect harness to connector (Fi g. 41).
(8) I nstal l the gri l l (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - I NSTALLATI ON).
(9) I nstal l the fan/vi scous fan dri ve assembl y to
the water pump.
(10) Rotate the fan bl ades (by hand) and check for
i nterference at fan shroud.
(11) Be sure of at l east 25 mm (1.0 i nch) between
ti ps of fan bl ades and fan shroud.
(13) Connect battery cabl e at battery.
(14) Start and warm engi ne. Check for l eaks.
RADIATOR FAN MOTOR
DIAGNOSIS AND TESTING ELECTRIC
COOLING FAN
The powertrai n control modul e (PCM) wi l l enter a
di agnosti c troubl e code (DTC) i n memory i f i t detects
a probl em i n the auxi l i ary cool i ng fan rel ay or ci rcui t.
TI ON).
I f the el ectri c cool i ng fan i s i noperati ve, check the
15A fuse i n the juncti on bl ock and the 40A fuse i n
the Power Di stri buti on Center (PDC) wi th a 12 vol t
test l amp or DVOM. Refer to the i nsi de of the PDC
cover for the exact l ocati on of the fuse. I f fuses are
okay, refer to ELECTRI CAL for cool i ng fan and rel ay
ci rcui t schemati c.
WATER PUMP - 4.7L
DESCRIPTION
DESCRIPTION WATER PUMP
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary.
Both heater hoses are connected to fi tti ngs on the
ti mi ng chai n front cover. The water pump i s al so
mounted di rectl y to the ti mi ng chai n cover and i s
equi pped wi th a non servi ceabl e i ntegral pul l ey (Fi g.
42).
DESCRIPTION WATER PUMP BYPASS
The 4.7L engi ne uses an i nternal water/cool ant
bypass system. The desi gn uses gal l eri es i n the ti m-
i ng chai n cover to ci rcul ate cool ant duri ng engi ne
warm-up preventi ng the cool ant from fl owi ng
through the radi ator. The thermostat uses a stub
shaft l ocated at the rear of the thermostat (Fi g. 43)
to control fl ow through the bypass gal l ery.
OPERATION
OPERATION WATER PUMP
WJ ENGINE 7 - 47
radi ator core, cool i ng system hoses and heater core,
thi s cool ant absorbs the heat generated when the
engi ne i s runni ng. The pump i s dri ven by the engi ne
crankshaft vi a a dri ve bel t.
OPERATION WATER PUMP BYPASS
When the thermostat i s i n the cl osed posi ti on the
bypass gal l ery i s not obstructed al l owi ng 100% fl ow.
When the thermostat i s i n the open posi ti on the stub
shaft enters the bypass gal l ery obstructi ng bypass
cool ant fl ow by 50%. Thi s desi gn al l ows the cool ant
to reach operati ng temperature qui ckl y when col d,
whi l e addi ng extra cool i ng duri ng normal tempera-
ture operati on.
DIAGNOSIS AND TESTING WATER PUMP
LOOSE IMPELLER - 4. 0L and 4. 7L
NOTE: Due to the design of the 4.0L and 4.7L
engine water pumps, testing the pump for a loose
impeller must be done by verifying coolant flow in
the radiator. To accomplish this refer to the follow-
ing procedure.
(1) Drai n cool ant unti l the fi rst row of cores i s vi s-
i bl e i n the radi ator (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE) 4.7L Engi ne or (Refer to 7 -
COOLI NG - STANDARD PROCEDURE) 4.0L
Engi ne.
(2) Leavi ng the radi ator cap off, start the engi ne.
Run engi ne unti l thermostat opens.
(3) Whi l e l ooki ng i nto the radi ator through the
radi ator fi l l neck, rai se engi ne rpm to 2000 RPM.
Observe the fl ow of cool ant from the fi rst row of
cores.
(4) I f there i s no fl ow or very l i ttl e fl ow vi sabl e,
repl ace the water pump.
INSPECTING FOR INLET RESTRICTIONS
I nadequate heater performance may be caused by
a metal casti ng restri cti on i n the heater hose i nl et.
reuse.
Fig. 42 Water Pump and Timing Chain Cover
1 - INTEGRAL WATER PUMP PULLEY
4 - HEATER HOSE FITTINGS
5 - WATER PUMP
Fig. 43 Water/Coolant Bypass Flow and Thermostat
1 - FROM HEATER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
7 - 48 ENGINE WJ
WATER PUMP - 4.7L (Continued)
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Drai n suffi ci ent cool ant from the radi ator to
decrease the l evel bel ow the heater hose i nl et. On
4.7L engi nes thi s requi res compl ete drai ni ng.
(2) Remove the heater hose.
(3) I nspect the i nl et for metal casti ng fl ash or
other restri cti ons.
NOTE: On 4.0L engines remove the pump from the
engine before removing restriction to prevent con-
tamination of the coolant with debris. . On 4.7L
engine remove the fitting from the timing chain
cover, If the restriction is in the timing chain cover,
remove the timing chain cover.
REMOVAL
The water pump on 4.7L engi nes i s bol ted di rectl y
to the engi ne ti mi ng chai n case/cover.
A gasket i s used as a seal between the water pump
and ti mi ng chai n case/cover.
The water pump can be removed wi thout di scharg-
i ng the ai r condi ti oni ng system (i f equi pped).
STANDARD PROCEDURE). Do not waste reusabl e
cool ant. I f sol uti on i s cl ean, drai n cool ant i nto a cl ean
contai ner for reuse.
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
is necessary, use only an original equipment clamp
with matching number or letter.
REMOVAL).
(4) Remove l ower radi ator hose cl amp and remove
l ower hose at water pump.
(5) Remove seven water pump mounti ng bol ts and
one stud bol t.
CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
(6) Remove water pump and gasket. Di scard gas-
ket.
CLEANING
Cl ean the gasket mati ng surface. Use cauti on not
to damage the gasket seal i ng surface.
INSPECTION
I nspect the water pump assembl y for cracks i n the
housi ng, Water l eaks from shaft seal , Loose or rough
turni ng beari ng or I mpel l er rubbi ng ei ther the pump
body or ti mi ng chai n case/cover.
INSTALLATION
(1) Cl ean gasket mati ng surfaces.
(2) Usi ng a new gasket, posi ti on water pump and
i nstal l mounti ng bol ts as shown. (Fi g. 44). Ti ghten
water pump mounti ng bol ts to 54 Nm (40 ft. l bs.)
torque.
(3) Spi n water pump to be sure that pump i mpel -
l er does not rub agai nst ti mi ng chai n case/cover.
(4) Connect radi ator l ower hose to water pump.
(5) I nstal l accessory dri ve bel t (Refer to 7 - COOL-
LATI ON).
Fig. 44 Water Pump Installation
1 - WATER PUMP
WJ ENGINE 7 - 49
drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction.
(7) Connect negati ve battery cabl e.
WATER PUMP - 4.0L
DESCRIPTION
CAUTION: All 4.0L 6-cylinder engines are equipped
with a reverse (counterclockwise) rotating water
pump and thermal viscous fan drive assembly.
REVERSE is stamped or imprinted on the cover of
the viscous fan drive and inner side of the fan. The
letter R is stamped into the back of the water pump
impeller. Engines from previous model years,
depending upon application, may have been
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump or vis-
cous fan drive will cause engine over heating.
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary (Fi g. 45).
DIAGNOSIS AND TESTING WATER PUMP
LOOSE IMPELLER - 4. 0L and 4. 7L
NOTE: Due to the design of the 4.0L and 4.7L
engine water pumps, testing the pump for a loose
impeller must be done by verifying coolant flow in
the radiator. To accomplish this refer to the follow-
ing procedure.
(1) Drai n cool ant unti l the fi rst row of cores i s vi s-
i bl e i n the radi ator (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE) 4.7L Engi ne or (Refer to 7 -
COOLI NG - STANDARD PROCEDURE) 4.0L
Engi ne.
(2) Leavi ng the radi ator cap off, start the engi ne.
Run engi ne unti l thermostat opens.
(3) Whi l e l ooki ng i nto the radi ator through the
radi ator fi l l neck, rai se engi ne rpm to 2000 RPM.
Observe the fl ow of cool ant from the fi rst row of
cores.
(4) I f there i s no fl ow or very l i ttl e fl ow vi sabl e,
repl ace the water pump.
INSPECTING FOR INLET RESTRICTIONS
I nadequate heater performance may be caused by
a metal casti ng restri cti on i n the heater hose i nl et.
reuse.
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Drai n suffi ci ent cool ant from the radi ator to
decrease the l evel bel ow the heater hose i nl et. On
4.7L engi nes thi s requi res compl ete drai ni ng.
(2) Remove the heater hose.
(3) I nspect the i nl et for metal casti ng fl ash or
other restri cti ons.
Fig. 45 Water Pump
1 - HEATER HOSE FITTING BORE
2 - WATER PUMP
3 - WATER PUMP HUB
7 - 50 ENGINE WJ
NOTE: On 4.0L engines remove the pump from the
engine before removing restriction to prevent con-
tamination of the coolant with debris. . On 4.7L
engine remove the fitting from the timing chain
cover, If the restriction is in the timing chain cover,
remove the timing chain cover.
REMOVAL
CAUTION: If the water pump is replaced because of
mechanical damage, the fan blades and viscous fan
drive should also be inspected. These components
could have been damaged due to excessive vibra-
tion.
The water pump i mpel l er i s pressed on the rear of
the pump shaft and beari ng assembl y. The water
pump i s servi ced onl y as a compl ete assembl y.
NOTE: The water pump can be replaced without
discharging the A/C system.
WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n cool ant i nto a cl ean contai ner for
reuse.
(2) Drai n the cool i ng system (Refer to 7 - COOL-
I NG - STANDARD PROCEDURE).
(3) The thermal vi scous fan dri ve i s attached
(threaded) to the water pump hub shaft. Remove fan/
vi scous fan dri ve assembl y from water pump by turn-
i ng mounti ng nut countercl ockwi se as vi ewed from
front. Threads on vi scous fan dri ve are RIGHT
HAND Do not attempt to remove fan/vi scous fan
dri ve assembl y from vehi cl e at thi s ti me.
(4) I f water pump i s bei ng repl aced, do not unbol t
fan bl ade assembl y from thermal vi scous fan dri ve.
(5) Remove fan shroud-to-radi ator nuts (Fi g. 46).
Do not attempt to remove fan shroud at thi s ti me.
(6) Remove fan shroud and fan bl ade/vi scous fan
dri ve assembl y from vehi cl e as a compl ete uni t.
(7) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
Loosen but do not remove the water pump pul l ey
mounti ng bol ts.
Remove accessory dri ve bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - REMOV-
AL).
Remove the water pump pul l ey.
(8) Remove the i dl er pul l ey (l ocated over the water
pump).
6094) (Fig. 47) SNAP-ON CLAMP TOOL (NUMBER
(9) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump fi tti ng.
(10) Remove the fi ve pump mounti ng bol ts (Fi g.
49) and remove pump from vehi cl e. Di scard ol d gas-
ket. Note that one of the fi ve bol ts i s l onger than the
other bol ts.
(11) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
Fig. 46 Fan Shroud Mounting
1 - SHROUD FASTENERS
2 - DRAIN COCK
3 - RADIATOR FAN SHROUD
4 - SHROUD FASTENERS
WJ ENGINE 7 - 51
CLEANING
Cl ean the gasket mati ng surface. Use cauti on not
to damage the gasket seal i ng surface.
INSPECTION
I nspect the water pump assembl y for cracks i n the
housi ng, Water l eaks from shaft seal , Loose or rough
turni ng beari ng or I mpel l er rubbi ng ei ther the pump
body or ti mi ng chai n case/cover.
INSTALLATION
CAUTION: If the water pump is replaced because of
mechanical damage, the fan blades and viscous fan
drive should also be inspected. These components
could have been damaged due to excessive vibra-
tion.
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose fi tti ng to the pump. Use a seal ant on the fi tti ng
such as Mopar Thread Seal ant Wi th Tefl on. Refer to
the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
pump mati ng surfaces for erosi on or damage from
cavi tati on.
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 30 Nm (22 ft. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
(5) Posi ti on water pump pul l ey to water pump
hub. Ti ghten bol ts 28 Nm (250 i n. l bs.).
I nstal l the i dl er pul l ey. Ti ghten the bol t 47 Nm (35
ft. l bs.).
2 - HOSE CLAMP
Fig. 48 Clamp - Typical
3 - TYPICAL HOSE
Fig. 49 Water Pump Remove/Install - Typical
1 - HEATER HOSE FITTING
2 - PUMP GASKET
3 - WATER PUMP
4 - LONG BOLT
5 - BOLTS (4) SHORT
7 - 52 ENGINE WJ
CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. Refer to
the Belt Removal and Installtion in this group for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.
I nstal l accessory dri ve bel t (Refer to 7 - COOLI NG/
ACCESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(6) I nstal l fan bl ade and vi scous fan dri ve onto
water pump.
(7) Fi l l cool i ng system wi th cool ant and check for
l eaks. (Refer to 7 - COOLI NG - STANDARD PROCE-
DURE).
(8) Connect battery cabl e to battery.
RADIATOR PRESSURE CAP
DESCRIPTION
Al l radi ators are equi pped wi th a pressure cap
(Fi g. 50). Thi s cap rel eases pressure at some poi nt
wi thi n a range of 124-to-145 kPa (18-to-21 psi ). The
pressure rel i ef poi nt (i n pounds) i s engraved on top of
the cap
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap contai ns a spri ng-
l oaded pressure rel i ef val ve. Thi s val ve opens when
system pressure reaches the rel ease range of 124-to-
145 kPa (18-to-21 psi ).
A rubber gasket seal s the radi ator fi l l er neck. Thi s i s
done to mai ntai n vacuum duri ng cool ant cool -down and
to prevent l eakage when system i s under pressure.
OPERATION
A vent val ve i n the center of the cap wi l l remai n
shut as l ong as the cool i ng system i s pressuri zed. As
the cool ant cool s, i t contracts and creates a vacuum
i n cool i ng system. Thi s causes the vacuum val ve to
open and cool ant i n reserve/overfl ow tank to be
drawn through connecti ng hose i nto radi ator. I f the
vacuum val ve i s stuck shut, or overfl ow hose i s
ki nked, radi ator hoses wi l l col l apse on cool -down.
DIAGNOSIS AND TESTING RADIATOR
PRESSURE CAP
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l the cap on pressure tester (tool 7700 or
an equi val ent) (Fi g. 51).
Operate the tester pump and observe the gauge
poi nter at i ts hi ghest poi nt. The cap rel ease pressure
shoul d be 124 to 145 kPa (18 to 21 psi ). The cap i s
sati sfactory when the pressure hol ds steady. I t i s al so
good i f i t hol ds pressure wi thi n the 124 to 145 kPa
(18 to 21 psi ) range for 30 seconds or more. I f the
poi nter drops qui ckl y, repl ace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Cl ean the radi ator pressure cap usi ng a mi l d soap
and water onl y.
Fig. 50 Radiator Pressure Cap - Typical
1 - FILLER NECK SEAL
2 - VACUUM VENT VALVE
3 - PRESSURE RATING
4 - PRESSURE VALVE
WJ ENGINE 7 - 53
INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
WATER PUMP INLET TUBE
REMOVAL
(1) Parti al l y drai n cool i ng system .
(2) Do not waste reusabl e cool ant. I f sol uti on i s
(3) Loosen both bypass hose cl amps (Fi g. 52) and
posi ti on to center of hose. Remove hose from vehi cl e.
INSTALLATION
(1) Posi ti on bypass hose cl amps (Fi g. 52) to center
of hose.
(2) I nstal l bypass hose to engi ne.
(3) Secure both hose cl amps (Fi g. 52).
(4) Refi l l cool i ng system .
Fig. 51 Pressure Testing Radiator Pressure
CapTypical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
Fig. 52 Hose Clamp ToolTypical
2 - HOSE CLAMP
Fig. 53 Clamp Number/Letter Location
3 - TYPICAL HOSE
7 - 54 ENGINE WJ
RADIATOR PRESSURE CAP (Continued)
TRANSMISSION
TABLE OF CONTENTS
page page
TRANS COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 55
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES . . . . . . . . . . . . . . . . . 55
TRANS COOLER
DESCRIPTION
An i nternal hi gh capaci ty/hi gh effi ci ency cool er i s
used on al l vehi cl es these cool ers are an oi l -to-cool ant
type whi ch consi sts of pl ates mounted i n the radi ator
outl et tank (Fi g. 36). Because the i nternal oi l cool er
i s so effi ci ent, no auxi l i ary oi l cool er i s offered The
cool er i s not servi cabl e seperatl y from the radi ator.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
When a transmi ssi on fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The torque
converter must al so be repl aced. Thi s wi l l i nsure that
metal parti cl es or sl udged oi l are not l ater trans-
ferred back i nto the recondi ti oned (or repl aced) trans-
mi ssi on.
The onl y recommended procedure for fl ushi ng cool -
ers and l i nes i s to use Tool 6906-B Cool er Fl usher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.11968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover pl ate fi l l er pl ug on Tool 6906-B.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906-B.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes.
(8) Turn pump OFF.
(9) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(10) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(11) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar ATF +4, type 9602, Automati c
Transmi ssi on Fl ui d.
(12) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(13) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
WJ TRANSMISSION 7 - 55
AUDIO
TABLE OF CONTENTS
page page
AUDIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - AUDIO . . . . . . . . . . 3
SPECIAL TOOLS
AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . . 6
AMPLIFIER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - AMPLIFIER . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ANTENNA BODY & CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
ANTENNA MODULE - EXPORT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - ANTENNA
MODULE - EXPORT . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
CD CHANGER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - CD CHANGER . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTRUMENT PANEL ANTENNA CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
QUARTER GLASS INTEGRAL ANTENNA -
EXPORT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - QUARTER
GLASS INTEGRAL ANTENNA - EXPORT . . . . 16
RADIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - RADIO . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
RADIO NOISE SUPPRESSION GROUND STRAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL
REMOVAL - ENGINE-TO-BODY GROUND
STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL - EXHAUST-TO-BODY GROUND
STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION
INSTALLATION - ENGINE TO BODY
GROUND STRAP. . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION - EXHAUST-TO-BODY
GROUND STRAP. . . . . . . . . . . . . . . . . . . . . . 19
REMOTE SWITCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - REMOTE
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPEAKER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING - SPEAKER . . . . . . 23
REMOVAL
REAR DOOR SPEAKER . . . . . . . . . . . . . . . . 24
INSTRUMENT PANEL SPEAKER . . . . . . . . . . 24
FRONT DOOR SPEAKER . . . . . . . . . . . . . . . 24
INSTALLATION
INSTALLATION - REAR DOOR SPEAKER . . . 25
INSTALLATION - INSTRUMENT PANEL
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION - FRONT DOOR SPEAKER . . 25
WJ AUDIO 8A - 1
AUDIO
DESCRIPTION
An audi o system i s standard factory-i nstal l ed
equi pment on thi s model . The standard equi pment
audi o system i ncl udes an AM/FM/cassette (RBB sal es
code) radi o recei ver, and speakers i n si x l ocati ons.
Several combi nati ons of radi o recei vers and speaker
systems are offered as opti onal equi pment on thi s
model . The audi o system uses an i gni ti on swi tched
control of battery current so that the system wi l l onl y
operate when the i gni ti on swi tch i s i n the On or
Accessory posi ti ons.
A Compact Di sc (CD) changer wi th a ten di sc mag-
azi ne, remote radi o swi tches wi th si x functi ons
mounted to the backs of the steeri ng wheel spokes,
and a memory system that automati cal l y stores and
recal l s up to twenty radi o stati on presets (ten AM
and ten FM) and the l ast stati on l i stened to for two
dri vers are opti onal factory-i nstal l ed equi pment on
thi s model . Refer to El ectri cal , Power Seats for more
i nformati on on the memory system.
The audi o system i ncl udes the fol l owi ng compo-
nents:
Antenna
Compact di sc changer (avai l abl e wi th RBP sal es
code radi o recei vers onl y)
Power ampl i fi er (wi th premi um speaker system
onl y)
Radi o noi se suppressi on components
Radi o recei ver
Remote radi o swi tches
Speakers
Certai n functi ons and features of the audi o system
rel y upon resources shared wi th other el ectroni c
modul es i n the vehi cl e over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus network. The
PCI data bus network al l ows the shari ng of sensor
i nformati on. Thi s hel ps to reduce wi re harness com-
pl exi ty, i nternal control l er hardware, and component
sensor current l oads. At the same ti me, thi s system
provi des i ncreased rel i abi l i ty, enhanced di agnosti cs,
and al l ows the addi ti on of many new feature capabi l -
i ti es. For di agnosi s of these el ectroni c modul es or of
the PCI data bus network, the use of a DRB scan
tool and the proper Di agnosti c Procedures manual
are recommended.
The other el ectroni c modul es that may affect audi o
system operati on are as fol l ows:
Body Control Module (BCM) - (Refer to 8 -
ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/BODY CONTROL/CENTRAL TI MER MODUL
- DESCRI PTI ON) for more i nformati on.
Driver Door Module (DDM) (Refer to 8 -
ULES/DRI VER DOOR MODULE - DESCRI PTI ON)
for more i nformati on.
Passenger Door Module (PDM) (Refer to 8 -
The audi o system i ncl udes the fol l owi ng major
components, whi ch are descri bed i n further detai l
el sewhere i n thi s servi ce i nformati on:
Amplifier - On model s equi pped wi th the
opti onal premi um speaker system, an audi o power
ampl i fi er i s l ocated on the rear fl oor panel under-
neath the ri ght end of the rear seat cushi on i n the
passenger compartment.
Antenna Body and Cable - The most vi si bl e
component of the antenna body and cabl e are the
antenna adapter and the antenna cap nut, whi ch are
l ocated on the top of the ri ght front fender panel of
the vehi cl e, near the ri ght end of the cowl pl enum.
Antenna Mast - The antenna mast i s a metal
rod that extends upward from the antenna body and
cabl e on the top of the ri ght front fender panel of the
vehi cl e, near the ri ght end of the cowl pl enum.
Radio - The radi o for thi s model i s l ocated i n
the i nstrument panel center stack area, i nboard of
the i nstrument cl uster and above the heater and ai r
condi ti oner control s.
Radio Noise Suppression Ground Strap - A
radi o noi se suppressi on ground strap i s i nstal l ed
between the rear of the engi ne cyl i nder head(s) and
the dash panel sheet metal i n the engi ne compart-
ment.
Speaker - The standard speaker system
i ncl udes si x speakers i n si x l ocati ons, whi l e the pre-
mi um speaker system i ncl udes an ampl i fi er for the
si x speakers i n si x l ocati ons.
Hard wi red ci rcui try connects the audi o system
components to each other through the el ectri cal sys-
tem of the vehi cl e. These hard wi red ci rcui ts are
i ntegral to several wi re harnesses, whi ch are routed
throughout the vehi cl e and retai ned by many di ffer-
ent methods. These ci rcui ts may be connected to each
other, to the vehi cl e el ectri cal system and to the
audi o system components through the use of a com-
bi nati on of sol dered spl i ces, spl i ce bl ock connectors
and many di fferent types of wi re harness termi nal
connectors and i nsul ators. Refer to the appropri ate
wi ri ng i nformati on i n thi s servi ce manual for com-
pl ete standard and premi um audi o system ci rcui t
di agrams. The wi ri ng i nformati on i ncl udes proper
wi re and connector repai r procedures, further detai l s
on wi re harness routi ng and retenti on, as wel l as
pi n-out and l ocati on vi ews for the vari ous wi re har-
ness connectors, spl i ces, and grounds.
8A - 2 AUDIO WJ
OPERATION
The audi o system components are desi gned to pro-
vi de audi o entertai nment and i nformati on through
the recepti on, tuni ng and ampl i fi cati on of l ocal l y
broadcast radi o si gnal s i n both the Ampl i tude Modu-
l ati ng (AM) and Frequency Modul ati ng (FM) com-
merci al frequency ranges. El ectromagneti c radi o
si gnal s that are broadcast from a radi o stati on
i nduce el ectri cal modul ati ons i nto the audi o system
antenna mast. The antenna body and cabl e conduct
these weak si gnal s from the antenna mast to the
radi o. The radi o then tunes and ampl i fi es these weak
radi o frequency si gnal s i nto stronger el ectri cal audi o
si gnal s that are requi red i n order to operate the
audi o system speakers. The speakers convert these
el ectri cal si gnal s i nto ai r movement, whi ch repro-
duces the sounds bei ng broadcast by the radi o sta-
ti on.
Some audi o systems al so offer the user the opti on
of sel ecti ng from and l i steni ng to prerecorded audi o
cassette tapes, audi o compact di scs, or both. Regard-
l ess of the medi a type, the audi o system components
provi de the user wi th the abi l i ty to el ectroni cal l y
ampl i fy and adjust the audi o si gnal s bei ng repro-
duced by the speakers wi thi n the vehi cl e to sui t the
preferences of the vehi cl e occupants.
The audi o system components operate on battery
current recei ved through a fuse i n the Juncti on Bl ock
(JB) on a fused i gni ti on swi tch output (run-acc) ci r-
cui t so that the system wi l l onl y operate when the
i gni ti on swi tch i s i n the On or Accessory posi ti ons.
On vehi cl es that are equi pped wi th the opti onal
remote radi o swi tches, the BCM recei ves hard wi red
resi stor mul ti pl exed i nputs from the remote radi o
swi tches. The programmi ng i n the BCM al l ows i t to
process those i nputs and send the proper messages to
the radi o recei ver over the PCI data bus to control
the radi o vol ume up or down, stati on seek up or
down, preset stati on advance, and mode advance
functi ons.
On vehi cl es equi pped wi th the opti onal memory
system, when the DDM recei ves a Dri ver 1 or Dri ver
2 memory recal l i nput from the memory swi tch on
the dri ver si de front door tri m panel or a memory
recal l message from the Remote Keyl ess Entry (RKE)
recei ver i n the PDM, the DDM sends a memory
recal l message back to the radi o recei ver over the
PCI data bus to recal l the radi o stati on presets and
l ast stati on l i stened to i nformati on.
See the owners manual i n the vehi cl e gl ove box for
more i nformati on on the features, use and operati on
of each of the avai l abl e audi o systems.
DIAGNOSIS AND TESTING - AUDIO
Any diagnosis of the Audio system should
begin with the use of the DRB III diagnostic
tool. For information on the use of the DRB
III, refer to the appropriate Diagnostic Service
Manual.
Refer to the appropri ate wi ri ng i nformati on. The
wi ri ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WJ AUDIO 8A - 3
AUDIO (Continued)
AUDIO SYSTEM DIAGNOSIS
NO AUDIO 1. Fuse faulty. 1. Check radio fuse in Junction Block (JB) and
Ignition-Off Draw (IOD) fuse in Power Distribution
Center (PDC). Replace fuses, if required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector.
Repair, if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Radio ground faulty. 4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. Radio faulty. 5. (Refer to 8 - ELECTRICAL/AUDIO/RADIO -
6. Speakers faulty. 6. (Refer to 8 - ELECTRICAL/AUDIO/SPEAKER -
7. Amplifier faulty (if
equipped).
7. (Refer to 8 - ELECTRICAL/AUDIO/AMPLIFIER
- DIAGNOSIS AND TESTING).
NO RADIO DISPLAY 1. Fuse faulty. 1. Check radio fuse in Junction Block (JB) and
Ignition-Off Draw (IOD) fuse in Power Distribution
Center (PDC). Replace fuses, if required.
CLOCK WILL NOT KEEP
SET TIME
1. Fuse faulty. 1. Check Ignition-Off Draw (IOD) fuse in the
Power Distribution Center (PDC). Replace fuse, if
required.
8A - 4 AUDIO WJ
AUDIO (Continued)
POOR RADIO RECEPTION 1. Antenna faulty. 1. (Refer to 8 - ELECTRICAL/AUDIO/ANTENNA
BODY & CABLE - DIAGNOSIS AND TESTING).
3. Radio noise suppression
faulty.
3. (Refer to 8 - ELECTRICAL/AUDIO/RADIO
NOISE SUPPRESSION - DIAGNOSIS AND
TESTING).
NO/POOR TAPE
OPERATION
1. Faulty tape. 1. Insert known good tape and test operation.
2. Foreign objects behind
tape door.
2. Remove foreign objects and test operation.
3. Dirty cassette tape head. 3. Clean head with Mopar Cassette Head
Cleaner.
4. Faulty tape deck. 4. Exchange or replace radio, if required.
NO COMPACT DISC
OPERATION, OR CD
SKIPPING SOUND
1. Faulty CD. 1. Insert known good CD and test operation.
2. Foreign material on CD. 2. Clean CD and test operation.
3. Condensation on CD or
optics.
3. Allow temperature of vehicle interior to stabilize
and test operation.
4. Faulty CD player. 4. Exchange or replace radio, if required.
NO COMPACT DISC
CHANGER OPERATION, OR
CD SKIPPING SOUND
1. Faulty CD. 1. Insert known good CD and test operation.
2. Foreign material on CD. 2. Clean CD and test operation.
3. Condensation on CD or
optics.
3. Allow temperature of vehicle interior to stabilize
and test operation.
4. CD changer connector
faulty.
4. Check for loose or corroded CD changer
connections. Repair, if required.
5. Wiring faulty. 5. Refer to Compact Disc Changer in the
Diagnosis and Testing section of this group.
6. PCI data bus faulty. 6. Use DRB scan tool and the Diagnostic
Procedures manual to test PCI data bus. Repair,
if required.
7. CD changer faulty. 7. Refer to Compact Disc Changer in the
Diagnosis and Testing section of this group.
WJ AUDIO 8A - 5
AUDIO (Continued)
SPECIAL TOOLS
AUDIO SYSTEMS
AMPLIFIER
DESCRIPTION
Model s equi pped wi th the I nfi ni ty premi um
speaker package have a separate power ampl i fi er
uni t. Thi s power ampl i fi er i s rated at 180 watts out-
put. The power ampl i fi er uni t i s mounted to the rear
fl oor panel under the passenger si de rear seat cush-
i on. The power ampl i fi er uni t can be accessed for ser-
vi ce by unl atchi ng and ti l ti ng the passenger si de rear
seat cushi on forward.
The power ampl i fi er uni t shoul d be checked i f
there i s no sound output noted from the speakers.
For di agnosi s of the power ampl i fi er, (Refer to 8 -
ELECTRI CAL/AUDI O/SPEAKER - DI AGNOSI S
AND TESTI NG). The power ampl i fi er cannot be
repai red or adjusted and, i f faul ty or damaged, the
uni t must be repl aced.
OPERATION
The power ampl i fi er i s energi zed by a fused 12 vol t
output from the radi o recei ver whenever the radi o i s
turned on. The power ampl i fi er recei ves the sound
si gnal i nputs for four speaker channel s from the
radi o recei ver, then sends the ampl i fi ed speaker out-
puts for each of those channel s to the si x I nfi ni ty
speakers. For compl ete ci rcui t di agrams, refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, detai l s of wi re harness
routi ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness con-
nectors, spl i ces and grounds.
DIAGNOSIS AND TESTING - AMPLIFIER
The power ampl i fi er uni t shoul d be checked i f
there i s no sound output noted from the speakers.
For di agnosi s of the power ampl i fi er, (Refer to 8 -
ELECTRI CAL/AUDI O/SPEAKER - DI AGNOSI S
AND TESTI NG). For compl ete ci rcui t di agrams, refer
to the appropri ate wi ri ng i nformati on. The wi ri ng
i nformati on i ncl udes wi ri ng di agrams, proper wi re
and connector repai r procedures, detai l s of wi re har-
ness routi ng and retenti on, connector pi n-out i nfor-
mati on and l ocati on vi ews for the vari ous wi re
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unl atch and l i ft the ri ght rear seat cushi on to
the upri ght posi ti on.
(3) Di sconnect the two ri ght body wi re harness
connectors from the ampl i fi er (Fi g. 1).
(4) Remove the three mounti ng nuts.
(5) Remove the power ampl i fi er.
INSTALLATION
(1) Posi ti on the power ampl i fi er onto the three
fl oor panel studs.
(2) I nstal l the mounti ng nuts. Ti ghten the nuts to
11.8 Nm (105 i n. l bs.).
(3) Reconnect the two ri ght body wi re harness con-
nectors.
(4) Lower the ri ght rear seat cushi on to the fl oor
panel .
(5) Reconnect the battery negati ve cabl e.
Antenna Nut Wrench C-4816
Fig. 1 Power Amplifier Remove/Install
1 - NUT (3)
2 - RIGHT BODY WIRE HARNESS
3 - AMPLIFIER
4 - STUD (3)
5 - RIGHT REAR FLOOR PANEL
8A - 6 AUDIO WJ
AUDIO (Continued)
ANTENNA BODY & CABLE
DESCRIPTION
The antenna body and cabl e i s secured bel ow the
fender panel by the antenna cap nut through a
mounti ng hol e i n the of the ri ght front fender (Fi g.
2). The pri mary coaxi al antenna cabl e i s then routed
beneath the fender sheet metal and through a entry
hol e i n the ri ght cowl si de panel i nto the i nteri or of
the vehi cl e. I nsi de the vehi cl e, the pri mary coaxi al
cabl e i s connected to a secondary i nstrument panel
antenna coaxi al cabl e wi th an i n-l i ne connector that
i s l ocated behi nd the ri ght ki ck panel . The secondary
coaxi al cabl e i s then routed behi nd the i nstrument
panel to the back of the radi o.
OPERATION
The antenna body and cabl e connects the antenna
mast to the radi o. The radi o antenna i s an el ectro-
magneti c ci rcui t component used to capture radi o fre-
quency si gnal s that are broadcast by l ocal
commerci al radi o stati ons i n both the Ampl i tude
Modul ati ng (AM) and Frequency Modul ati ng (FM)
frequency ranges. These el ectromagneti c radi o fre-
quency si gnal s i nduce smal l el ectri cal modul ati ons
i nto the antenna as they move past the mast. The
antenna body transfers the weak el ectromagneti c
radi o waves i nduced i nto the ri gi d antenna mast i nto
the center conductor of the fl exi bl e pri mary antenna
coaxi al cabl e. The brai ded outer shi el d of the
antenna coaxi al cabl e i s grounded through both the
antenna body and the radi o chassi s, effecti vel y
shi el di ng the radi o waves as they are conducted to
the radi o. The radi o then tunes and ampl i fi es the
weak radi o si gnal s i nto stronger el ectri cal si gnal s i n
order to operate the audi o system speakers.
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
Test 1 - Mast to ground test
Test 2 - Ti p-of-mast to ti p-of-conductor test
Test 3 - Body ground to battery ground test
Test 4 - Body ground to antenna coaxi al cabl e
shi el d test.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
INJURY.
The ohmmeter test l ead connecti ons for each test
are shown i n the i l l ustrati on (Fi g. 3).
Fig. 2 Antenna Body and Cable
1 - MAST
2 - BODY & CABLE
3 - CAP NUT
4 - ADAPTER
WJ AUDIO 8A - 7
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate an antenna cable problem. First,
test the primary antenna cable (integral to the
antenna body and cable) from the coaxial cable
connector under the right end of the instrument
panel near the right cowl side inner panel to the
antenna body. Then, test the secondary antenna
cable (instrument panel antenna cable) from the
coaxial cable connector under the right end of the
instrument panel near the right cowl side inner
panel to the coaxial cable connector at the radio.
NOTE: Use extreme caution when checking continu-
ity of center conductor to avoid damage.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from ground. Proceed as fol l ows:
(1) Di sconnect and i sol ate the antenna coaxi al
cabl e connector under the ri ght end of the i nstru-
ment panel near the ri ght cowl si de i nner panel .
(2) Touch one ohmmeter test l ead to the ti p of the
antenna mast. Touch the other test l ead to the
antenna cap nut. Check the ohmmeter readi ng for
conti nui ty.
(3) There shoul d be no conti nui ty. I f OK, go to Test
2. I f not OK, repl ace the faul ty antenna body and
cabl e.
TEST 2
Test 2 checks the antenna conductor components
for an open ci rcui t. Thi s test shoul d be performed
fi rst on the enti re antenna ci rcui t, from the antenna
mast to the center conductor of the coaxi al cabl e con-
nector at the radi o. I f an open ci rcui t i s detected,
each of the three antenna conductor components
(antenna mast, antenna body and pri mary cabl e uni t,
i nstrument panel antenna secondary cabl e) shoul d be
i sol ated and tested i ndi vi dual l y to l ocate the exact
component that i s the source of the open ci rcui t. To
begi n thi s test, proceed as fol l ows:
(1) Di sconnect the i nstrument panel (secondary)
antenna cabl e coaxi al connector from the back of the
radi o.
(2) Touch one ohmmeter test l ead to the ti p of the
antenna mast. Touch the other test l ead to the center
conductor pi n of the i nstrument panel antenna cabl e
coaxi al connector for the radi o. Check the ohmmeter
readi ng for conti nui ty.
(3) There shoul d be conti nui ty. The ohmmeter
shoul d regi ster onl y a fracti on of an ohm resi stance.
Hi gh or i nfi ni te resi stance i ndi cates a damaged or
open antenna conductor. I f OK, go to Test 3. I f not
OK, i sol ate and test each of the i ndi vi dual antenna
conductor components. Repl ace onl y the faul ty
antenna conductor component.
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. To begi n thi s test, proceed as fol -
l ows:
(1) Thi s test must be performed wi th the battery
posi ti ve cabl e di sconnected from the battery. Di scon-
nect and i sol ate both battery cabl es, negati ve cabl e
fi rst.
(3) Touch one ohmmeter test l ead to a good cl ean
ground poi nt on the vehi cl e fender. Touch the other
test l ead to the battery negati ve termi nal post. Check
the ohmmeter readi ng for conti nui ty.
shoul d regi ster l ess than one ohm resi stance. Hi gh or
i nfi ni te resi stance i ndi cates a l oose, corroded, or
damaged connecti on between the battery negati ve
termi nal and the vehi cl e body. I f OK, go to Test 4. I f
not OK, check the battery negati ve cabl e connecti on
to the vehi cl e body and the radi o noi se suppressi on
ground strap connecti ons to the engi ne and the vehi -
cl e body for bei ng l oose or corroded. Cl ean or ti ghten
these connecti ons as requi red.
TEST 4
Test 4 checks the condi ti on of the connecti on
between the antenna coaxi al cabl e shi el d and the
vehi cl e body ground as fol l ows:
(1) Di sconnect and i sol ate the antenna coaxi al
Fig. 3 Antenna Tests - Typical
8A - 8 AUDIO WJ
ANTENNA BODY & CABLE (Continued)
(2) Touch one ohmmeter test l ead to a good cl ean
ground poi nt on the vehi cl e fender. Touch the other
test l ead to the outer cri mp on the antenna coaxi al
Check the ohmmeter readi ng for conti nui ty.
shoul d regi ster l ess than one ohm resi stance. Hi gh or
i nfi ni te resi stance i ndi cates a l oose, corroded, or
damaged connecti on between the antenna body and
the vehi cl e body or between the antenna body and
the antenna coaxi al cabl e shi el d. I f not OK, cl ean the
antenna body to fender mati ng surfaces and ti ghten
the antenna cap nut to speci fi cati ons.
(4) Check the resi stance agai n wi th an ohmmeter.
I f the resi stance i s sti l l more then one ohm, repl ace
the faul ty antenna body and cabl e.
REMOVAL
INJURY.
cabl e.
(2) Remove the scuff pl ate from the ri ght front
door si l l . (Refer to 23 - BODY/I NTERI OR/DOOR
SI LL SCUFF PLATE - REMOVAL) for the proce-
dures.
(3) Remove the tri m panel from the ri ght i nner
cowl si de.(Refer to 23 - BODY/I NTERI OR/COWL
TRI M - REMOVAL) for the procedures.
(4) Reach under the passenger si de of the i nstru-
ment panel near the ri ght cowl si de i nner panel to
di sconnect the antenna coaxi al cabl e connector by
pul l i ng i t apart whi l e twi sti ng the metal connector
hal ves (Fi g. 4). Do not pul l on the cabl e.
(5) Remove the l ower rear hal f of the i nner l i ner
from the ri ght front fender wheel house. (Refer to 23
- BODY/EXTERI OR/FRONT FENDER - REMOVAL)
for the procedures.
(6) Reach through the rear of the ri ght front
fender wheel house openi ng to access and unseat the
antenna l ead grommet from the hol e i n the ri ght
cowl si de outer panel .
(7) Pul l the antenna l ead coaxi al cabl e and connec-
tor out of the passenger compartment and i nto the
ri ght front fender wheel house through the hol e i n
the ri ght cowl si de outer panel .
(8) Unscrew the antenna mast from the antenna
base (Fi g. 5).
(9) Remove the pl asti c shroud from the antenna
base cap nut.
(10) Remove the antenna base cap nut usi ng an
antenna nut wrench (Speci al Tool C-4816) (Fi g. 6).
(11) Remove the antenna escutcheon from the
antenna base on the top of the ri ght front fender.
(12) Lower the antenna base from the mounti ng
hol e i n the top of the ri ght front fender.
(13) Remove the antenna base and l ead from the
rear of the ri ght front fender wheel house openi ng.
Fig. 4 Antenna Base and Lead Remove/Install
1 - BASE AND LEAD
2 - ESCUTCHEON
3 - MAST
4 - SHROUD
5 - CAP NUT
7 - GROMMET
8 - CONNECTOR
WJ AUDIO 8A - 9
INSTALLATION
(1) Posi ti on the antenna base and l ead i nto the
rear of the ri ght front fender wheel house openi ng.
(2) I nsert the antenna base i nto the mounti ng hol e
i n the top of the ri ght front fender.
(3) I nstal l the antenna escutcheon onto the
antenna base on the top of the ri ght front fender.
(4) I nstal l and ti ghten the antenna base cap nut
usi ng an antenna nut wrench (Speci al Tool C-4816).
Ti ghten the cap nut to 6.8 Nm (60 i n. l bs.).
(5) I nstal l the pl asti c shroud onto the antenna
base cap nut.
(6) I nstal l and ti ghten the antenna mast onto the
antenna base. Ti ghten the antenna mast to 3.3 Nm
(30 i n. l bs.).
(7) Reach through the rear of the ri ght front
fender wheel house openi ng to access and i nsert the
antenna l ead coaxi al cabl e and connector i nto the
passenger compartment through the hol e i n the ri ght
(8) From the ri ght front fender wheel house, seat
the antenna l ead grommet i nto the hol e i n the ri ght
(9) I nstal l the l ower rear hal f of the i nner l i ner
i nto the ri ght front fender wheel house.
reconnect the antenna coaxi al cabl e connector hal ves.
(11) I nstal l the tri m panel onto the ri ght i nner
cowl si de.
(12) I nstal l the scuff pl ate onto the ri ght front door
si l l .
ANTENNA MODULE - EXPORT
DESCRIPTION
The antenna modul e (Fi g. 7) i s an el ectromagneti c
ci rcui t component desi gned to capture and enhance
RF (Radi o Frequency) si gnal s i n both the AM and
FM broadcast bands. The antenna modul e i s
mounted to the ri ght rear roof rai l under the head-
l i ner. The modul es mounti ng brackets al so doubl e as
the ground ci rcui t. The modul e has a two wi re el ec-
tri cal connector that connects to the el ectri c backl i te
i ntegral radi o antenna, l ocated on the ri ght rear
quarter gl ass, a connector for the radi o coax cabl e
and a connector for battery vol tage.
Fig. 5 Antenna Mast Remove/Install - Typical
1 - ANTENNA MAST
2 - ADAPTER
3 - CAP NUT
Fig. 6 Antenna Base Cap Nut Remove/Install -
Typical
1 - CAP NUT
2 - ANTENNA ADAPTER
3 - TOOL
8A - 10 AUDIO WJ
OPERATION
The antenna modul e recei ves both AM and FM
radi o si gnal s suppl i ed by the si de wi ndow i ntegral
radi o antenna system and sel ecti vel y ampl i fi es them
whi l e at the same ti me avoi di ng unusabl e or
unwanted si gnal s. The ampl i fi ed si gnal i s then sent
through the body l ength coax cabl e to the radi o
i nput.
DIAGNOSIS AND TESTING - ANTENNA MODULE - EXPORT
ANTENNA MODULE DIAGNOSIS TABLE
NO AM RECEPTION,
WEAK FM RECEPTION
1. Antenna module to antenna
connector open or disconnected.
1. Repair open, reconnect
antenna module connector to
glass mounted antenna.
2. Coax open or disconnected. 2. Repair open, reconnect coax.
3. No battery power at antenna
module.
3. Check fuse. if okay, repair
open in battery voltage circuit.
NO AM OR FM
RECEPTION
1. Coax disconnected at radio. 1. Reconnect coax.
2. Coax shorted to ground. 2. Repair or Replace coax
WEAK OR NO AM/FM
RECEPTION
1. Antenna Module faulty. 1. Substitute known good
module. If reception improves,
Antenna Module was faulty.
Fig. 7 ANTENNA MODULE
1 - ANTENNA LEAD CONNECTOR
2 - ANTENNA MODULE
3 - ANTENNA MODULE MOUNT/GROUND BRACKETS
4 - BATTERY SUPPLY CONNECTION POINT
5 - COAX CONNECTION POINT
WJ AUDIO 8A - 11
ANTENNA MODULE - EXPORT (Continued)
REMOVAL
(1) Remove the headl i ner. (Refer to 23 - BODY/I N-
TERI OR/HEADLI NER - REMOVAL)
(2) Di sconnect the battery power l ead connector
from the antenna modul e.
(3) Di sconnect the antenna modul e connector from
the i ntegral antenna (Fi g. 8).
(4) Remove the mounti ng screws and the antenna
modul e.
(5) Di sconnect the coax l ead from the antenna
modul e.
INSTALLATION
(1) Pl ug coax i nto antenna modul e.
(2) Posi ti on antenna modul e onto ri ght si de upper
roof rai l and i nstal l screws. Ti ghten the screws to 8
Nm (71 i n. l bs.).
(3) Connect antenna modul e l ead to the i ntegral
antenna.
(4) Connect battery power suppl y l ead to antenna
modul e.
(5) I nstal l headl i ner. (Refer to 23 - BODY/I NTERI -
OR/HEADLI NER - I NSTALLATI ON)
CD CHANGER
DESCRIPTION
A factory-i nstal l ed Compact Di sc (CD) changer fea-
turi ng a ten-CD magazi ne i s an avai l abl e opti on on
thi s model when i t i s al so equi pped wi th the pre-
mi um speaker package and a radi o recei ver i ncl udi ng
the CD control s feature. The CD changer i s mounted
i n the cargo area of the passenger compartment on
the ri ght rear quarter panel .
The CD changer i s connected to a take out from
the ri ght body wi re harness and recei ves both ground
and radi o-swi tched battery current through the radi o
recei ver. The control s on the radi o recei ver operate
the CD changer through messages sent over the Pro-
grammabl e Communi cati ons I nterface (PCI ) data bus
network. The two-channel audi o outputs of the CD
changer are hard wi red back to the radi o recei ver,
whi ch then outputs the si gnal through four channel s
to the power ampl i fi er. For di agnosi s of the messag-
i ng functi ons of the radi o recei ver and the CD
changer, or of the PCI data bus, a DRB scan tool and
the proper Di agnosti c Procedures manual are
requi red.
Fig. 8 ANTENNA MODULE
1 - COAX
2 - RIGHT SIDE ROOF RAIL
3 - ANTENNA MODULE
4 - ANTENNA MODULE TO ANTENNA CONNECTOR
5 - SCREW (2)
8A - 12 AUDIO WJ
ANTENNA MODULE - EXPORT (Continued)
The CD changer can onl y be servi ced by an autho-
ri zed radi o repai r stati on. See the l atest Warranty
Pol i ci es and Procedures manual for a current l i sti ng
of authori zed radi o repai r stati ons.
OPERATION
The CD changer wi l l onl y operate when the i gni -
ti on swi tch i s i n the On or Accessory posi ti ons, and
the radi o i s turned on. For more i nformati on on the
features, l oadi ng procedures and radi o control func-
ti ons for the operati on of the CD changer, see the
owners manual i n the vehi cl e gl ove box.
DIAGNOSIS AND TESTING - CD CHANGER
Fol l owi ng are tests that wi l l hel p to di agnose the
hard wi red components and ci rcui ts of the Compact
Di sc (CD) changer uni t. However, these tests may not
prove concl usi ve i n the di agnosi s of thi s uni t. I n
order to obtai n concl usi ve testi ng of the CD changer
uni t, the Programmabl e Communi cati ons I nterface
(PCI ) data bus network, the CD changer uni t, the
radi o recei ver uni t and any other el ectroni c modul es
that provi de i nputs to, or recei ve outputs from the
audi o system must be checked.
Manual.
INJURY.
COMPACT DISC CHANGER INOPERATIVE
(1) Turn the i gni ti on swi tch to the On posi ti on.
Turn the radi o recei ver on and check i ts operati on. I f
OK, go to Step 2. I f not OK, (Refer to 8 - ELECTRI -
CAL/AUDI O/RADI O - OPERATI ON).
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Di sconnect the ri ght body wi re harness connector
from the CD changer connector receptacl e. Check for
conti nui ty between the power ground (Z17) ci rcui t of
the ri ght body wi re harness connector for the CD
changer and a good ground. There shoul d be conti nu-
i ty. I f OK, go to Step 3. I f not OK, repai r the open
power ground ci rcui t to the radi o recei ver as
requi red.
(3) Reconnect the battery negati ve cabl e. Check for
battery vol tage at the B(+) ci rcui t cavi ty of the ri ght
body wi re harness connector for the CD changer. I f
OK, go to Step 4. I f not OK, go to Step 5.
Check for battery vol tage at the i gni ti on swi tch out-
put ci rcui t cavi ty of the ri ght body wi re harness con-
nector for the CD changer. I f OK, use a DRB scan
tool and the proper Di agnosti c Procedures manual for
further di agnosi s. I f not OK, go to Step 6.
cabl e. Remove the radi o recei ver from the i nstrument
panel . Di sconnect the 10 pi n cabl e connector from the
radi o recei ver, but do not di sconnect the other wi re
harness connectors. Reconnect the battery negati ve
cabl e. Check for battery vol tage at the B(+) ci rcui t
cavi ty of the 10 pi n connector receptacl e on the radi o
recei ver. I f OK, repai r the open B(+) ci rcui t to the CD
changer as requi red. I f not OK, check for a shorted
B(+) ci rcui t to the CD changer and repai r as
requi red, then repl ace the faul ty radi o recei ver.
Remove the radi o recei ver from the i nstrument
radi o recei ver, but do not di sconnect the other wi re
harness connectors. Reconnect the battery negati ve
cabl e. Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the i gni ti on swi tch out-
put ci rcui t cavi ty of the 10 pi n connector receptacl e
on the radi o recei ver. I f OK, repai r the open i gni ti on
swi tch output ci rcui t to the CD changer as requi red.
I f not OK, check for a shorted i gni ti on swi tch output
ci rcui t to the CD changer and repai r as requi red,
then repl ace the faul ty radi o recei ver.
NO SOUND OR ONLY ONE CHANNEL SOUND
FROM CD CHANGER
Turn the radi o recei ver on and check i ts audi o output
operati on. I f OK, go to Step 2. I f not OK, (Refer to 8
- ELECTRI CAL/AUDI O/SPEAKER - OPERATI ON).
cabl e. Di sconnect the ri ght body wi re harness connec-
tor from the CD changer connector receptacl e.
WJ AUDIO 8A - 13
CD CHANGER (Continued)
radi o recei ver. Check for conti nui ty between the
audi o ground (Z4) ci rcui t cavi ty of the ri ght body
wi re harness connector for the CD changer and a
good ground. There shoul d be no conti nui ty. I f OK, go
to Step 3. I f not OK, repai r the shorted audi o ground
(Z4) ci rcui t as requi red.
(3) Check for conti nui ty between the audi o ground
(Z4) ci rcui t cavi ty of the ri ght body wi re harness con-
nector for the CD changer and the audi o ground (Z4)
ci rcui t pi n of the 10 pi n cabl e connector for the radi o
recei ver. There shoul d be conti nui ty. I f OK, go to
Step 4. I f not OK, repai r the open audi o ground (Z4)
ci rcui t as requi red.
(4) Check for conti nui ty between the audi o out
ri ght ci rcui t cavi ty of the ri ght body wi re harness
connector for the CD changer and a good ground.
There shoul d be no conti nui ty. I f OK, go to Step 5. I f
not OK, repai r the shorted audi o out ri ght ci rcui t as
requi red.
(5) Check for conti nui ty between the audi o out
ri ght ci rcui t cavi ty of the ri ght body wi re harness
connector for the CD changer and the audi o out ri ght
ci rcui t pi n of the 10 pi n cabl e connector for the radi o
recei ver. There shoul d be conti nui ty. I f OK, go to
Step 6. I f not OK, repai r the open audi o out ri ght ci r-
cui t as requi red.
(6) Check for conti nui ty between the audi o out l eft
ci rcui t cavi ty of the ri ght body wi re harness connec-
tor for the CD changer and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 7. I f not
OK, repai r the shorted audi o out l eft ci rcui t as
requi red.
(7) Check for conti nui ty between the audi o out l eft
ci rcui t cavi ty of the ri ght body wi re harness connec-
tor for the CD changer and the audi o out l eft ci rcui t
pi n of the 10 pi n cabl e connector for the radi o
recei ver. There shoul d be conti nui ty. I f OK, repl ace
the faul ty CD changer. I f not OK, repai r the open
audi o out l eft ci rcui t as requi red.
REMOVAL
cabl e.
(2) Rel ease the l atch and open the l i d of the com-
pact di sc changer storage bi n on the ri ght si de quar-
ter tri m panel (Fi g. 9).
(3) Remove the two mounti ng screws.
(4) Grasp the bottom of the compact di sc changer
storage bi n fi rml y wi th both hands and l i ft i t
upwards.
(5) Remove the compact di sc changer storage bi n
from the ri ght si de quarter tri m panel .
(6) Di sconnect the ri ght body wi re harness connec-
tor from compact di sc changer (Fi g. 10).
(7) Remove the four mounti ng nuts.
(8) Remove the compact di sc changer from the
ri ght si de quarter i nner panel .
INSTALLATION
(1) Posi ti on the compact di sc changer onto the four
studs.
Fig. 9 Compact Disc Changer Storage Bin Remove/
Install
1 - RIGHT SIDE QUARTER TRIM PANEL
2 - LID
3 - LATCH
4 - SCREW (2)
5 - CD CHANGER STORAGE BIN
Fig. 10 Compact Disc Changer Remove/Install
1 - RIGHT SIDE QUARTER INNER PANEL
2 - RIGHT SIDE QUARTER TRIM PANEL
3 - COMPACT DISC CHANGER
4 - NUT (4)
6 - STUD (4)
8A - 14 AUDIO WJ
(2) I nstal l the four mounti ng nuts. Ti ghten the
nuts to 12 Nm (105 i n. l bs.).
(3) Reconnect the ri ght body wi re harness connec-
tor.
(4) Posi ti on the compact di sc changer storage bi n
onto the ri ght si de quarter tri m panel .
(5) Usi ng both hands push the compact di sc
changer storage bi n fi rml y and evenl y toward the
ri ght si de quarter tri m panel far enough to engage
the hooks on the bi n wi th the sl ots i n the panel .
(6) Usi ng both hands push the compact di sc
changer storage bi n fi rml y and evenl y downward far
enough to al i gn the screw hol es i n the bi n wi th the
mounti ng hol es i n the ri ght si de quarter tri m panel .
(7) I nstal l the two screws that secure the top of
the compact di sc changer storage bi n. Ti ghten the
screws to 1.7 Nm (15 i n. l bs.).
INSTRUMENT PANEL
ANTENNA CABLE
REMOVAL
BAGS, REFER TO ELECTRICAL, RESTRAINTS
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.
cabl e.
(2) Remove the scuff pl ate from the ri ght front
door si l l . (Refer to 23 - BODY/I NTERI OR/DOOR
SI LL SCUFF PLATE - REMOVAL) for the proce-
dures.
(3) Remove the tri m panel from the ri ght i nner
cowl si de. (Refer to 23 - BODY/I NTERI OR/COWL
TRI M - REMOVAL) for the procedures.
di sconnect the antenna coaxi al cabl e connector by
pul l i ng i t apart whi l e twi sti ng the metal connector
hal ves. Do not pul l on the cabl e.
(5) Di sengage the antenna cabl e retai ner from the
mounti ng hol e i n the wi re harness mounti ng tab
under the passenger si de end of the i nstrument
panel .
(6) Remove the radi o recei ver from the i nstrument
panel . (Refer to 8 - ELECTRI CAL/AUDI O/RADI O -
REMOVAL) for the procedures.
(7) Remove the passenger si de ai rbag modul e from
the i nstrument panel . (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/PASSENGER AI RBAG - REMOVAL)
for the procedures.
(8) Di sengage the antenna cabl e retai ner from the
mounti ng hol e i n the top of the radi o mount on the
i nstrument panel structural duct (Fi g. 11).
(9) Di sengage the antenna cabl e from the l ocator
tabs on the top of the i nstrument panel structural
duct above the gl ove box openi ng.
(10) Remove the antenna cabl e from the i nstru-
ment panel .
INSTALLATION
(1) Posi ti on the antenna cabl e onto the i nstrument
panel .
(2) Engage the antenna cabl e wi th the l ocator tabs
on the top of the i nstrument panel structural duct
above the gl ove box openi ng.
(3) Engage the antenna cabl e retai ner i nto the
mounti ng hol e i n the top of the radi o mount on the
i nstrument panel structural duct.
(4) I nstal l the passenger si de ai rbag modul e onto
RESTRAI NTS/PASSENGER AI RBAG - I NSTALLA-
TI ON) for the procedures.
(5) I nstal l the radi o recei ver onto the i nstrument
panel . (Refer to 8 - ELECTRI CAL/AUDI O/RADI O -
I NSTALLATI ON) for the procedures.
(6) Engage the antenna cabl e retai ner i nto the
mounti ng hol e i n the wi re harness mounti ng tab
under the passenger si de end of the i nstrument
panel .
Fig. 11 Instrument Panel Antenna Cable Routing
1 - INSTRUMENT PANEL STRUCTURAL DUCT
2 - RETAINER
3 - COAXIAL CABLE
4 - COAXIAL CABLE CONNECTORS
WJ AUDIO 8A - 15
reconnect the antenna coaxi al cabl e connector hal ves.
(8) I nstal l the tri m panel onto the ri ght i nner cowl
si de. (Refer to 23 - BODY/I NTERI OR/COWL TRI M -
(9) I nstal l the scuff pl ate onto the ri ght front door
si l l . (Refer to 23 - BODY/I NTERI OR/DOOR SI LL
SCUFF PLATE - I NSTALLATI ON) for the proce-
dures.
QUARTER GLASS INTEGRAL
ANTENNA - EXPORT
DESCRIPTION
The i ntegral radi o antenna el ement i s bonded to
the ri ght rear quarter gl ass and i s repl aced wi th the
gl ass assembl y onl y.
OPERATION
The i ntegral antenna recei ves RF (Radi o Frequen-
ci es) and sends them to the antenna modul e for
ampl i fi cati on.
DIAGNOSIS AND TESTING - QUARTER GLASS
INTEGRAL ANTENNA - EXPORT
For compl ete ci rcui t di agrams, refer to the Appro-
pri ate Wi ri ng I nformati on. To detect breaks i n the
i ntegral antenna el ements, the fol l owi ng procedure i s
requi red:
(1) Di sconnect the antenna modul e connector from
the antenna.
(2) Usi ng a Ohmmeter, pl ace both l eads onto the
connector pi ns on the i ntegral antenna. I f conti nui ty
i s present antenna gri d i s Okay. I f conti nui ty i s not
present move one l ead through the gri d i n progres-
si on unti l conti nui ty i s detected. A break i n the
antenna gri d can be repai red usi ng a Mopar Rear
Wi ndow Defogger Repai r Ki t (Part Number 4267922)
or equi val ent. (Refer to 8 - ELECTRI CAL/WI NDOW
DEFOGGER/REAR WI NDOW DEFOGGER GRI D -
STANDARD PROCEDURE)
RADIO
DESCRIPTION
Avai l abl e factory-i nstal l ed radi o recei vers for thi s
model i ncl ude an AM/FM/cassette wi th CD changer
control feature (RBB sal es code), an AM/FM/CD/2-
band graphi c equal i zer wi th CD changer control fea-
ture (RBK sal es code), or an AM/FM/CD/cassette/2-
band graphi c equal i zer (RBP sal es code). Al l factory-
i nstal l ed radi o recei vers can communi cate on the
Programmabl e Communi cati ons I nterface (PCI ) data
bus network through a separate wi re harness connec-
tor. Al l factory-i nstal l ed recei vers are stereo El ectron-
i cal l y Tuned Radi os (ETR) and i ncl ude an el ectroni c
di gi tal cl ock functi on.
These radi o recei vers can onl y be servi ced by an
authori zed radi o repai r stati on. See the l atest War-
ranty Pol i ci es and Procedures manual for a current
l i sti ng of authori zed radi o repai r stati ons.
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse that i s removed when the vehi cl e i s
shi pped from the factory. Thi s fuse feeds vari ous
accessori es that requi re battery current when the
i gni ti on swi tch i s i n the Off posi ti on, i ncl udi ng the
cl ock. The I OD fuse i s removed to prevent battery
di scharge duri ng vehi cl e storage.
When removi ng or i nstal l i ng the I OD fuse, i t i s
i mportant that the i gni ti on swi tch be i n the Off posi -
ti on. Fai l ure to pl ace the i gni ti on swi tch i n the Off
posi ti on can cause the radi o di spl ay to become scram-
bl ed when the I OD fuse i s removed and repl aced.
Removi ng and repl aci ng the I OD fuse agai n, wi th the
i gni ti on swi tch i n the Off posi ti on, wi l l correct the
scrambl ed di spl ay condi ti on.
The I OD fuse shoul d be checked i f the radi o or
cl ock di spl ays are i noperati ve. The I OD fuse i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to the fuse l ayout l abel on the undersi de of the
PDC cover for I OD fuse i denti fi cati on and l ocati on.
OPERATION
The radi o recei ver operates on i gni ti on swi tched
battery current that i s avai l abl e onl y when the i gni -
ti on swi tch i s i n the On or Accessory posi ti ons. The
el ectroni c di gi tal cl ock functi on of the radi o operates
on fused battery current suppl i ed through the I OD
fuse, regardl ess of the i gni ti on swi tch posi ti on.
For more i nformati on on the features, setti ng pro-
cedures, and control functi ons for each of the avai l -
abl e factory-i nstal l ed radi o recei vers, refer to the
owners manual . For compl ete ci rcui t di agrams, refer
DIAGNOSIS AND TESTING - RADIO
Manual.
I f the vehi cl e i s equi pped wi th the opti onal remote
radi o swi tches l ocated on the steeri ng wheel and the
8A - 16 AUDIO WJ
INSTRUMENT PANEL ANTENNA CABLE (Continued)
probl em bei ng di agnosed i s rel ated to one of the
symptoms l i sted bel ow, be certai n to check the
remote radi o swi tches and ci rcui ts. (Refer to 8 -
ELECTRI CAL/AUDI O/REMOTE SWI TCHES -
OPERATI ON).
Stati ons changi ng wi th no remote radi o swi tch
i nput
Radi o memory presets not worki ng properl y
Vol ume changes wi th no remote radi o swi tch
i nput
Remote radi o swi tch buttons taki ng on other
functi ons
CD pl ayer ski ppi ng tracks
Mode (AM, FM, CD, CD changer) changes wi th
no remote radi o swi tch i nput
Remote radi o swi tch i noperati ve.
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, detai l s of wi re harness routi ng
and retenti on, connector pi n-out i nformati on and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
INJURY.
CAUTION: The speaker output of the radio receiver
is a floating ground system. Do not allow any
speaker lead to short to ground, as damage to the
radio receiver may result.
(1) Check the fused B(+) fuse i n the juncti on bl ock.
I f OK, go to Step 2. I f not OK, repai r the shorted ci r-
cui t or component as requi red and repl ace the faul ty
fuse.
(2) Check for battery vol tage at the fused B(+) fuse
i n the juncti on bl ock. I f OK, go to Step 3. I f not OK,
repai r the open fused B(+) ci rcui t to the Power Di s-
tri buti on Center (PDC) fuse as requi red.
(3) Check the fused i gni ti on swi tch output (acc/
run) fuse i n the juncti on bl ock. I f OK, go to Step 4. I f
not OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse(s).
Check for battery vol tage at the fused i gni ti on swi tch
output (acc/run) fuse i n the juncti on bl ock. I f OK, go
to Step 5. I f not OK, repai r the open fused i gni ti on
swi tch output (acc/run) ci rcui t to the i gni ti on swi tch
as requi red.
panel , but do not di sconnect the wi re harness connec-
tors. Check for conti nui ty between the radi o recei ver
chassi s and a good ground. There shoul d be conti nu-
ground ci rcui t to ground as requi red.
(6) Test the radi o recei ver antenna. (Refer to 8 -
ELECTRI CAL/AUDI O/ANTENNA BODY & CABLE -
DI AGNOSI S AND TESTI NG). I f OK, go to Step 7. I f
not OK, repl ace the faul ty antenna or coaxi al cabl e
as requi red.
(7) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (acc/run)
ci rcui t cavi ty of the 22 pi n radi o wi re harness connec-
tor. I f OK, go to Step 8. I f not OK, repai r the open
fused i gni ti on swi tch output (acc/run) ci rcui t to the
juncti on bl ock fuse as requi red.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the 22 pi n radi o wi re harness connector. I f
OK, repl ace the faul ty radi o recei ver. I f not OK,
repai r the open fused B(+) ci rcui t to the juncti on
bl ock fuse as requi red.
REMOVAL
INJURY.
cabl e.
(2) Remove the center upper bezel from the i nstru-
ment panel .(Refer to 23 - BODY/I NSTRUMENT
PANEL - REMOVAL).
(3) Remove the four screws that secure the radi o
recei ver to the i nstrument panel (Fi g. 12).
WJ AUDIO 8A - 17
RADIO (Continued)
(4) Di sconnect the i nstrument panel wi re harness
connectors and the antenna coaxi al cabl e connector
from the receptacl es on the rear of the radi o recei ver.
(5) Remove the radi o recei ver from the i nstrument
panel .
INSTALLATION
INJURY.
(1) Posi ti on the radi o recei ver to the i nstrument
panel .
(2) Reconnect the i nstrument panel wi re harness
connectors and the antenna coaxi al cabl e connector
to the receptacl es on the rear of the radi o recei ver.
(3) I nstal l the four mounti ng screws. Ti ghten the
(4) I nstal l the center upper bezel onto the i nstru-
ment panel . (Refer to 23 - BODY/I NSTRUMENT
PANEL - I NSTALLATI ON) for the procedures.
RADIO NOISE SUPPRESSION
GROUND STRAP
DESCRIPTION
Radi o Frequency I nterference (RFI ) and El ectro-
Magneti c I nterference (EMI ) noi se suppressi on i s
accompl i shed pri mari l y through ci rcui try i nternal to
the radi o recei vers. These i nternal suppressi on
devi ces are onl y servi ced as part of the radi o recei ver.
External suppressi on devi ces that are used on thi s
vehi cl e to control RFI or EMI noi se i ncl ude the fol -
l owi ng:
Radi o antenna base ground
Radi o recei ver chassi s ground wi re or strap
Engi ne-to-body ground strap(s)
Exhaust system-to-body and transmi ssi on
ground strap (4.7L engi nes onl y)
Resi stor-type spark pl ugs
Radi o suppressi on-type secondary i gni ti on wi r-
i ng.
For more i nformati on on the spark pl ugs and sec-
ondary i gni ti on components, refer to I gni ti on System
i n I gni ti on System.
REMOVAL
REMOVAL - ENGINE-TO-BODY GROUND
STRAP
(1) Remove the screw that secures the engi ne-to-
body ground strap eyel et to the l ower pl enum panel
(Fi g. 13) or (Fi g. 14).
(2) On model s wi th a 4.0L engi ne, remove the nut
that secures the engi ne-to-body ground strap eyel et
to the stud on the ri ght rear si de of the engi ne cyl -
i nder head.
(3) On model s wi th a 4.7L engi ne, remove the two
nuts that secure the engi ne-to-body ground strap eye-
l ets to the studs on the ri ght and l eft rear si des of
the engi ne i ntake mani fol d.
(4) Remove the engi ne-to-body ground strap eye-
l et(s) from the stud(s) on the engi ne.
(5) Remove the engi ne-to-body ground strap from
the engi ne compartment.
Fig. 12 Radio Remove/Install
1 - INSTRUMENT PANEL
2 - SCREW (4)
3 - RADIO RECEIVER
8A - 18 AUDIO WJ
RADIO (Continued)
REMOVAL - EXHAUST-TO-BODY GROUND
STRAP
(2) Remove fasteners from exhaust, crossmember
and transmi ssi on/transfer case.
(3) Remove the ground strap.
INSTALLATION
INSTALLATION - ENGINE TO BODY GROUND
STRAP
(1) Posi ti on the engi ne-to-body ground strap i nto
(2) I nstal l the engi ne-to-body ground strap eye-
l et(s) onto the stud(s) on the engi ne.
(3) On model s wi th a 4.0L engi ne, i nstal l and
ti ghten the nut that secures the engi ne-to-body
ground strap eyel et to the stud on the ri ght rear si de
of the engi ne cyl i nder head. Ti ghten the nut to 5.6
Nm (50 i n. l bs.).
(4) On model s wi th a 4.7L engi ne, i nstal l and
ti ghten the two nuts that secure the engi ne-to-body
ground strap eyel ets to the studs on the ri ght and
l eft rear si des of the engi ne i ntake mani fol d. Ti ghten
the nuts to 11.3 Nm (100 i n. l bs.).
(5) I nstal l and ti ghten the screw that secures the
engi ne-to-body ground strap eyel et to the l ower pl e-
num panel . Ti ghten the screw to 4.5 Nm (40 i n. l bs.).
INSTALLATION - EXHAUST-TO-BODY GROUND
STRAP
(1) I nstal l the ground strap to the exhaust, cross-
member and transmi ssi on/transfer case.
(2) I nstal l the fasteners.
REMOTE SWITCHES
DESCRIPTION
Remote radi o control swi tches are i ncl uded on
model s equi pped wi th the opti onal l eather-wrapped
steeri ng wheel . The two rocker-type swi tch uni ts
(Fi g. 15) are mounted i n the upper spoke covers of
the rear (i nstrument panel si de) steeri ng wheel tri m
cover. The swi tch uni t on the l eft si de i s the seek
swi tch and has seek up, seek down, and preset sta-
ti on advance swi tch functi ons. The swi tch uni t on the
ri ght si de i s the vol ume control swi tch and has vol -
ume up, vol ume down, and mode advance swi tch
functi ons.
Fig. 13 Engine-To-Body Ground Strap Remove/
Install - 4.0L Engine
1 - SCREW
2 - LOWER PLENUM PANEL
3 - ENGINE
4 - STUD
5 - NUT
6 - GROUND STRAP
Fig. 14 Engine-To-Body Ground Strap Remove/
Install - 4.7L Engine
1 - GROUND STRAP
2 - SCREW
3 - ENGINE
4 - STUD (2)
5 - NUT (2)
6 - LOWER PLENUM PANEL
WJ AUDIO 8A - 19
RADIO NOISE SUPPRESSION GROUND STRAP (Continued)
The two remote radi o swi tch uni ts share a common
steeri ng wheel wi re harness wi th the vehi cl e speed
control swi tches. The steeri ng wheel wi re harness i s
connected to the i nstrument panel wi re harness
through the cl ockspri ng. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/CLOCKSPRI NG - DESCRI PTI ON) for
more i nformati on on thi s component.
OPERATION
The si x swi tches i n the two remote radi o swi tch
uni ts are normal l y open, resi stor mul ti pl exed
momentary swi tches that are hard wi red to the Body
Control Modul e (BCM) through the cl ockspri ng. The
BCM sends a fi ve vol t reference si gnal to both swi tch
uni ts on one ci rcui t, and senses the status of al l of
the swi tches by readi ng the vol tage drop on a second
ci rcui t.
When the BCM senses an i nput (vol tage drop) from
any one of the remote radi o swi tches, i t sends the
proper swi tch status messages on the Programmabl e
Communi cati on I nterface (PCI ) data bus network to
the radi o recei ver. The el ectroni c ci rcui try wi thi n the
radi o recei ver i s programmed to respond to these
remote radi o swi tch status messages by adjusti ng the
radi o setti ngs as requested. For di agnosi s of the
BCM or the PCI data bus, the use of a DRB scan tool
and the proper Di agnosti c Procedures manual are
recommended.
For more i nformati on on the features and control
functi ons for each of the remote radi o swi tches, see
the owners manual i n the vehi cl e gl ove box.
SWITCHES
Manual.
INJURY.
cabl e. Remove the remote radi o swi tch(es) (Fi g. 16)
from the steeri ng wheel .
(2) Use an ohmmeter to check the swi tch resi s-
tances as shown i n the Remote Radi o Swi tch Test
chart. I f the remote radi o swi tch resi stances check
OK, go to Step 3. I f not OK, repl ace the faul ty
swi tch.
Fig. 15 Remote Radio Switches
1 - PRESET ADVANCE
2 - SEEK
3 - MODE ADVANCE
4 - VOLUME
8A - 20 AUDIO WJ
REMOTE SWITCHES (Continued)
Remote Radio Switch Test
Switch Switch Position Resistance
Right
(White)
Volume Up 1.210 Kilohms
Right
(White)
Volume Down 3.010 Kilohms
Right
(White)
Mode Advance 0.0511 Kilohms
Left
(Black)
Seek Up 0.261 Kilohms
Left
(Black)
Seek Down 0.681 Kilohms
Left
(Black)
Pre-Set Station
Advance
0.162 Kilohms
(3) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for 5 vol ts
at the radi o control mux ci rcui t cavi ti es of the steer-
i ng wheel wi re harness connectors for both remote
radi o swi tches. I f OK, go to Step 4. I f not OK, repai r
the open or shorted radi o control mux ci rcui t to the
Body Control Modul e (BCM) as requi red.
cabl e. Di sconnect the 22-way i nstrument panel wi re
harness connector from the BCM. Check for conti nu-
i ty between the remote radi o swi tch ground ci rcui t
cavi ti es of the steeri ng wheel wi re harness connec-
tors for both remote radi o swi tches and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 5. I f not OK, repai r the shorted remote radi o
swi tch ground ci rcui t to the BCM as requi red.
(5) Check for conti nui ty between the remote radi o
swi tch ground ci rcui t cavi ti es of the steeri ng wheel
wi re harness connectors for both remote radi o
swi tches and the 22-way i nstrument panel wi re har-
ness connector for the BCM. There shoul d be conti -
nui ty. I f OK, refer to the proper Di agnosti c
Procedures manual to test the BCM and the PCI
data bus. I f not OK, repai r the open remote radi o
swi tch ground ci rcui t as requi red.
REMOVAL
cabl e.
(2) Remove the dri ver si de ai rbag from the steer-
i ng wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - REMOVAL) for the procedures.
(3) Remove the speed control swi tch l ocated on the
same si de of the steeri ng wheel as the remote radi o
swi tch that i s bei ng servi ced. Refer to El ectri cal ,
Speed Control for the procedures.
(4) Di sconnect the steeri ng wheel wi re harness
connector from the connector receptacl e of the remote
radi o swi tch (Fi g. 17).
(5) From the i nsi de of the steeri ng wheel rear tri m
cover, press fi rml y and evenl y outward on the back of
the swi tch.
(6) From the outsi de of the steeri ng wheel rear
tri m cover, remove the remote radi o swi tch from the
tri m cover mounti ng hol e.
INSTALLATION
(1) Posi ti on the remote radi o swi tch to the mount-
i ng hol e on the outsi de of the steeri ng wheel rear
tri m cover. Be certai n that the connector receptacl e i s
ori ented toward the bottom of the swi tch and poi nted
toward the center of the steeri ng wheel .
Fig. 16 Remote Radio Switches
1 - BLACK (LEFT) SWITCH
2 - WHITE (RIGHT) SWITCH
WJ AUDIO 8A - 21
(2) Press fi rml y and evenl y on the remote radi o
swi tch unti l each of the swi tch snap features i s ful l y
engaged i n the mounti ng hol e of the steeri ng wheel
rear tri m cover.
(3) Reconnect the steeri ng wheel wi re harness con-
nector to the connector receptacl e of the remote radi o
swi tch.
(4) I nstal l the speed control swi tch onto the steer-
i ng wheel . Refer to El ectri cal , Speed Control for the
procedures.
(5) I nstal l the dri ver si de ai rbag onto the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - I NSTALLATI ON) for the proce-
dures.
SPEAKER
DESCRIPTION
STANDARD
The standard equi pment speaker system i ncl udes
speakers i n si x l ocati ons. One 6.4 centi meter (2.50
i nch) di ameter tweeter i s i nstal l ed on each end of the
i nstrument panel top pad. One 15.2 by 22.9 centi me-
ter (6 by 9 i nch) ful l -range speaker i s l ocated i n each
front door. There i s al so one ful l -range 16.5 centi me-
ter (6.5 i nch) di ameter ful l -range speaker l ocated i n
each rear door.
PREMIUM
The opti onal premi um speaker system features si x
I nfi ni ty model speakers i n si x l ocati ons. Each of the
standard speakers i s repl aced wi th I nfi ni ty model
speakers. One 6.4 centi meter (2.50 i nch) di ameter
I nfi ni ty tweeter i s i nstal l ed on each end of the
i nstrument panel top pad. One 15.2 by 22.9 centi me-
ter (6 by 9 i nch) I nfi ni ty woofer i s l ocated i n each
front door. There i s al so one ful l -range 16.5 centi me-
ter (6.5 i nch) di ameter I nfi ni ty ful l -range speaker
l ocated i n each rear door. The premi um speaker sys-
tem al so i ncl udes an addi ti onal I nfi ni ty power ampl i -
fi er. The total avai l abl e power of the premi um
speaker system i s about 180 watts.
OPERATION
STANDARD
Each of the two tweeters and four ful l -range speak-
ers used i n the standard speaker system i s dri ven by
the ampl i fi er that i s i ntegral to the factory-i nstal l ed
radi o recei ver. For compl ete ci rcui t di agrams, refer to
the appropri ate wi ri ng i nformati on. The wi ri ng i nfor-
mati on i ncl udes wi ri ng di agrams, proper wi re and
connector repai r procedures, detai l s of wi re harness
PREMIUM
The si x I nfi ni ty speakers used i n the premi um
speaker system are al l dri ven by the radi o recei ver
through an I nfi ni ty power ampl i fi er. For compl ete ci r-
cui t di agrams, refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng
di agrams, proper wi re and connector repai r proce-
dures, detai l s of wi re harness routi ng and retenti on,
connector pi n-out i nformati on and l ocati on vi ews for
the vari ous wi re harness connectors, spl i ces and
grounds.
Fig. 17 Remote Radio Switches Remove/Install
1 - STEERING WHEEL
2 - SPEED CONTROL SWITCH
3 - SCREW
4 - DRIVER SIDE AIRBAG MODULE
5 - REMOTE RADIO SWITCH
6 - REAR TRIM COVER
8A - 22 AUDIO WJ
DIAGNOSIS AND TESTING - SPEAKER
Manual.
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.
Turn the radi o recei ver on. Adjust the bal ance and
fader control s to check the performance of each i ndi -
vi dual speaker. Note the speaker l ocati ons that are
not performi ng correctl y. Go to Step 2.
(2) Turn the radi o recei ver off. Turn the i gni ti on
swi tch to the Off posi ti on. Di sconnect and i sol ate the
battery negati ve cabl e. Remove the radi o recei ver
from the i nstrument panel . I f the vehi cl e i s equi pped
wi th the I nfi ni ty speaker package, al so di sconnect
the wi re harness connectors at the power ampl i fi er.
Check both the speaker feed (+) ci rcui t and return ()
ci rcui t cavi ti es for the i noperati ve speaker l ocati on(s)
at the radi o recei ver wi re harness connectors for con-
ti nui ty to ground. I n each case, there shoul d be no
conti nui ty. I f OK, go to Step 3. I f not OK, repai r the
shorted speaker feed (+) and/or return () ci rcui t(s) to
the speaker as requi red.
(3) I f the vehi cl e i s equi pped wi th the I nfi ni ty
speaker package, go to Step 6. I f the vehi cl e i s
equi pped wi th the standard speaker system, check
the resi stance between the speaker feed (+) ci rcui t
and return () ci rcui t cavi ti es of the radi o recei ver
wi re harness connectors for the i noperati ve speaker
l ocati on(s). The meter shoul d read between 2 and 3
ohms (speaker resi stance). I f OK, go to Step 4. I f not
OK, go to Step 5.
(4) I nstal l a known good radi o recei ver. Connect
the battery negati ve cabl e. Turn the i gni ti on swi tch
to the On posi ti on. Turn on the radi o recei ver and
test the speaker operati on. I f OK, repl ace the faul ty
radi o recei ver. I f not OK, turn the radi o recei ver off,
turn the i gni ti on swi tch to the Off posi ti on, di scon-
nect and i sol ate the battery negati ve cabl e, remove
the test radi o recei ver, and go to Step 5.
(5) Di sconnect the wi re harness connector at the
i noperati ve speaker. Check for conti nui ty between
the speaker feed (+) ci rcui t cavi ti es of the radi o
recei ver wi re harness connector and the speaker wi re
harness connector. Repeat the check between the
speaker return () ci rcui t cavi ti es of the radi o
recei ver wi re harness connector and the speaker wi re
harness connector. I n each case, there shoul d be con-
ti nui ty. I f OK, repl ace the faul ty speaker. I f not OK,
repai r the open speaker feed (+) and/or return () ci r-
cui t(s) as requi red.
(6) For each i noperati ve speaker l ocati on, check for
conti nui ty between the speaker feed (+) ci rcui t cavi -
ti es of the radi o recei ver wi re harness connectors and
the power ampl i fi er wi re harness connectors. Repeat
the check for each i noperati ve speaker l ocati on
between the speaker return () ci rcui t cavi ti es of the
radi o recei ver wi re harness connectors and the power
ampl i fi er wi re harness connectors. I n each case,
there shoul d be conti nui ty. I f OK, go to Step 7. I f not
OK, repai r the open speaker feed (+) and/or return
() ci rcui t(s) as requi red.
(7) Check for conti nui ty between the two ground
ci rcui t cavi ti es of the power ampl i fi er wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 8. I f not OK, repai r the open
ground ci rcui t(s) to ground as requi red.
(8) Check the fused B(+) fuse for the power ampl i -
fi er i n the juncti on bl ock. I f OK, go to Step 9. I f not
OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse.
(9) I nstal l the radi o recei ver. Connect the battery
negati ve cabl e. Check for battery vol tage at the fused
B(+) fuse for the power ampl i fi er i n the juncti on
bl ock. I f OK, go to Step 10. I f not OK, repai r the
open fused B(+) ci rcui t to the Power Di stri buti on
Center (PDC) fuse as requi red.
(10) Check for battery vol tage at the two fused
B(+) ci rcui t cavi ti es of the power ampl i fi er wi re har-
ness connector. I f OK, go to Step 11. I f not OK, repai r
the open fused B(+) ci rcui t(s) to the power ampl i fi er
fuse i n the juncti on bl ock as requi red.
Turn the radi o recei ver on. Check for battery vol tage
WJ AUDIO 8A - 23
SPEAKER (Continued)
at the enabl e si gnal to ampl i fi er ci rcui t cavi ty of the
power ampl i fi er wi re harness connector. I f OK, go to
Step 12. I f not OK, repai r the open enabl e si gnal to
ampl i fi er ci rcui t to the radi o recei ver as requi red.
(12) Turn the radi o recei ver off. Turn the i gni ti on
swi tch to the Off posi ti on. Di sconnect and i sol ate the
battery negati ve cabl e. For each i noperati ve speaker
l ocati on, check both the ampl i fi ed feed (+) ci rcui t and
the ampl i fi ed return () ci rcui t cavi ti es of the power
ampl i fi er wi re harness connectors for conti nui ty to
ground. I n each case there shoul d be no conti nui ty. I f
OK, go to Step 13. I f not OK, repai r the shorted
ampl i fi ed feed (+) and/or ampl i fi ed return () ci r-
cui t(s) to the speaker as requi red.
(13) For each i noperati ve speaker l ocati on, check
the resi stance between the ampl i fi ed feed (+) ci rcui t
and the ampl i fi ed return () ci rcui t cavi ti es of the
power ampl i fi er wi re harness connectors. The meter
shoul d read between 2 and 3 ohms (speaker resi s-
tance). I f OK, repl ace the faul ty power ampl i fi er. I f
not OK, go to Step 14.
(14) Di sconnect the speaker wi re harness connec-
tor at the i noperati ve speaker. Check for conti nui ty
between the ampl i fi ed feed (+) ci rcui t cavi ti es of the
speaker wi re harness connector and the power ampl i -
fi er wi re harness connector. Repeat the check
between the ampl i fi ed return () ci rcui t cavi ti es of
the speaker wi re harness connector and the power
ampl i fi er wi re harness connector. I n each case there
shoul d be conti nui ty. I f OK, repl ace the faul ty
speaker. I f not OK, repai r the open ampl i fi ed feed (+)
and/or ampl i fi ed return () ci rcui t(s) as requi red.
REMOVAL
REAR DOOR SPEAKER
REMOVAL
cabl e.
(2) Remove the tri m panel from the rear door.
(Refer to 23 - BODY/DOORS - REAR/TRI M PANEL -
(3) Remove the three screws that secure the
speaker to the rear door i nner panel (Fi g. 18).
(4) Di sconnect the rear door wi re harness connec-
tor from the speaker connector receptacl e.
(5) Remove the speaker from the rear door i nner
panel .
INSTRUMENT PANEL SPEAKER
REMOVAL
cabl e.
(2) Remove the top cover from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
I NSTRUMENT PANEL TOP COVER - REMOVAL).
connector from the speaker wi re harness connector
(Fi g. 19).
(4) Remove the two screws that secure the speaker
to the top of the i nstrument panel .
(5) Remove the speaker from the top of i nstrument
panel .
FRONT DOOR SPEAKER
REMOVAL
cabl e.
(2) Remove the tri m panel from the front door.
(Refer to 23 - BODY/DOOR - FRONT/TRI M PANEL -
(3) Remove the four screws that secure the
speaker to the front door i nner panel (Fi g. 20).
(4) Di sconnect the front door wi re harness connec-
tor from the speaker connector receptacl e.
(5) Remove the speaker from the front door i nner
panel .
Fig. 18 Rear Door Speaker Remove/Install
1 - PLASTIC NUT (3)
2 - REAR DOOR
3 - REAR DOOR SPEAKER
4 - REAR DOOR WIRE HARNESS
5 - SCREW (3)
8A - 24 AUDIO WJ
SPEAKER (Continued)
INSTALLATION
INSTALLATION - REAR DOOR SPEAKER
(1) Posi ti on the speaker to the rear door i nner
panel .
(2) Reconnect the rear door wi re harness connector
to the speaker connector receptacl e.
(3) Posi ti on the speaker onto the rear door i nner
panel .
(4) I nstal l and ti ghten the three screws that secure
the speaker to the rear door i nner panel . Ti ghten the
(5) I nstal l the tri m panel onto the rear door. (Refer
to 23 - BODY/DOORS - REAR/TRI M PANEL -
INSTALLATION - INSTRUMENT PANEL
SPEAKER
(1) Posi ti on the speaker onto the top of the i nstru-
ment panel .
(2) I nstal l and ti ghten the two screws that secure
the speaker to the top of the i nstrument panel .
Ti ghten the screws to 2.2 Nm (20 i n. l bs.).
connector to the speaker wi re harness connector.
(4) I nstal l the top cover onto the i nstrument panel .
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL TOP COVER - I NSTALLA-
TI ONl for the procedures.
INSTALLATION - FRONT DOOR SPEAKER
(1) Posi ti on the speaker to the front door i nner
panel .
(2) Reconnect the front door wi re harness connec-
tor to the speaker connector receptacl e.
(3) Posi ti on the speaker onto the front door i nner
door panel .
(4) I nstal l and ti ghten the four screws that secure
the speaker to the front door i nner panel . Ti ghten
the screws to 2.2 Nm (20 i n. l bs.).
(5) I nstal l the tri m panel onto the front door.
Fig. 19 Instrument Panel Speaker Remove/Install
1 - INSTRUMENT PANEL WIRE HARNESS
2 - INSTRUMENT PANEL SPEAKER
3 - SCREW (2)
Fig. 20 Front Door Speaker Remove/Install
1 - PLASTIC NUT (4)
2 - FRONT DOOR
3 - FRONT DOOR SPEAKER
4 - FRONT DOOR WIRE HARNESS
5 - SCREW (4)
WJ AUDIO 8A - 25
SPEAKER (Continued)
CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME WARNING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - CHIME
WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
CHIME WARNING SYSTEM
DESCRIPTION
The chi me warni ng system uses a si ngl e chi me
tone generator that i s i ntegral to the Body Control
Modul e (BCM) to provi de an audi bl e i ndi cati on of
vehi cl e condi ti ons that may requi re the attenti on of
the vehi cl e operator (Fi g. 1). The chi me warni ng sys-
tem i ncl udes the fol l owi ng major components:
Body Control Modul e
Door Ajar Swi tch
Headl amp Swi tch
I gni ti on Swi tch
Seat Bel t Swi tch
Hard wi red ci rcui try connects many of the chi me
warni ng system components to each other through
the el ectri cal system of the vehi cl e.
I f the BCM or the chi me tone generator are dam-
aged or faul ty, the BCM uni t must be repl aced.
OPERATION
The chi me warni ng system components operate on
battery vol tage recei ved through the I gni ti on-Off
Draw (I OD) fuse i n the Power Di stri buti on Center
(PDC) on a non-swi tched B(+) ci rcui t so that the sys-
tem may operate regardl ess of the i gni ti on swi tch
posi ti on.
Fig. 1 Chime Warning System
1 - IGNITION SWITCH
2 - SEAT BELT SWITCH
3 - DOOR AJAR SWITCH
4 - HEADLAMP SWITCH
5 - BODY CONTROL MODULE
WJ CHIME/BUZZER 8B - 1
The chi me warni ng system provi des an audi bl e
i ndi cati on to the vehi cl e operator under the fol l owi ng
condi ti ons:
Fasten Seat Belt Warning - The Body Control
Modul e (BCM) chi me tone generator wi l l generate
repeti ti ve chi mes to announce that an i nput from the
seat bel t swi tch i ndi cates the dri ver si de front seat
bel t i s not fastened. Unl ess the dri ver si de front seat
bel t i s fastened, the chi mes wi l l conti nue to sound for
a durati on of about si x seconds each ti me the i gni ti on
swi tch i s turned to the On posi ti on or unti l the dri ver
si de front seat bel t i s fastened.
Head/Park Lights-On Warning - The BCM
chi me tone generator wi l l generate repeti ti ve chi mes
at a fast rate to announce that a Programmabl e
Communi cati ons I nterface (PCI ) data bus dri ver door
ajar message, al ong wi th hard wi red i nputs from the
headl amp swi tch i ndi cate that the exteri or l amps are
turned On wi th the dri ver si de front door opened.
The chi me wi l l conti nue to sound unti l the exteri or
l amps are turned Off, the dri ver si de front door i s
cl osed, or the i gni ti on swi tch i s turned to the On
posi ti on.
Key-In-Ignition Warning - The BCM chi me
tone generator wi l l generate repeti ti ve chi mes at a
fast rate to announce that a PCI data bus dri ver door
ajar message recei ved from the Dri ver Door Modul e
(DDM), al ong wi th hard wi red i nputs from the key-
i n-i gni ti on warni ng swi tch i ndi cate that the key i s i n
the i gni ti on cyl i nder wi th the dri ver si de front door
opened and the i gni ti on swi tch i n the Off posi ti on.
The chi me wi l l conti nue to sound unti l the key i s
removed from the i gni ti on l ock cyl i nder, the dri ver
si de front door i s cl osed, or the i gni ti on swi tch i s
turned to the On posi ti on.
Overspeed Warning - The BCM chi me tone
generator wi l l generate repeti ti ve chi mes at a sl ow
rate to announce that a PCI data bus vehi cl e speed
message recei ved from the Powertrai n Control Mod-
ul e (PCM) i ndi cates that the vehi cl e speed i s above
120 ki l ometers-per-hour (75 mi l es-per-hour). The
chi mes wi l l conti nue to sound unti l the vehi cl e speed
i s bel ow 120 ki l ometers-per-hour (75 mi l es-per-hour).
Thi s feature i s onl y enabl ed on a BCM that has been
programmed wi th a Mi ddl e East Gul f Coast Country
(GCC) country code.
Tactile Beep Support - The BCM chi me tone
generator wi l l generate a si ngl e beep each ti me a
PCI data bus tacti l e beep request message i s recei ved
from the El ectroni c Vehi cl e I nformati on Center
(EVI C) or the Sentry Key I mmobi l i zer Modul e
(SKI M). Thi s beep provi des an audi bl e confi rmati on
that an EVI C button was compl etel y depressed, or
that the opti onal Sentry Key I mmobi l i zer System
(SKI S) i s i n the Customer Learn mode.
Warning Beep Support - The BCM chi me tone
generator wi l l generate a short seri es of beeps each
ti me a PCI data bus warni ng beep request message
i s recei ved from the EVI C or the El ectro-Mechani cal
I nstrument Cl uster (EMI C). These beeps provi de an
audi bl e al ert to the vehi cl e operator, of certai n vi sual
warni ng i ndi cati ons di spl ayed by the EVI C and/or
the EMI C.
The BCM provi des chi me servi ce for al l avai l abl e
features i n the chi me warni ng system. The BCM
rel i es upon message i nputs recei ved from other mod-
ul es over the PCI data bus network to provi de chi me
servi ce for al l of the remai ni ng chi me warni ng sys-
tem features.
The i nternal programmi ng of the BCM determi nes
the pri ori ty of each chi me tone request i nput that i s
recei ved, as wel l as the rate and durati on of each
chi me tone that i s to be generated.
8B - 2 CHIME/BUZZER WJ
CHIME WARNING SYSTEM (Continued)
DIAGNOSIS AND TESTING - CHIME WARNING
SYSTEM
Refer to the appropri ate wi ri ng i nformati on. Con-
venti onal di agnosti c methods may not prove concl u-
si ve i n the di agnosi s of the i nstrument cl uster or the
bus network. The most rel i abl e, effi ci ent and accu-
rate means to di agnose the BCM and the PCI data
bus network i nputs for the chi me warni ng system
requi res the use of a DRBI I I scan tool and the
appropri ate di agnosti c i nformati on.
INJURY.
CHIME WARNING SYSTEM DIAGNOSIS
NO SEAT BELT WARNING
CHIME WITH SEAT BELT
UNBUCKLED, BUT OTHER
CHIME FEATURES OK
1. Seat belt switch ground
circuit open.
1. Check for continuity between the ground circuit
of the wire harness connector for the seat belt
switch and a good ground. Repair the ground
circuit, if required.
2. Seat belt switch sense
circuit open.
2. Check for continuity between the seat belt
switch sense circuit of the wire harness connector
for the seat belt switch and the body wire harness
junction block connector. Repair the seat belt
switch sense circuit, if required.
3. Faulty seat belt switch. 3. Check for continuity between the ground circuit
and the seat belt switch sense circuit of the seat
belt switch pigtail wire connector. There should be
continuity with the seat belt unbuckled. Replace
the faulty seat belt, if required.
SEAT BELT WARNING
CHIME WITH SEAT BELT
BUCKLED
1. Seat belt switch sense
circuit shorted.
1. With the wire harness connector for the seat
belt switch and the body wire harness junction
block connector disconnected, there should be no
continuity between the seat belt switch sense
circuit and a good ground. Repair the seat belt
switch sense circuit, if required.
2. Faulty seat belt switch. 2. Check for continuity between the ground circuit
and the seat belt switch sense circuit of the seat
belt switch pigtail wire connector. There should be
no continuity with the seat belt buckled. Replace
the faulty seat belt, if required.
WJ CHIME/BUZZER 8B - 3
CHIME WARNING SYSTEM DIAGNOSIS
NO KEY-IN IGNITION OR
HEADLAMPS-ON WARNING
CHIME WITH DRIVER SIDE
FRONT DOOR OPEN
1. Faulty door ajar switch or
circuits.
1. Check that interior lights illuminate with driver
door open. If not OK, repair the interior lighting
system as required.
2. Faulty headlamp switch
(left multi-function switch) or
circuits.
2. Check for proper exterior lighting operation. If
not OK, repair the exterior lighting system as
required.
3. Key-in ignition switch
sense circuit open.
2. Check for continuity between the key-in ignition
switch sense circuit of the instrument panel wire
harness connector for the ignition switch and the
body wire harness connector for the junction
block. Repair the key-in ignition switch sense
4. Faulty ignition switch. 3. Check for continuity between the two terminals
in the ignition switch connector. There should be
continuity with a key in the ignition lock cylinder.
Replace the faulty ignition switch, if required.
CHIME SOUNDS WITH
DRIVER SIDE FRONT
DOOR OPEN
1. Key-in ignition switch
sense circuit shorted.
1. Disconnect the instrument panel wire harness
connector for the ignition switch and the body
wire harness connector for the junction block.
There should be no continuity between the key-in
ignition switch sense circuit of the instrument
panel wire harness connector for the ignition
switch and a good ground. Repair the key-in
ignition switch sense circuit, if required.
2. Faulty ignition switch. 2. Check for continuity between the two terminals
in the ignition switch connector. There should be
no continuity with the key removed from the
ignition lock cylinder. Replace the faulty ignition
switch, if required.
NO CHIMES AT ALL TIMES 1. Faulty Body Control
Module (BCM).
1. Use a DRBIII scan tool and refer to the
appropriate diagnostic information. Replace the
faulty BCM, if required
8B - 4 CHIME/BUZZER WJ
ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 1
ADJUSTABLE PEDALS MODULE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BODY CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMMUNICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONTROLLER ANTILOCK BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR . . . . . 7
OPERATION - DATA LINK CONNECTOR . . . . . . 7
DOOR MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - DOOR MODULE . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
MEMORY HEATED SEAT/MIRROR MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - HEATED SEAT
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION - PCM . . . . . . . . . . . . . . . . . . 12
MODES OF OPERATION . . . . . . . . . . . . . . . . 12
DESCRIPTION - 5 VOLT SUPPLIES . . . . . . . 14
DESCRIPTION - IGNITION CIRCUIT SENSE . 14
DESCRIPTION - POWER GROUNDS . . . . . . 15
DESCRIPTION - SENSOR RETURN . . . . . . . 15
OPERATION
OPERATION - PCM . . . . . . . . . . . . . . . . . . . . 15
OPERATION - 5 VOLT SUPPLIES . . . . . . . . . 16
OPERATION - IGNITION CIRCUIT SENSE . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STANDARD PROCEDURE
STANDARD PROCEDURE - TCM QUICK
LEARN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ELECTRONIC CONTROL
MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: Before replacing the PCM, be sure to check
the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM failures are caused by internal compo-
nent failures (i.e. relays and solenoids) and shorted
circuits (i.e. pull-ups, drivers, and switched cir-
cuits). These failures are difficult to detect when a
double fault has occurred and only one DTC has
been set.
When a PCM (JTEC) and the SKI M are repl aced
at the same ti me, perform the fol l owi ng steps i n
order:
(1) Program the new PCM (JTEC).
(2) Program the new SKI M.
(3) Repl ace al l i gni ti on keys and program them to
the new SKI M.
PROGRAMMING THE PCM (JTEC)
The SKI S Secret Key i s an I D code that i s uni que
to each SKI M. Thi s code i s programmed and stored
i n the SKI M, the PCM, and the i gni ti on key tran-
sponder chi p(s). When repl aci ng the PCM, i t i s nec-
essary to program the secret key i nto the new PCM
usi ng the DRBI I I scan tool . Perform the fol l owi ng
steps to program the secret key i nto the PCM.
WJ ELECTRONIC CONTROL MODULES 8E - 1
(1) Turn the i gni ti on swi tch to the On posi ti on
(transmi ssi on i n Park/Neutral ).
(2) Use the DRBI I I and sel ect THEFT ALARM,
SKI M, then MI SCELLANEOUS.
(3) Sel ect PCM REPLACED (GAS ENGI NE).
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
(5) Sel ect ENTER to update PCM VI N.
NOTE: If three attempts are made to enter secure
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition switch to
the ON position for one hour, then enter the correct
PIN. (Ensure all accessories are turned off. Also
monitor the battery state and connect a battery
charger if necessary).
(6) Press ENTER to transfer the secret key (the
SKI M wi l l send the secret key to the PCM).
(7) Press Page Back to get to the Sel ect System
menu and sel ect ENGI NE, MI SCELLANEOUS, and
SRI MEMORY CHECK.
(8) The DRBI I I wi l l ask, I s odometer readi ng
between XX and XX? Sel ect the YES or NO button
on the DRBI I I . I f NO i s sel ected, the DRBI I I wi l l
read, Enter Odometer Readi ng (From I .P. odome-
ter). Enter the odometer readi ng from the i nstru-
ment cl uster and press ENTER.
PROGRAMMING THE SKIM
(3) Sel ect PCM REPLACED (GAS ENGI NE).
(4) Program the vehi cl e four-di gi t PI N i nto SKI M.
(5) Sel ect COUNTRY CODE and enter the correct
country.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, it cannot be changed and the SKIM must be
replaced.
(6) Sel ect YES to update VI N (the SKI M wi l l l earn
the VI N from the PCM).
(7) Press ENTER to transfer the secret key (the
PCM wi l l send the secret key to the SKI M).
(8) Program i gni ti on keys to the SKI M.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle ignition keys will need to be
replaced and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
(3) Sel ect PROGRAM I GNI TI ON KEYS.
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
(5) Obtai n i gni ti on keys to be programmed from
the customer (8 keys maxi mum).
(6) Usi ng the DRBI I I , erase al l i gni ti on keys by
sel ecti ng MI SCELLANEOUS, and ERASE ALL CUR-
RENT I GN. KEYS.
(7) Program al l of the i gni ti on keys.
I f i gni ti on key programmi ng i s unsuccessful , the
DRBI I I wi l l di spl ay one of the fol l owi ng messages:
Programming Not Attempted - The DRBI I I
attempts to read the programmed key status and
there are no keys programmed i nto SKI M memory.
Programming Key Failed (Possible Used
Key FromWrong Vehicle) - SKI M i s unabl e to pro-
gram an i gni ti on key transponder due to one of the
fol l owi ng:
The i gni ti on key transponder i s faul ty.
The i gni ti on key transponder i s or has been
al ready programmed to another vehi cl e.
8 Keys Already Learned, Programming Not
Done - The SKI M transponder I D memory i s ful l .
Learned Key In Ignition - The I D for the i gni -
ti on key transponder currentl y i n the i gni ti on l ock
cyl i nder i s al ready programmed i n SKI M memory.
ADJ USTABLE PEDALS
MODULE
REMOVAL
AL).
(4) Remove the adjustabl e pedal motor for accessi -
bi l i ty. (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/PEDAL - REMOVAL).
(5) Remove the two mounti ng cl i ps from the mod-
ul e (Fi g. 1).
(6) Di sconnect the el ectri cal connector.
(7) Remove the adjustabl e pedal modul e.
8E - 2 ELECTRONIC CONTROL MODULES WJ
ELECTRONIC CONTROL MODULES (Continued)
INSTALLATION
(1) I nstal l the modul e on the mounti ng pi ns i n the
vehi cl e.
(2) Reconnect the el ectri cal connector.
(3) I nstal l the two mounti ng cl i ps for the modul e
(Fi g. 1).
(4) I nstal l the adjustabl e pedal motor. (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/PEDAL -
I NSTALLATI ON).
TI ON).
I NSTALLATI ON).
BODY CONTROL MODULE
DESCRIPTION
A Body Control Modul e (BCM) i s conceal ed bel ow
the dri ver si de end of the i nstrument panel (Fi g. 2).
The BCM uti l i zes i ntegrated ci rcui try and i nforma-
ti on carri ed on the Programmabl e Communi cati ons
I nterface (PCI ) data bus network al ong wi th many
hard wi red i nputs to moni tor many sensor and
swi tch i nputs throughout the vehi cl e. I n response to
those i nputs, the i nternal ci rcui try and programmi ng
of the BCM al l ow i t to control and i ntegrate many
el ectroni c functi ons and features of the vehi cl e
through both hard wi red outputs and the transmi s-
si on of el ectroni c message outputs to other el ectroni c
modul es i n the vehi cl e over the PCI data bus. The
el ectroni c functi ons and features that the BCM sup-
ports or control s i ncl ude the fol l owi ng:
The BCM for thi s model i s servi ced onl y as a com-
pl ete uni t. Many of the el ectroni c features i n the
vehi cl e control l ed or supported by the BCM are pro-
grammabl e usi ng ei ther the El ectroni c Vehi cl e I nfor-
mati on Center (EVI C) user i nterface, or the DRBI I I
scan tool . I n addi ti on, the BCM software i s Fl ash
compati bl e, whi ch means i t can be reprogrammed
usi ng Fl ash reprogrammi ng procedures. A BCM can
onl y be repai red by or repl aced through an autho-
ri zed el ectroni c warranty repai r stati on. Refer to the
l atest versi on of the Warranty Pol i ci es and Proce-
dures manual for a current l i sti ng of authori zed el ec-
troni c repai r stati ons.
OPERATION
The Body Control Modul e (BCM) i s desi gned to
control and i ntegrate many of the el ectroni c features
and functi ons of the vehi cl e. The mi croprocessor-
based BCM hardware and software moni tors many
hard wi red swi tch and sensor i nputs as wel l as those
resources i t shares wi th other el ectroni c modul es i n
the vehi cl e through i ts communi cati on over the PCI
data bus network. The i nternal programmi ng of the
BCM mi croprocessor al l ows the BCM to determi ne
the tasks i t needs to perform and thei r pri ori ti es. The
Fig. 1 ADJUSTABLE PEDALS MODULE
2 - MODULE MOUNTING BRACKET
3 - BRAKE BOOSTER
4 - ADJUSTABLE PEDALS MOUNTING BRACKET
5 - ADJUSTABLE PEDALS CONTROL MODULE
6 - HOLD DOWN CLIPS
Fig. 2 Body Control Module
1 - JUNCTION BLOCK
2 - SCREWS (4)
4 - FUSE COVER LOCATOR CHANNELS
5 - FUSE COVER MOUNTING SLOTS
6 - INSTRUMENT PANEL WIRE HARNESS CONNECTORS
ADJ USTABLE PEDALS MODULE (Continued)
BCM programmi ng then performs those tasks and
provi des features through both PCI data bus commu-
ni cati on wi th other el ectroni c modul es and hard
wi red outputs to a number of rel ays. These rel ays
provi de the BCM wi th the abi l i ty to control numer-
ous hi gh current accessory systems i n the vehi cl e.
The BCM ci rcui try operates on battery current
recei ved through fuses i n the Juncti on Bl ock (JB) on a
non-swi tched fused B(+) ci rcui t, a fused i gni ti on swi tch
output (start-run) ci rcui t, and a fused i gni ti on swi tch
output (run-accessory) ci rcui t. Thi s arrangement al l ows
the BCM to provi de some features regardl ess of the
i gni ti on swi tch posi ti on. The BCM ci rcui try i s grounded
through the chassi s beneath the center consol e.
The BCM moni tors i ts own i nternal ci rcui try as
wel l as many of i ts i nput and output ci rcui ts, and
wi l l store a Di agnosti c Troubl e Code (DTC) i n el ec-
troni c memory for any fai l ure i t detects. These DTCs
can be retri eved and di agnosed usi ng a DRBI I I scan
tool . Refer to the appropri ate di agnosti c i nformati on.
HARD WIRED INPUTS
The hard wi red i nputs to the BCM i ncl ude the fol -
l owi ng:
A/C swi tch si gnal
Ambi ent temperature sensor si gnal
Body control modul e fl ash enabl e
Cool ant l evel swi tch sense
Door ajar swi tch sense (two ci rcui ts - one l eft
rear, and one ri ght rear)
Dri ver seat heater swi tch mux
Fog l amp swi tch sense
Fused B(+)
Fused i gni ti on swi tch output (run-acc)
Fused i gni ti on swi tch output (st-run)
Ground (fi ve ci rcui ts - two Z1, and three Z2)
Hazard swi tch sense
Headl amp swi tch mux
Hi gh beam swi tch sense
Hood ajar swi tch sense (export)
Key-i n i gni ti on swi tch sense
Li ftgate ajar swi tch sense
Li ftgate courtesy di sabl e
Li ftgate fl i p-up ajar swi tch sense
Panel l amps di mmer si gnal
Park l amp rel ay output
Passenger seat heater swi tch mux
PCI bus
Radi o control mux
Rear wi ndow defogger swi tch sense
Seat bel t swi tch sense
Ul tral i ght sensor si gnal
Washer fl ui d swi tch sense
Washer pump swi tch sense
Wi ndshi el d wi per swi tch mux
Wi per park swi tch sense
MESSAGING
The BCM uses the fol l owi ng messages recei ved
from other el ectroni c modul es over the PCI data bus:
Accessory Del ay Control (DDM/PDM)
Battery Temperature (PCM)
Chi me Request (EMI C, EVI C, SKI M)
Cyl i nder Lock Swi tch Status (DDM)
Door Ajar Status/Front Doors (DDM/PDM)
Door Lock Status (DDM/PDM)
Engi ne Model (PCM)
Engi ne RPM (PCM)
Engi ne Temperature (PCM)
Engl i sh/Metri c Defaul t (EMI C)
Fuel Tank Level (PCM)
Fuel Used/I njector Pul ses (PCM)
Pani c Control (PDM)
Programmabl e Features Preferences/Audi bl e &
Opti cal Chi rps/Headl amp Del ay (EVI C)
RKE Status (PDM)
Vehi cl e I denti fi cati on Number (PCM)
Vehi cl e Speed (PCM)
The BCM provi des the fol l owi ng messages to other
el ectroni c modul es over the PCI data bus:
A/C Swi tch Status (PCM)
Ambi ent Temperature Data (AZC/EVI C/PCM)
Average/I nstantaneous Fuel Economy (EVI C)
Country Code (EMI C)
Courtesy Lamp Status (DDM/PDM)
Di stance To Empty (EVI C)
El apsed I gni ti on On Ti mer (EVI C)
Engl i sh/Metri c Status (EMI C)
Front & Rear Door Ajar Status (EVI C)
Front & Rear Fog Lamp Status (EMI C)
Heated Seat Swi tch Status (HSM/MHSM)
Hi gh Beam Status (EMI C)
I gni ti on Off Ti mer (EVI C)
I gni ti on Swi tch Posi ti on (DDM/PDM)
Key-I n I gni ti on Status (DDM/PDM)
Low Beam Status (EMI C)
Panel Lamp Status (AZC/EMI C/Radi o)
Rear Wi ndow Defogger Rel ay Status (DDM/
PDM)
Remote Radi o Swi tch Status (Radi o)
Seatbel t Status (EMI C/MHSM/MSM)
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE
The hard wi red i nputs to and outputs from the
Body Control Modul e (BCM) may be di agnosed and
tested usi ng conventi onal di agnosti c tool s and proce-
dures. Refer to the appropri ate wi ri ng i nformati on.
Conventi onal di agnosti c methods may not prove
concl usi ve i n the di agnosi s of the BCM. I n order to
obtai n concl usi ve testi ng of the BCM, the Program-
mabl e Communi cati ons I nterface (PCI ) data bus net-
work and al l of the el ectroni c modul es that provi de
BODY CONTROL MODULE (Continued)
i nputs to or recei ve outputs from the BCM must al so
be checked. The most rel i abl e, effi ci ent, and accurate
means to di agnose the BCM, the PCI data bus net-
work, and the el ectroni c modul es that provi de i nputs
to or recei ve outputs from the BCM requi res the use
of a DRBI I I scan tool and the appropri ate di agnosti c
i nformati on. The DRBI I I scan tool can provi de con-
fi rmati on that the PCI data bus network i s func-
ti onal , that al l of the modul es are sendi ng and
recei vi ng the proper messages over the PCI data bus,
and that the BCM i s recei vi ng the proper hard wi red
i nputs and respondi ng wi th the proper hard wi red
outputs needed to perform i ts many functi ons.
INJURY.
REMOVAL
INJURY.
cabl e.
(2) Remove the i nstrument panel fuse cover.(Refer
to 8 - ELECTRI CAL/POWER DI STRI BUTI ON/FUSE
COVER - REMOVAL).
(3) Access and di sconnect the i nstrument panel
wi re harness connectors from the BCM (Fi g. 3).
(4) Remove the mounti ng screws (Torx T-20) that
secure the BCM to the JB.
(5) Pul l the BCM strai ght out towards the dash
panel far enough to di sconnect the i ntegral BCM to
JB connector.
(6) Remove the BCM.
INSTALLATION
INJURY.
(1) Posi ti on the Body Control Modul e (BCM) to i ts
mounti ng l ocati on (Fi g. 3).
(2) Al i gn the termi nal pi ns of the BCM connector
wi th the connector on the JB.
(3) Engage the BCM i ntegral connector i nto the
JB.
(4) I nstal l the four screws. Ti ghten the screws to
2.2 Nm (20 i n. l bs.).
Fig. 3 Body Control Module Remove/Install
1 - JUNCTION BLOCK
2 - SCREWS (4)
(5) Connect the two i nstrument panel wi re harness
connectors to the BCM.
(6) Rei nstal l the i nstrument panel fuse cover to
the bottom of the BCM and JB uni t. (Refer to 8 -
ELECTRI CAL/POWER DI STRI BUTI ON/FUSE
COVER - I NSTALLATI ON).
(7) Connect the battery negati ve cabl e.
COMMUNICATION
DESCRIPTION
The Programmabl e Communi cati on I nterface (PCI )
data bus system i s a si ngl e wi re mul ti pl ex system
used for vehi cl e communi cati ons. Mul ti pl exi ng i s a
system that enabl es the transmi ssi on of several mes-
sages over a si ngl e channel or ci rcui t.
Many of the control modul es i n a vehi cl e requi re
i nformati on from the same sensi ng devi ce. Mul ti pl ex-
i ng reduces wi re harness compl exi ty, sensor current
l oads and control l er hardware because each sensi ng
devi ce i s connected to onl y one control l er, whi ch
reads and di stri butes the sensor i nformati on to the
other control l ers over the data bus. Al so, because
each control l er on the data bus can access the con-
trol l er sensor i nputs to every other control l er on the
data bus, more functi on and feature capabi l i ti es are
possi bl e.
A mul ti pl ex system al l ows the i nformati on fl owi ng
between control l ers to be moni tored usi ng a di agnos-
ti c scan tool . Thi s system al l ows a control modul e to
broadcast message data out onto the bus where al l
other control modul es can read the messages that are
bei ng sent. When a modul e reads a message on the
data bus that i t requi res, i t rel ays that message to
i ts mi croprocessor. Each modul e i gnores the mes-
sages on the data bus that i t dosent recogni ze.
OPERATION
Data exchange between modul es i s achi eved by
seri al transmi ssi on of encoded data over a si ngl e wi re
broadcast network. The PCI data bus messages are
carri ed over the bus i n the form of Vari abl e Pul se
Wi dth Modul ated (VPWM) si gnal s. The PCI data bus
speed i s an average 10.4 Ki l o-bi ts per second (Kbps).
The vol tage network used to transmi t messages
requi res bi asi ng and termi nati on. Each modul e on
the PCI data bus system provi des i ts own bi asi ng
and termi nati on. Each modul e (al so referred to as a
node) termi nates the bus through a termi nati ng
resi stor and a termi nati ng capaci tor. The Powertrai n
Control Modul e (PCM) i s the onl y domi nant node for
the PCI data bus system.
The PCI bus uses l ow and hi gh vol tage l evel s to
generate si gnal s. The vol tage on the buss vari es
between zero and seven and one-hal f vol ts. The l ow
and hi gh vol tage l evel s are generated by means of
vari abl e-pul se wi dth modul ati on to form si gnal s of
varyi ng l ength.
When a modul e i s transmi tti ng on the bus, i t i s
readi ng the bus at the same ti me to ensure message
i ntegri ty.
Each modul e i s capabl e of transmi tti ng and recei v-
i ng data si mul taneousl y.
The PCI data bus can be moni tored usi ng the
DRBI I I scan tool . I t i s possi bl e for the bus to pass
al l DRBI I I tests and sti l l be faul ty i f the vol tage
parameters are al l wi thi n the speci fi ed range and
fal se messages are bei ng sent.
CONTROLLER ANTILOCK
BRAKE
DESCRIPTION
The Control er Anti l ock Brake (CAB) i s mounted to
the Hydraul i c Control Uni t (HCU) and operates the
ABS system (Fi g. 4).
OPERATION
The CAB vol tage i s suppl i ed by the i gni ti on swi tch
i n the RUN posi ti on. The CAB contai ns dual mi cro-
processors. A l ogi c bl ock i n each mi croprocessor
recei ves i denti cal sensor si gnal s. These si gnal s are
processed and compared si mul taneousl y. The CAB
contai ns a sel f check program that i l l umi nates the
ABS warni ng l i ght when a system faul t i s detected.
Faul ts are stored i n a di agnosti c program memory
and are accessi bl e wi th the DRBI I I scan tool . ABS
faul ts remai n i n memory unti l cl eared, or unti l after
the vehi cl e i s started approxi matel y 50 ti mes. Stored
Fig. 4 Controller Antilock Brakes
1 - HCU
2 - MOTOR
3 - CAB
faul ts are not erased i f the battery i s di sconnected.
(Fi g. 4)
REMOVAL
(1) Remove negati ve battery cabl e from the bat-
tery.
(2) Remove ai r cl eaner housi ng,(Refer to 9 -
HOUSI NG - REMOVAL) OR (Refer to 9 - ENGI NE/
AI R I NTAKE SYSTEM/AI R CLEANER HOUSI NG -
REMOVAL).
(3) Rel ease CAB harness connector and remove
connector (Fi g. 5).
(4) Remove pump motor connector.
(5) Remove CAB mounti ng bol ts (Fi g. 6) and
remove the CAB from the HCU.
INSTALLATION
(1) I nstal l the CAB onto the HCU and ti ghten
mounti ng bol ts to 1.8 Nm (16 i n. l bs.).
(2) I nstal l pump motor connector.
(3) I nstal l CAB harness connector and push down
connector rel ease.
(4) I nstal l ai r cl eaner housi ng,(Refer to 9 -
HOUSI NG - I NSTALLATI ON) OR (Refer to 9 -
(5) I nstal l negati ve battery cabl e to the battery.
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR
The data l i nk connector (DLC) i s l ocated at the
l ower edge of the i nstrument panel near the steeri ng
col umn.
OPERATION - DATA LINK CONNECTOR
The 16way DLC l i nks the DRBI I I scan tool or
the Mopar Di agnosti c System (MDS) wi th the Power-
trai n Control Modul e (PCM).
DOOR MODULE
DESCRIPTION
A door modul e i s conceal ed behi nd the tri m panel
of each front door (Fi g. 7).The modul e on the dri ver
si de i s referred to as the Dri ver Door Modul e (DDM),
whi l e the modul e on the passenger si de i s the Pas-
senger Door Modul e (PDM). Each door modul e
houses both the front power l ock and power wi ndow
swi tches. I n addi ti on to the power wi ndow and power
l ock swi tches for i ts own door, the DDM al so houses
i ndi vi dual swi tches for each passenger door power
wi ndow, a power wi ndow l ockout swi tch, the power
mi rror swi tch, and the power fol daway mi rror swi tch
for export vehi cl es.
The DDM and PDM each uti l i ze i ntegrated ci r-
cui try and i nformati on carri ed on the Programmabl e
Communi cati ons I nterface (PCI ) data bus network
al ong wi th many hard wi red i nputs to moni tor many
sensor and swi tch i nputs throughout the vehi cl e. The
PDM al so recei ves i nputs through an i ntegral Radi o
Fig. 5 CAB Connector Release
1 - CONNECTOR RELEASE
2 - CAB
Fig. 6 CAB Mounting Bolts
1 - MOUNTING BOLTS
CONTROLLER ANTILOCK BRAKE (Continued)
Frequency (RF) Remote Keyl ess Entry (RKE)
recei ver. The DDM and PDM control and i ntegrate
many functi ons and features of the vehi cl e through
both hard wi red outputs and messages over the PCI
data bus. The functi ons and features that the door
modul es support or control i ncl ude the fol l owi ng:
Automatic Door Lock - The two door modul es
provi de an automati c door l ock feature whi ch l ocks
the doors when the vehi cl e i s movi ng. Thi s i s a pro-
grammabl e feature.
Automatic Door Unlock On Exit - The two
door modul es provi de an automati c door unl ock on
exi t feature. Thi s feature wi l l unl ock al l the doors i f
they were l ocked vi a the automati c door l ock feature
after the vehi cl e has stopped movi ng and the dri ver
door i s opened. Thi s i s a programmabl e feature vi a
the EVI C.
Customer Programmable Features - Each
door modul e provi des support for certai n customer
programmabl e features that are moni tored on the
PCI bus.
Cylinder Lock Switch Status - The DDM
moni tors and transmi ts the status of the cyl i nder
l ock swi tch on the dri ver si de front door l ock cyl i n-
der.
Door Courtesy Lamp Control - Each door
modul e provi des control of i ts own opti onal front
door-mounted courtesy l amp.
Door Lock Inhibit - Each door modul e pro-
vi des a door l ock i nhi bi t feature whi ch prevents the
doors from bei ng l ocked wi th a power l ock swi tch i f
the key was l eft i n the i gni ti on and a front door i s
open.
Express-Down Window - The DDM provi des
an express-down feature for the dri ver si de front door
wi ndow onl y.
Extended Window Operation - Both door
modul es provi de an extended power wi ndow opera-
ti on feature that al l ows operati on of the power wi n-
dows for 45 seconds fol l owi ng i gni ti on Off or unti l a
front door i s opened.
Front Door Ajar Switch Status - Each door
modul e moni tors and transmi ts the status of i ts own
front door ajar swi tch.
Heated Mirrors - Each door modul e provi des
control for i ts own opti onal heated outsi de rear vi ew
mi rror.
Illuminated Entry - Each door modul e sup-
ports an i l l umi nated entry feature through i ts own
opti onal front door-mounted courtesy l amp.
Memory Mirrors - Each door modul e provi des
control for i ts own opti onal memory outsi de rear vi ew
mi rror.
Memory Switch - The DDM moni tors the sta-
tus of the opti onal memory swi tch and control s the
i l l umi nati on of the memory swi tch set Li ght Emi t-
ti ng Di ode (LED) i ndi cator and i l l umi nati on l amps.
Memory System- The DDM transmi ts memory
set and recal l messages based upon i nputs from the
memory swi tch. I f the opti onal RKE l i nked to mem-
ory feature i s enabl ed, the DDM wi l l al so transmi t
memory recal l messages based upon memory
requests recei ved from the Remote Keyl ess Entry
(RKE) system i n the PDM. Certai n memory system
features are programmabl e.
Power Foldaway Mirrors - Export Only -
Each door modul e provi des support for the opti onal
power fol daway outsi de mi rrors. The DDM al so
houses the control swi tch for thi s system.
Power Lock Control - The DDM provi des con-
trol for the dri ver si de front door power l ock motor,
whi l e the PDM provi des control for the power l ock
motors of the three remai ni ng doors and the l i ftgate.
Power Lock Switch Status - Each door mod-
ul e moni tors and transmi ts the status of i ts own i nte-
gral power l ock swi tch.
Power Window Control - Each door modul e
provi des control for both the front and rear door
power wi ndow motors and the rear door power wi n-
dow swi tches on the same si de of the vehi cl e.
Power Window Switch Status - The DDM
moni tors and transmi ts the status of i ts i ntegral pas-
senger si de front and rear power wi ndow swi tches.
Remote Keyless Entry - The PDM moni tors
and transmi ts the status of the Remote Keyl ess
Entry (RKE) system and provi des support for the
RKE Lock (wi th the opti onal horn chi rp and park
Fig. 7 Door Module
1 - FRONT DOOR TRIM PANEL
2 - SCREW (5)
3 - DOOR MODULE
DOOR MODULE (Continued)
l amp fl ash features), Unl ock wi th the opti onal RKE
unl ock, and Pani c Mode functi ons. The opti onal RKE
features are programmabl e.
Switch Illumination - Each door modul e pro-
vi des control of the power wi ndow and power l ock
swi tch i l l umi nati on for the front and rear doors on
the same si de of the vehi cl e. The DDM provi des con-
trol of the power mi rror swi tch i l l umi nati on.
Window Lockout - The DDM moni tors and
transmi ts the status of i ts i ntegral wi ndow l ockout
swi tch to provi de the power wi ndow l ockout feature
and coordi nate power wi ndow swi tch knob i l l umi na-
ti on.
The door modul es are servi ced onl y as compl ete
uni ts. Many of the features i n the vehi cl e control l ed
or supported by the door modul es are programmabl e
usi ng ei ther the El ectroni c Vehi cl e I nformati on Cen-
ter (EVI C) user i nterface, or the DRBI I I scan tool . I f
a door modul e i s damaged or faul ty, the enti re door
modul e uni t must be repl aced.
OPERATION
The mi croprocessor-based DDM and PDM hard-
ware and software moni tors i ntegral and hard wi red
external swi tch i nputs as wel l as those resources i t
shares wi th other el ectroni c modul es i n the vehi cl e
through i ts communi cati on over the PCI data bus
network. The i nternal programmi ng and al l of these
i nputs al l ow the DDM or PDM mi croprocessor to
determi ne the tasks i t needs to perform and thei r
pri ori ti es, as wel l as both the standard and opti onal
features that i t shoul d provi de.
The DDM and PDM are powered by a fused bat-
tery ci rcui t so that they can operate regardl ess of the
i gni ti on swi tch posi ti on. The DDM and PDM ci r-
cui try i s grounded to the chassi s beneath the front
seat.
The DDM and PDM can be di agnosed usi ng a
DRBI I I scan tool . Refer to the appropri ate di agnos-
ti c i nformati on.
HARD WIRED INPUTS
The hard wi red i nputs to the door modul es i ncl ude
the fol l owi ng:
Door ajar swi tch sense
Dri ver door key cyl i nder swi tch sense (DDM)
Fused B(+)
Ground
Memory swi tch mux (DDM)
Mi rror hori zontal posi ti on si gnal
Mi rror verti cal posi ti on si gnal
PCI bus
HARD WIRED OUTPUTS
The hard wi red outputs of the door modul es
i ncl ude the fol l owi ng:
Courtesy l amp dri ver
Courtesy l amp ground
Di agnosti c out (DDM)
Door/l i ftgate l ock dri ver
Door/l i ftgate unl ock dri ver
Door swi tch i l l umi nati on (rear power wi ndow)
Front wi ndow dri ver (down)
Front wi ndow dri ver (up)
Memory set i ndi cator dri ver (DDM)
Memory swi tch return (DDM)
Mi rror common dri ver
Mi rror heater ground
Mi rror heater 12V suppl y
Rear wi ndow dri ver (down)
Rear wi ndow dri ver (up)
Mi rror hori zontal dri ver
Mi rror sensor ground
Mi rror verti cal dri ver
PCI bus
Swi tch i l l umi nati on dri ver (memory - DDM)
MESSAGING
The door modul es use the fol l owi ng messages
recei ved from other el ectroni c modul es over the PCI
data bus:
Accessory Del ay Control (PDM)
Courtesy Lamp Status (BCM)
Door Ajar Status/Rear Doors (BCM)
I gni ti on Swi tch Posi ti on (BCM)
Key-I n I gni ti on Status (BCM)
Programmabl e Features Preferences/Auto Lock/
Auto Unl ock/RKE Unl ock Sequence/RKE Li nk to
Memory (EVI C)
Memory Recal l (DDM)
Rear Wi ndow Defogger Rel ay Status (BCM)
Vehi cl e Speed (PCM)
The door modul es provi de the fol l owi ng messages
to other el ectroni c modul es over the PCI data bus:
Cyl i nder Lock Swi tch Status (BCM)
Door Ajar Status/Front Doors (BCM/DDM/PDM)
Memory Recal l (PDM/MHSM/MSM/Radi o)
Memory Set Swi tch Status (PDM/MHSM/MSM/
Radi o)
Pani c Control (BCM)
Power Wi ndow Swi tch Status (PDM)
RKE Status (BCM/DDM)
Wi ndow Lockout Swi tch Status (PDM)
DIAGNOSIS AND TESTING - DOOR MODULE
INJURY.
The hard wi red i nputs to and outputs from the
Dri ver Door Modul e (DDM) or the Passenger Door
Modul e (PDM) may be di agnosed and tested usi ng
conventi onal di agnosti c tool s and procedures. I t i s
suggested that the proper operati on of the i nopera-
ti ve power wi ndow motor, power door l ock motor,
power l i ftgate l ock motor, power mi rror motors, or
heated mi rror gri d be confi rmed usi ng jumper wi res
to bypass the door modul e. I f the i noperati ve compo-
nent operates when the door modul e i s bypassed,
check the ci rcui ts between the component and the
door modul e, as wel l as the fused B(+) and ground
ci rcui ts of the door modul e for shorts or opens.
These conventi onal di agnosti c methods may not
prove concl usi ve i n the di agnosi s of the DDM or the
PDM. I n order to obtai n concl usi ve testi ng of these
modul es, the Programmabl e Communi cati ons I nter-
face (PCI ) data bus network and al l of the modul es
that provi de i nputs to or recei ve outputs from the
door modul es must al so be checked. The most rel i -
abl e, effi ci ent, and accurate means to di agnose the
DDM, the PDM, the PCI data bus network, and the
modul es that provi de i nputs to or recei ve outputs
from the door modul es requi res the use of a DRBI I I
scan tool and the appropri ate di agnosti c i nformati on.
REMOVAL
cabl e.
(2) Remove the tri m panel from the front door.
REMOVAL).
(3) Remove the door modul e from the back of the
front door tri m panel (Fi g. 8).
(4) Remove the door modul e from the front door
tri m panel .
INSTALLATION
(1) Posi ti on the door modul e onto the front door
tri m panel .
(2) I nstal l the door modul e to the back of the front
door tri m panel (Fi g. 8). Ti ghten the screws to 2.2
Nm (20 i n. l bs.).
(3) Rei nstal l the tri m panel onto the front door.
I NSTALLATI ON).
MEMORY HEATED SEAT/
MIRROR MODULE
DESCRIPTION
There are two di fferent modul es that can be used
i n the opti onal heated seat system. The Heated Seat
Modul e (HSM) i s used on vehi cl es that are not
equi pped wi th the opti onal Memory System. The
Memory Heated Seat Modul e (MHSM) i s used on
vehi cl es that are equi pped wi th the opti onal Memory
System and the opti onal heated seat system.Refer to
Memory System i n Power Seat Systems for more
i nformati on on the memory system opti on.
The modul e i s mounted on a bracket that i s l ocated
between the power seat track and the seat cushi on
frame (Fi g. 9). The HSM or MHSM i s used to control
the heated seat system functi ons for both front seats.
The HSM or MHSM contai ns a central processi ng
uni t that communi cates wi th other modul es on the
Fig. 8 Door Module Remove/Install
1 - FRONT DOOR TRIM PANEL
2 - SCREW (5)
3 - DOOR MODULE
bus network.
For di agnosi s of the HSM, MHSM or the PCI data
bus, a DRBI I I scan tool and the proper Di agnosti c
Procedures manual are recommended. The HSM or
MHSM cannot be repai red and, i f faul ty or damaged,
i t must be repl aced.
OPERATION
The MSM recei ves hard wi red i nputs from the
power seat swi tch and the potenti ometers on each of
the dri ver si de power seat motors. The MSM recei ves
messages over the PCI data bus from the Dri ver
Door Modul e (DDM) (memory swi tch status), the
Powertrai n Control Modul e (PCM) (vehi cl e speed sta-
tus), and the Body Control Modul e (seat bel t swi tch
status).The MSM wi l l prevent the seat memory recal l
functi on from bei ng i ni ti ated i f the dri ver si de seat
bel t i s buckl ed, i f the transmi ssi on gear sel ector l ever
i s not i n the Park or Neutral posi ti ons, or i f the vehi -
cl e i s movi ng.
MODULE
Vi sual l y i nspect the rel ated wi ri ng harness connec-
tors. Look for broken, bent, pushed out, or corroded
termi nal s. I f any of the above condi ti ons are present,
repai r as necessary. I f not, use a DRBI I I scan tool
and the proper Di agnosti c Procedures Manual to test
the HSM or MHSM. For compl ete ci rcui t di agrams,
refer to Power Seat Premium I/III i n Wi ri ng Di a-
grams.
REMOVAL
cabl e.
(2) Remove the dri ver si de front bucket seat from
the power seat track uni t. Refer to Bucket Seat
Track Adjuster i n Body for the procedure.
(3) Li ft the heated seat modul e off of the power
seat track and di sconnect the power seat wi re har-
ness connectors (Fi g. 10).
(4) Remove the modul e from the bracket.
Fig. 9 Heated Seat Module Remove/Install
1 - NUT (4)
2 - SEAT CUSHION FRAME
3 - POWER SEAT TRACK
4 - STUD (4)
5 - MODULE
6 - BRACKET
Fig. 10 Heated Seat Module Remove/Install
1 - NUT (4)
3 - POWER SEAT TRACK
4 - STUD (4)
5 - MODULE
6 - BRACKET
MEMORY HEATED SEAT/MIRROR MODULE (Continued)
INSTALLATION
(1) I nstal l the MHSM,HSM i nto the bracket.
(2) Posi ti on the heated seat modul e and mounti ng
bracket onto the power seat track.
(3) Reconnect the power seat wi ri ng harness con-
nectors to the heated seat modul e.
(4) I nstal l the dri ver si de front bucket seat onto
the power seat track uni t (Refer to 23 - BODY/
SEATS/SEAT TRACK ADJUSTER - I NSTALLA-
TI ON).
NOTE: If the vehicle is equipped with the optional
Memory System, following installation, it will be
necessary to initialize the Memory Heated Seat
Module (MHSM). In order to function properly, the
MHSM must learn the sensor values of each of
the power seat motor position transducers in each
of the adjuster hard stop positions. This is done by
performing the Reset Guard Band procedure
using a DRBIII scan tool and the proper Diagnostic
Procedures manual.
WARNING: THE RESET GUARD BAND PROCE-
DURE WILL CAUSE THE DRIVER SIDE FRONT
SEAT TO AUTOMATICALLY ADJUST TO EACH OF
ITS TRAVEL LIMITS. BE CERTAIN THAT NO ONE IS
SEATED IN THE VEHICLE AND THAT THERE IS
NOTHING IN THE VEHICLE THAT WILL OBSTRUCT
SEAT MOVEMENT. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN PERSONAL INJURIES
AND/OR VEHICLE DAMAGE.
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION - PCM
The Powertrai n Control Modul e (PCM) i s l ocated
i n the engi ne compartment (Fi g. 11). The PCM i s
referred to as JTEC.
MODES OF OPERATION
As i nput si gnal s to the Powertrai n Control Modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the PCM recei ves i nput
si gnal s and responds onl y accordi ng to preset PCM
programmi ng. I nput from the oxygen (O2S) sensors
i s not moni tored duri ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
I gni ti on swi tch ON
Engi ne start-up (crank)
Engi ne warm-up
I dl e
Crui se
Accel erati on
Decel erati on
Wi de open throttl e (WOT)
I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
Fig. 11 PCM Location
1 - PCM
2 - COOLANT TANK
MEMORY HEATED SEAT/MIRROR MODULE (Continued)
The PCM pre-posi ti ons the i dl e ai r control (I AC)
motor.
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
Throttl e posi ti on sensor (TPS) i s moni tored.
The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
The O2S sensor heater el ement i s energi zed vi a
the O2S rel ays. The O2S sensor i nput i s not used by
the PCM to cal i brate ai r-fuel rati o duri ng thi s mode
of operati on.
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The PCM recei ves i nputs from:
Battery vol tage
Engi ne cool ant temperature sensor
Crankshaft posi ti on sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Starter motor rel ay
Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n approxi matel y 3 seconds of
cranki ng the engi ne, i t wi l l shut down the fuel i njec-
ti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the PCM recei ves i nputs from:
Battery vol tage
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
on and off.
The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
The PCM operates the A/C compressor cl utch
through the cl utch rel ay. Thi s i s done i f A/C has been
sel ected by the vehi cl e operator and requested by the
A/C thermostat.
When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the PCM
recei ves i nputs from:
Battery vol tage
Battery vol tage
trans. onl y)
Oxygen sensors
Based on these i nputs, the fol l owi ng occurs:
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
POWERTRAIN CONTROL MODULE (Continued)
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
CRUISE MODE
i s a Cl osed Loop mode. At crui si ng speed, the PCM
recei ves i nputs from:
Battery vol tage
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
ACCELERATION MODE
Thi s i s an Open Loop mode. The PCM recogni zes
an abrupt i ncrease i n throttl e posi ti on or MAP pres-
sure as a demand for i ncreased engi ne output and
vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased throttl e openi ng.
DECELERATION MODE
i s an Open Loop mode. Duri ng hard decel erati on, the
PCM recei ves the fol l owi ng i nputs.
Battery vol tage
trans. onl y)
Vehi cl e speed
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the PCM recei ves the fol l owi ng
i nputs.
Battery vol tage
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
DESCRIPTION - 5 VOLT SUPPLIES
Two di fferent Powertrai n Control Modul e (PCM)
fi ve vol t suppl y ci rcui ts are used; pri mary and sec-
ondary.
DESCRIPTION - IGNITION CIRCUIT SENSE
Thi s ci rcui t ti es the i gni ti on swi tch to the Power-
DESCRIPTION - POWER GROUNDS
The Powertrai n Control Modul e (PCM) has 2 mai n
grounds. Both of these grounds are referred to as
power grounds. Al l of the hi gh-current, noi sy, el ectri -
cal devi ces are connected to these grounds as wel l as
al l of the sensor returns. The sensor return comes
i nto the sensor return ci rcui t, passes through noi se
suppressi on, and i s then connected to the power
ground.
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng PCM l oads:
Generator fi el d wi ndi ng
Fuel i njectors
I gni ti on coi l (s)
Certai n rel ays/sol enoi ds
Certai n sensors
DESCRIPTION - SENSOR RETURN
The Sensor Return ci rcui ts are i nternal to the Pow-
ertrai n Control Modul e (PCM).
Sensor Return provi des a l ownoi se ground refer-
ence for al l engi ne control system sensors. Refer to
Power Grounds for more i nformati on.
OPERATION
OPERATION - PCM
(1) Al so refer to Modes of Operati on.
The PCM operates the fuel system. The PCM i s a
pre-programmed, tri pl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, certai n
transmi ssi on features, speed control , ai r condi ti oni ng
compressor cl utch engagement and i dl e speed. The
PCM can adapt i ts programmi ng to meet changi ng
operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as Powertrai n Control Modul e
(PCM) Outputs. The sensors and swi tches that pro-
vi de i nputs to the PCM are consi dered Powertrai n
Control Modul e (PCM) I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed and the
brake swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: PCM Inputs:
A/C request
Auto shutdown (ASD) sense
Battery temperature
Battery vol tage
Brake swi tch
J1850 bus ci rcui ts
Data l i nk connecti ons for DRB scan tool
Fi ve vol ts (pri mary)
Fi ve vol ts (secondary)
Fuel l evel
Generator (battery vol tage) output
I gni ti on ci rcui t sense (i gni ti on swi tch i n on/off/
crank/run posi ti on)
Leak detecti on pump (swi tch) sense (i f equi pped)
Oi l pressure
Overdri ve/overri de swi tch
Oxygen sensors
Park/neutral swi tch (auto. trans. onl y)
Power ground
Sensor return
Si gnal ground
Speed control mul ti pl exed si ngl e wi re i nput
Throttl e posi ti on sensor
Transmi ssi on governor pressure sensor
Transmi ssi on temperature sensor
Vehi cl e speed (from ABS modul e)
NOTE: PCM Outputs:
A/C cl utch rel ay
Auto shutdown (ASD) rel ay
J1850 (+/-) ci rcui ts for: speedometer, vol tmeter,
fuel gauge, oi l pressure gauge/l amp, engi ne temp.
gauge and speed control warn. l amp
Data l i nk connecti on for DRBI I I scan tool
EGR val ve control sol enoi d (i f equi pped)
EVAP cani ster purge sol enoi d
Fuel i njectors
Fuel pump rel ay
Generator fi el d dri ver (-)
Generator fi el d dri ver (+)
Generator l amp (i f equi pped)
I dl e ai r control (I AC) motor
I gni ti on coi l
Leak detecti on pump
Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through J1850 ci rcui ts.
Overdri ve i ndi cator l amp (i f equi pped). Dri ven
through J1850 ci rcui ts.
Oxygen sensor heater rel ays (i f equi pped).
Radi ator cool i ng fan rel ay (pul se wi dth modu-
l ated)
Speed control source
Speed control vacuum sol enoi d
Speed control vent sol enoi d
Tachometer (i f equi pped). Dri ven through J1850
ci rcui ts.
Transmi ssi on convertor cl utch ci rcui t
Transmi ssi on 34 shi ft sol enoi d
Transmi ssi on rel ay
Transmi ssi on temperature l amp (i f equi pped)
Transmi ssi on vari abl e force sol enoi d
OPERATION - 5 VOLT SUPPLIES
Pri mary 5vol t suppl y:
suppl i es the requi red 5 vol t power source to the
Crankshaft Posi ti on (CKP) sensor.
Camshaft Posi ti on (CMP) sensor.
suppl i es a reference vol tage for the Mani fol d
Absol ute Pressure (MAP) sensor.
suppl i es a reference vol tage for the Throttl e
Posi ti on Sensor (TPS) sensor.
Secondary 5vol t suppl y:
oi l pressure sensor.
suppl i es the requi red 5 vol t power source for the
Vehi cl e Speed Sensor (VSS) (i f equi pped).
suppl i es the 5 vol t power source to the transmi s-
si on pressure sensor (i f equi pped wi th an RE auto-
mati c transmi ssi on).
OPERATION - IGNITION CIRCUIT SENSE
The i gni ti on ci rcui t sense i nput tel l s the PCM the
i gni ti on swi tch has energi zed the i gni ti on ci rcui t.
Battery vol tage i s al so suppl i ed to the PCM
through the i gni ti on swi tch when the i gni ti on i s i n
the RUN or START posi ti on. Thi s i s referred to as
the i gni ti on sense ci rcui t and i s used to wake up
the PCM.
REMOVAL
USE THE DRBIII SCAN TOOL TO REPRO-
GRAM THE NEW POWERTRAIN CONTROL
MODULE (PCM) WITH THE VEHICLES ORIGI-
NAL IDENTIFICATION NUMBER (VIN) AND
THE VEHICLES ORIGINAL MILEAGE. IF THIS
STEP IS NOT DONE, A DIAGNOSTIC TROUBLE
CODE (DTC) MAY BE SET.
The PCM i s l ocated on the cowl panel i n ri ght/rear
si de of engi ne compartment (Fi g. 12).
To avoi d possi bl e vol tage spi ke damage to PCM,
i gni ti on key must be off, and negati ve battery cabl e
must be di sconnected before unpl uggi ng PCM connec-
tors.
Fig. 12 Powertrain Control Module (PCM) Location
1 - PCM
2 - COOLANT TANK
Fig. 13 Powertrain Control Module (PCM) 32Way
Connectors
1 - 3 32WAY CONNECTORS
2 - PCM/BRACKET ASSEMBLY
3 - BRACKET NUTS (3)
(2) I f equi pped, remove Transmi ssi on Control Mod-
ul e (TCM).
(3) Remove cool ant reserve/overfl ow tank.
(4) Remove cover over el ectri cal connectors. Cover
snaps onto PCM.
(5) Careful l y unpl ug three 32way connectors at
PCM.
(6) Remove three PCM bracket-to-body mounti ng
nuts (Fi g. 13).
(7) Remove PCM/PCM bracket assembl y from
vehi cl e.
(8) Remove 3 PCM-to-PCM bracket bol ts (screws)
(Fi g. 14).
INSTALLATION
USE THE DRBIII SCAN TOOL TO REPRO-
GRAM THE NEW POWERTRAIN CONTROL
MODULE (PCM) WITH THE VEHICLES ORIGI-
NAL IDENTIFICATION NUMBER (VIN) AND
THE VEHICLES ORIGINAL MILEAGE. IF THIS
STEP IS NOT DONE, A DIAGNOSTIC TROUBLE
CODE (DTC) MAY BE SET.
(1) Check pi ns i n three 32way el ectri cal connec-
tors for damage. Repai r as necessary.
(2) I nstal l PCM to i ts mounti ng bracket. Ti ghten
three mounti ng bol ts to 3 Nm (25 i n. l bs.) torque.
(3) I nstal l PCM/PCM bracket to body. I nstal l 3
nuts and ti ghten 9 Nm (80 i n. l bs.) torque.
(4) I nstal l three 32way connectors.
(5) I nstal l cover over el ectri cal connectors. Cover
snaps onto PCM.
(6) I nstal l cool ant reserve/overfl ow tank.
(7) I f equi pped, i nstal l Transmi ssi on Control Mod-
ul e (TCM).
(8) Connect negati ve cabl e to battery.
(9) Use the DRBI I I scan tool to reprogram new
PCM wi th vehi cl es ori gi nal I denti fi cati on Number
(VI N) and ori gi nal vehi cl e mi l eage.
SENTRY KEY IMMOBILIZER
MODULE
DESCRIPTION
The Sentry Key I mmobi l i zer Modul e (SKI M) i s the
pri mary component of the Sentry Key I mmobi l i zer
System (SKI S) (Fi g. 15). The SKI M i s l ocated i n the
steeri ng col umn, bel ow the i gni ti on l ock cyl i nder
housi ng. The SKI M has an i ntegral hal o-l i ke antenna
ri ng that extends from one si de.
The SKI M cannot be adjusted or repai red. I f faul ty
or damaged, the enti re SKI M uni t must be repl aced.
OPERATION
The Sentry Key I mmobi l i zer Modul e (SKI M) con-
tai ns a Radi o Frequency (RF) transcei ver and a
mi croprocessor. The SKI M transmi ts RF si gnal s to,
and recei ves RF si gnal s from the Sentry Key tran-
Fig. 14 Powertrain Control Module (PCM) Mounting
Bracket
1 - PCM BRACKET
2 - PCM
3 - PCM-TO-BRACKET SCREWS (3)
Fig. 15 Sentry Key Immobilizer Module
1 - STEERING COLUMN
2 - SKIM
3 - MOUNTING SCREW
sponder through a tuned antenna ri ng i ntegral to the
SKI M housi ng. I f thi s antenna ri ng i s not mounted
properl y around the i gni ti on l ock cyl i nder housi ng,
communi cati on probl ems between the SKI M and the
transponder may ari se. These communi cati on prob-
l ems wi l l resul t i n Sentry Key transponder-rel ated
faul ts. The SKI M al so communi cates over the Pro-
wi th the Powertrai n Control Modul e (PCM), the El ec-
troMechani cal I nstrument Cl uster (EMI C), the Body
Control Modul e (BCM), and/or the DRBI I I scan tool .
The SKI M retai ns i n memory the I D numbers of
any Sentry Key transponder that i s programmed i nto
i t. A maxi mum of ei ght transponders can be pro-
grammed i nto the SKI M. For added system securi ty,
each SKI M i s programmed wi th a uni que Secret Key
code. Thi s code i s stored i n memory, sent over the
PCI data bus to the PCM, and i s encoded to the tran-
sponder of every Sentry Key that i s programmed i nto
the SKI M. Another securi ty code, cal l ed a PI N, i s
used to gai n access to the SKI M Secured Access
Mode. The Secured Access Mode i s requi red duri ng
servi ce to perform the SKI S i ni ti al i zati on and Sentry
Key transponder programmi ng procedures. The
SKI M al so stores the Vehi cl e I denti fi cati on Number
(VI N) i n i ts memory, whi ch i t l earns through a PCI
data bus message from the PCM duri ng SKI S i ni ti al -
i zati on.
I n the event that a SKI M repl acement i s requi red,
the Secret Key code can be transferred to the new
SKI M from the PCM usi ng the DRBI I I scan tool
and the SKI S repl acement procedure. Proper compl e-
ti on of the SKI S i ni ti al i zati on wi l l al l ow the exi sti ng
Sentry Keys to be programmed i nto the new SKI M so
that new keys wi l l not be requi red. I n the event that
the ori gi nal Secret Key code cannot be recovered,
SKI M repl acement wi l l al so requi re new Sentry
Keys. The DRBI I I scan tool wi l l al ert the techni ci an
duri ng the SKI S repl acement procedure i f new Sen-
try Keys are requi red.
When the i gni ti on swi tch i s turned to the On posi -
ti on, the SKI M transmi ts an RF si gnal to the tran-
sponder i n the i gni ti on key. The SKI M then wai ts for
an RF si gnal response from the transponder. I f the
response recei ved i denti fi es the key as val i d, the
SKI M sends a val i d key message to the PCM over
the PCI data bus. I f the response recei ved i denti fi es
the key as i nval i d, or i f no response i s recei ved from
the key transponder, the SKI M sends an i nval i d key
message to the PCM. The PCM wi l l enabl e or di sabl e
engi ne operati on based upon the status of the SKI M
messages. I t i s i mportant to note that the defaul t
condi ti on i n the PCM i s an i nval i d key; therefore, i f
no message i s recei ved from the SKI M by the PCM,
the engi ne wi l l be di sabl ed and the vehi cl e i mmobi -
l i zed after two seconds of runni ng.
The SKI M al so sends i ndi cator l i ght status mes-
sages to the EMI C over the PCI data bus to tel l the
EMI C how to operate the SKI S i ndi cator. Thi s i ndi -
cator l i ght status message tel l s the EMI C to turn the
i ndi cator on for about three seconds each ti me the
i gni ti on swi tch i s turned to the On posi ti on as a bul b
test. After compl eti on of the bul b test, the SKI M
sends i ndi cator l i ght status messages to the EMI C to
turn the i ndi cator off, turn the i ndi cator on, or to
fl ash the i ndi cator on and off. I f the SKI S i ndi cator
l amp fl ashes or stays on sol i d after the bul b test, i t
si gni fi es a SKI S faul t. I f the SKI M detects a system
mal functi on and/or the SKI S has become i noperati ve,
the SKI S i ndi cator wi l l stay on sol i d. I f the SKI M
detects an i nval i d key or i f a key transponder-rel ated
faul t exi sts, the SKI S i ndi cator wi l l fl ash. I f the vehi -
cl e i s equi pped wi th the Customer Learn transponder
programmi ng feature, the SKI M wi l l al so send mes-
sages to the EMI C to fl ash the SKI S i ndi cator l amp,
and to the BCM to generate a si ngl e audi bl e chi me
tone whenever the Customer Learn programmi ng
mode i s bei ng uti l i zed. (Refer to 8 - ELECTRI CAL/
VEHI CLE THEFT SECURI TY - STANDARD PRO-
CEDURE - SENTRY KEY TRANSPONDER
PROGRAMMI NG).
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store faul t i nformati on i n the form of Di agnosti c
Troubl e Codes (DTCs) i n SKI M memory i f a system
mal functi on i s detected. The SKI M can be di agnosed,
and any stored DTCs can be retri eved usi ng a
ti c i nformati on.
REMOVAL
INJURY.
cabl e.
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
SENTRY KEY IMMOBILIZER MODULE (Continued)
connector from the SKI M connector.
(4) Remove the screw that secures the SKI M to
the bottom of the steeri ng col umn housi ng (Fi g. 16).
(5) Di sengage the antenna ri ng of the SKI M from
around the i gni ti on l ock cyl i nder housi ng.
(6) Remove the SKI M from the steeri ng col umn.
INSTALLATION
INJURY.
(1) Posi ti on the SKI M to the undersi de of the
steeri ng col umn (Fi g. 16).
(2) Engage the antenna ri ng of the SKI M around
the i gni ti on l ock cyl i nder housi ng.
SKI M to the bottom of the steeri ng col umn hous-
i ng.Ti ghten the screw to 3.4 Nm (30 i n l bs.).
connector to the SKI M connector.
(5) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
I NG COVER - I NSTALLATI ON).
(7) Perform the SKI S Repl acement procedure
usi ng the DRBI I I .
(8) Perform the SKI S I ni ti al i zati on Procedure
usi ng the DRBI I I .
TRANSMISSION CONTROL
MODULE
DESCRIPTION
The Transmi ssi on Control Modul e (TCM) i s l ocated
i n the engi ne compartment on the ri ght (passenger)
si de and i s mounted to the i nner fender (Fi g. 17).
OPERATION
The Transmi ssi on Control Modul e (TCM) control s
al l el ectroni c operati ons of the transmi ssi on. The
TCM recei ves i nformati on regardi ng vehi cl e opera-
ti on from both di rect and i ndi rect i nputs, and sel ects
the operati onal mode of the transmi ssi on. Di rect
i nputs are hardwi red to, and used speci fi cal l y by the
TCM. I ndi rect i nputs ori gi nate from other compo-
nents/modul es, and are shared wi th the TCM vi a the
vehi cl e communi cati on bus.
Some exampl es of direct inputs to the TCM are:
Battery (B+) vol tage
I gni ti on ON vol tage
Transmi ssi on Control Rel ay (Swi tched B+)
Throttl e Posi ti on Sensor
Crankshaft Posi ti on Sensor
Transmi ssi on Range Sensor
Fig. 16
Fig. 17 Transmission Control Module Location
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60WAY CONNECTOR
SENTRY KEY IMMOBILIZER MODULE (Continued)
Pressure Swi tches
Transmi ssi on Temperature Sensor
I nput Shaft Speed Sensor
Output Shaft Speed Sensor
Li ne Pressure Sensor
Some exampl es of indirect inputs to the TCM
are:
Engi ne/Body I denti fi cati on
Mani fol d Pressure
Target I dl e
Torque Reducti on Confi rmati on
Engi ne Cool ant Temperature
Ambi ent/Battery Temperature
DRB Scan Tool Communi cati on
Based on the i nformati on recei ved from these var-
i ous i nputs, the TCM determi nes the appropri ate
shi ft schedul e and shi ft poi nts, dependi ng on the
present operati ng condi ti ons and dri ver demand.
Thi s i s possi bl e through the control of vari ous di rect
and i ndi rect outputs.
Some exampl es of TCM direct outputs are:
Transmi ssi on Control Rel ay
Sol enoi ds
Torque Reducti on Request
Some exampl es of TCM indirect outputs are:
Transmi ssi on Temperature (to PCM)
PRNDL Posi ti on (to BCM)
I n addi ti on to moni tori ng i nputs and control l i ng
outputs, the TCM has other i mportant responsi bi l i -
ti es and functi ons:
Stori ng and mai ntai ni ng Cl utch Vol ume I ndexes
(CVI )
Stori ng and sel ecti ng appropri ate Shi ft Sched-
ul es
System sel f-di agnosti cs
Di agnosti c capabi l i ti es (wi th DRB scan tool )
NOTE: If the TCM has been replaced, the Quick
Learn Procedure must be performed. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
BATTERY FEED
A fused, di rect battery feed to the TCM i s used for
conti nuous power. Thi s battery vol tage i s necessary
to retai n adapti ve l earn val ues i n the TCMs RAM
(Random Access Memory). When the battery (B+) i s
di sconnected, thi s memory i s l ost. When the battery
(B+) i s restored, thi s memory l oss i s detected by the
TCM and a Di agnosti c Troubl e Code (DTC) i s set.
CLUTCH VOLUME INDEXES (CVI)
An i mportant functi on of the TCM i s to moni tor
Cl utch Vol ume I ndexes (CVI ). CVI s represent the vol -
ume of fl ui d needed to compress a cl utch pack.
The TCM moni tors gear rati o changes by moni tor-
i ng the I nput and Output Speed Sensors. The I nput,
or Turbi ne Speed Sensor sends an el ectri cal si gnal to
the TCM that represents i nput shaft rpm. The Out-
put Speed Sensor provi des the TCM wi th output
shaft speed i nformati on.
By compari ng the two i nputs, the TCM can deter-
mi ne transmi ssi on gear posi ti on. Thi s i s i mportant to
the CVI cal cul ati on because the TCM determi nes
CVI s by moni tori ng how l ong i t takes for a gear
change to occur (Fi g. 18).
Gear rati os can be determi ned by usi ng the
DRBI I I Scan Tool and readi ng the I nput/Output
Speed Sensor val ues i n the Moni tors di spl ay. Gear
rati o can be obtai ned by di vi di ng the I nput Speed
Sensor val ue by the Output Speed Sensor val ue.
The gear rati o changes as cl utches are appl i ed and
rel eased. By moni tori ng the l ength of ti me i t takes
for the gear rati o to change fol l owi ng a shi ft request,
the TCM can determi ne the vol ume of fl ui d used to
appl y or rel ease a fri cti on el ement.
The vol ume of transmi ssi on fl ui d needed to appl y
the fri cti on el ements are conti nuousl y updated for
adapti ve control s. As fri cti on materi al wears, the vol -
ume of fl ui d need to appl y the el ement i ncreases.
Fig. 18 Example of CVI Calculation
1 - OUTPUT SPEED SENSOR
2 - OUTPUT SHAFT
3 - CLUTCH PACK
4 - SEPARATOR PLATE
5 - FRICTION DISCS
6 - INPUT SHAFT
7 - INPUT SPEED SENSOR
8 - PISTON AND SEAL
TRANSMISSION CONTROL MODULE (Continued)
Certai n mechani cal fai l ures wi thi n the i nput cl utch
assembl y can cause i nadequate or out-of-range el e-
ment vol umes. Al so, defecti ve I nput/Output Speed
Sensors and wi ri ng can cause these condi ti ons. The
fol l owi ng chart i denti fi es the appropri ate cl utch vol -
umes and when they are moni tored/updated:
CLUTCH VOLUMES
Clutch When Updated
Proper Clutch
Volume
L/R
2-1 or 3-1
downshift
45 to 134
2C
3-2 kickdown
shift
25 to 85
OD 2-3 upshift 30 to 100
4C 3-4 upshift 30 to 85
UD
4-3 kickdown
shift
30 to 100
SHIFT SCHEDULES
As menti oned earl i er, the TCM has programmi ng
that al l ows i t to sel ect a vari ety of shi ft schedul es.
Shi ft schedul e sel ecti on i s dependent on the fol l ow-
i ng:
Shi ft l ever posi ti on
Throttl e posi ti on
Engi ne l oad
Fl ui d temperature
Software l evel
As dri vi ng condi ti ons change, the TCM appropri -
atel y adjusts the shi ft schedul e. Refer to the fol l ow-
i ng chart to determi ne the appropri ate operati on
expected, dependi ng on dri vi ng condi ti ons.
Schedule Condition Expected Operation
Extreme Cold Oil temperature below -16F -Park, Reverse, Neutral and 1st and
3rd gear only in D position, 2nd
gear only in Manual 2 or L
-No EMCC
Super Cold Oil temperature between -12F and
10F
- Delayed 2-3 upshift
- Delayed 3-4 upshift - Early 4-3
coastdown shift
- High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
-Shifts at high throttle openings willl
be early.
- No EMCC
Cold Oil temperature between 10F and
36F
-Shift schedule is the same as
Super Cold except that the 2-3
upshifts are not delayed.
Warm Oil temperature between 40F and
80F
- Normal operation (upshift,
kickdowns, and coastdowns)
- No EMCC
Hot Oil temperature between 80F and
240F
- Normal operation (upshift,
kickdowns, and coastdowns) -
Normal EMCC operation
Overheat Oil temperature above 240F or
engine coolant temperature above
244F
- 3rd gear FEMCC from 30-48 mph
- 3rd gear PEMCC above 35 mph
- Above 25 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
STANDARD PROCEDURE
STANDARD PROCEDURE - TCM QUICK LEARN
The qui ck l earn procedure requi res the use of the
DRBI I I scan tool .
Thi s program al l ows the el ectroni c transmi ssi on
system to recal i brate i tsel f. Thi s wi l l provi de the
proper transmi ssi on operati on. The qui ck l earn pro-
cedure shoul d be performed i f any of the fol l owi ng
procedures are performed:
Transmi ssi on Assembl y Repl acement
Transmi ssi on Control Modul e Repl acement
Sol enoi d Pack Repl acement
Cl utch Pl ate and/or Seal Repl acement
Val ve Body Repl acement or Recondi ti on
To perform the Qui ck Learn Procedure, the fol l ow-
i ng condi ti ons must be met:
The brakes must be appl i ed
The engi ne speed must be above 500 rpm
The throttl e angl e (TPS) must be l ess than 3
degrees
The shi ft l ever posi ti on must stay i n PARK unti l
prompted to shi ft to overdri ve
The shi ft l ever posi ti on must stay i n overdri ve
after the Shi ft to Overdri ve prompt unti l the DRB
i ndi cates the procedure i s compl ete
The cal cul ated oi l temperature must be above
60 and bel ow 200
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 7
BATTERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - BATTERY . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - USING MICRO
420 ELECTRICAL TESTER . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE - CHECKING
BATTERY ELECTROLYTE LEVEL . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY HOLDDOWN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
BATTERY CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
BATTERY TRAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
WJ ENGINE SYSTEMS 8F - 1
BATTERY SYSTEM
DESCRIPTION
A si ngl e 12-vol t battery system i s standard factory-
i nstal l ed equi pment on thi s model . Al l of the compo-
nents of the battery system are l ocated wi thi n the
engi ne compartment of the vehi cl e. The servi ce i nfor-
mati on for the battery system i n thi s vehi cl e covers
the fol l owi ng rel ated components, whi ch are covered
i n further detai l el sewhere i n thi s servi ce manual :
Battery - The storage battery provi des a rel i -
abl e means of stori ng a renewabl e source of el ectri cal
energy wi thi n the vehi cl e.
Battery Cables - The battery cabl es connect
the battery termi nal posts to the vehi cl e el ectri cal
system.
Battery Holddown - The battery hol ddown
hardware secures the battery i n the battery tray i n
Battery Tray - The battery tray provi des a
secure mounti ng l ocati on i n the vehi cl e for the bat-
tery and an anchor poi nt for the battery hol ddown
hardware.
For battery system mai ntenance schedul es and jump
starti ng procedures, see the owners manual i n the vehi -
cl e gl ove box. Opti onal l y, refer to Lubri cati on and Mai n-
tenance for the recommended battery mai ntenance
schedul es and for the proper battery jump starti ng pro-
cedures. Whi l e battery chargi ng can be consi dered a
mai ntenance procedure, the battery chargi ng procedures
and rel ated i nformati on are l ocated i n the standard pro-
cedures secti on of thi s servi ce manual . Thi s was done
because the battery must be ful l y-charged before any
battery system di agnosi s or testi ng procedures can be
performed. Refer to Standard procedures for the proper
battery chargi ng procedures.
OPERATION
The battery system i s desi gned to provi de a safe,
effi ci ent, rel i abl e and mobi l e means of del i veri ng and
stori ng el ectri cal energy. Thi s el ectri cal energy i s
requi red to operate the engi ne starti ng system, as
wel l as to operate many of the other vehi cl e acces-
sory systems for l i mi ted durati ons whi l e the engi ne
and/or the chargi ng system are not operati ng. The
battery system i s al so desi gned to provi de a reserve
of el ectri cal energy to suppl ement the chargi ng sys-
tem for short durati ons whi l e the engi ne i s runni ng
and the el ectri cal current demands of the vehi cl e
exceed the output of the chargi ng system. I n addi ti on
to del i veri ng, and stori ng el ectri cal energy for the
vehi cl e, the battery system serves as a capaci tor and
vol tage stabi l i zer for the vehi cl e el ectri cal system. I t
absorbs most abnormal or transi ent vol tages caused
by the swi tchi ng of any of the el ectri cal components
or ci rcui ts i n the vehi cl e.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starti ng, and chargi ng systems i n the
vehi cl e operate wi th one another and must be tested
as a compl ete system. I n order for the engi ne to start
and the battery to mai ntai n i ts charge properl y, al l of
the components that are used i n these systems must
perform wi thi n speci fi cati ons. I t i s i mportant that
the battery, starti ng, and chargi ng systems be thor-
oughl y tested and i nspected any ti me a battery needs
to be charged or repl aced. The cause of abnormal bat-
tery di scharge, overchargi ng or earl y battery fai l ure
must be di agnosed and corrected before a battery i s
repl aced and before a vehi cl e i s returned to servi ce.
The servi ce i nformati on for these systems has been
separated wi thi n thi s servi ce manual to make i t eas-
i er to l ocate the speci fi c i nformati on you are seeki ng.
However, when attempti ng to di agnose any of these
systems, i t i s i mportant that you keep thei r i nterde-
pendency i n mi nd.
The di agnosti c procedures used for the battery,
starti ng, and chargi ng systems i ncl ude the most
basi c conventi onal di agnosti c methods, to the more
sophi sti cated On-Board Di agnosti cs (OBD) bui l t i nto
the Powertrai n Control Modul e (PCM). Use of an
i nducti on-type mi l l i ampere ammeter, a vol t/ohmme-
ter, a battery charger, a carbon pi l e rheostat (l oad
tester) and a 12-vol t test l amp may be requi red. Al l
OBD-sensed systems are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for any fai l ure i t detects. Refer to
Chargi ng System for the proper chargi ng system on-
board di agnosti c test procedures.
MICRO 420 ELECTRICAL SYSTEM TESTER
The Mi cro 420 automoti ve battery tester i s
desi gned to hel p the deal ershi p techni ci ans di agnose
a defecti ve battery. Fol l ow the i nstructi on manual
suppl i ed wi th the tester to properl y di agnose a vehi -
cl e. I f the i nstructi on manual i s not avai l abl e refer to
the standard procedure i n thi s secti on, whi ch
i ncl udes the di recti ons for usi ng the Mi cro 420 el ec-
tri cal system tester.
8F - 2 BATTERY SYSTEM WJ
BATTERY SYSTEM DIAGNOSIS
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.
1. The electrical system
ignition-off draw is excessive.
1. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is
faulty.
2. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. The battery terminal
connections are loose or
corroded.
4. Refer to Battery Cables for the proper battery
cable diagnosis and testing procedures. Clean
and tighten the battery terminal connections, as
required.
5. The battery has an
incorrect size or rating for
this vehicle.
5. Refer to Battery System Specifications for the
proper size and rating. Replace an incorrect
battery, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity using
the Micro 420 battery tester. Refer to the
Standard Procedures in this section for additional
test procedures. Replace the faulty battery, as
required.
7. The starting system is
faulty.
7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The battery is physically
damaged.
8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
WJ BATTERY SYSTEM 8F - 3
BATTERY SYSTEM (Continued)
BATTERY SYSTEM DIAGNOSIS
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED.
1. The battery has an
incorrect size or rating for
this vehicle.
1. Refer to Battery System Specifications for the
proper specifications. Replace an incorrect
2. The battery terminal
connections are loose or
corroded.
2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. The electrical system
ignition-off draw is excessive.
3. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
5. The starting system is
faulty.
5. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. The charging system is
faulty.
6. Determine if the charging system is performing
to specifications using the Micro 420 battery.
Refer to Charging System for additional charging
system diagnosis and testing procedures. Repair
the faulty charging system, as required.
7. Electrical loads exceed the
output of the charging
system.
7. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
8. Slow driving or prolonged
idling with high-amperage
draw systems in use.
8. Advise the vehicle operator, as required.
THE BATTERY WILL NOT
ACCEPT A CHARGE.
1. The battery is faulty. 1. Test the battery using the Micro 420 battery
tester. Charge or replace the faulty battery, as
required.
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
1. A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Chargi ng System for addi ti onal charg-
i ng system di agnosi s and testi ng procedures.
2. A faul ty or i ncorrect battery. Use Mi cro 420 bat-
tery tester and refer to Battery System for addi ti onal
battery di agnosi s and testi ng procedures.
3. A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw.
4. El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
5. A faul ty or i ncorrect starti ng system component.
Refer to Starti ng System for the proper starti ng sys-
tem di agnosi s and testi ng procedures.
6. Corroded or l oose battery posts and/or termi nal
cl amps.
7. Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
CLEANING
The fol l owi ng i nformati on detai l s the recommended
cl eani ng procedures for the battery and rel ated com-
ponents. I n addi ti on to the mai ntenance schedul es
found i n thi s servi ce manual and the owners man-
ual , i t i s recommended that these procedures be per-
formed any ti me the battery or rel ated components
must be removed for vehi cl e servi ce.
(1) Cl ean the battery cabl e termi nal cl amps of al l
corrosi on. Remove any corrosi on usi ng a wi re brush
or a post and termi nal cl eani ng tool , and a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on (Fi g. 1).
(2) Cl ean the battery tray and battery hol ddown
hardware of al l corrosi on. Remove any corrosi on
usi ng a wi re brush and a sodi um bi carbonate (baki ng
soda) and warm water cl eani ng sol uti on. Pai nt any
exposed bare metal .
(3) I f the removed battery i s to be rei nstal l ed,
cl ean the outsi de of the battery case and the top
cover wi th a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on usi ng a sti ff bri stl e
parts cl eani ng brush to remove any aci d fi l m (Fi g. 2).
Ri nse the battery wi th cl ean water. Ensure that the
cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, refer to Battery System Speci fi cati ons for
the factory-i nstal l ed battery speci fi cati ons. Confi rm
that the repl acement battery i s the correct si ze and
has the correct rati ngs for the vehi cl e.
(4) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 3).
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Fig. 2 Clean Battery - Typical
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
INSPECTION
The fol l owi ng i nformati on detai l s the recommended
i nspecti on procedures for the battery and rel ated
components. I n addi ti on to the mai ntenance sched-
ul es found i n thi s servi ce manual and the owners
manual , i t i s recommended that these procedures be
performed any ti me the battery or rel ated compo-
nents must be removed for vehi cl e servi ce.
(1) I nspect the battery cabl e termi nal cl amps for
damage. Repl ace any battery cabl e that has a dam-
aged or deformed termi nal cl amp.
(2) I nspect the battery tray and battery hol ddown
hardware for damage. Repl ace any damaged parts.
(3) Sl i de the thermal guard off of the battery case.
I nspect the battery case for cracks or other damage
that coul d resul t i n el ectrol yte l eaks. Al so, check the
battery termi nal posts for l ooseness. Batteri es wi th
damaged cases or l oose termi nal posts must be
repl aced.
(4) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass for an i ndi cati on of the battery condi ti on. I f the
battery i s di scharged, charge as requi red. Refer to
Standard Procedures for the proper battery bui l t-i n
i ndi cator test procedures. Al so refer to Standard Pro-
cedures for the proper battery chargi ng procedures.
SPECIFICATIONS
The battery Group Si ze number, the Col d Cranki ng
Amperage (CCA) rati ng, and the Reserve Capaci ty
(RC) rati ng or Ampere-Hours (AH) rati ng can be
found on the ori gi nal equi pment battery l abel . Be
certai n that a repl acement battery has the correct
Group Si ze number, as wel l as CCA, and RC or AH
rati ngs that equal or exceed the ori gi nal equi pment
speci fi cati on for the vehi cl e bei ng servi ced. Battery
si zes and rati ngs are di scussed i n more detai l bel ow.
Group Size - The outsi de di mensi ons and ter-
mi nal pl acement of the battery conform to standards
establ i shed by the Battery Counci l I nternati onal
(BCI ). Each battery i s assi gned a BCI Group Si ze
number to hel p i denti fy a correctl y-si zed repl ace-
ment.
Cold Cranking Amperage - The Col d Crank-
i ng Amperage (CCA) rati ng speci fi es how much cur-
rent (i n amperes) the battery can del i ver for thi rty
seconds at -18 C (0 F). Termi nal vol tage must not
fal l bel ow 7.2 vol ts duri ng or after the thi rty second
di scharge peri od. The CCA requi red i s general l y
hi gher as engi ne di spl acement i ncreases, dependi ng
al so upon the starter current draw requi rements.
Reserve Capacity - The Reserve Capaci ty (RC)
rati ng speci fi es the ti me (i n mi nutes) i t takes for bat-
tery termi nal vol tage to fal l bel ow 10.5 vol ts, at a
di scharge rate of 25 amperes. RC i s determi ned wi th
the battery ful l y-charged at 26.7 C (80 F). Thi s rat-
i ng esti mates how l ong the battery mi ght l ast after a
chargi ng system fai l ure, under mi ni mum el ectri cal
l oad.
Ampere-Hours - The Ampere-Hours (AH) rat-
i ng speci fi es the current (i n amperes) that a battery
can del i ver steadi l y for twenty hours, wi th the vol t-
age i n the battery not fal l i ng bel ow 10.5 vol ts. Thi s
rati ng i s al so someti mes i denti fi ed as the twenty-
hour di scharge rati ng.
BATTERY CLASSIFICATIONS & RATINGS
Part Number
BCI Group Size
Classification
Cold Cranking
Amperage
Reserve
Capacity
Ampere -
Hours
Load Test
Amperage
56041113 65 625 120 Minutes 69 300
SPECIAL TOOLS
BATTERY
DESCRIPTION
A l arge capaci ty, l ow-mai ntenance storage battery
(Fi g. 4) i s standard factory-i nstal l ed equi pment on
thi s model . Mal e post type termi nal s made of a soft
l ead materi al protrude from the top of the mol ded
pl asti c battery case to provi de the means for connect-
i ng the battery to the vehi cl e el ectri cal system. The
battery posi ti ve termi nal post i s vi si bl y l arger i n
di ameter than the negati ve termi nal post, for easy
i denti fi cati on. The l etters POS and NEG are al so
mol ded i nto the top of the battery case adjacent to
thei r respecti ve posi ti ve and negati ve termi nal posts
for addi ti onal i denti fi cati on confi rmati on. Refer to
Battery Cables i n the i ndex of thi s servi ce manual
for the l ocati on of more i nformati on on the battery
cabl es that connect the battery to the vehi cl e el ectri -
cal system.
Thi s battery i s desi gned to provi de a safe, effi ci ent
and rel i abl e means of stori ng el ectri cal energy i n a
chemi cal form. Thi s means of energy storage al l ows
the battery to produce the el ectri cal energy requi red
to operate the engi ne starti ng system, as wel l as to
operate many of the other vehi cl e accessory systems
for l i mi ted durati ons whi l e the engi ne and/or the
chargi ng system are not operati ng. The battery i s
made up of si x i ndi vi dual cel l s that are connected i n
seri es. Each cel l contai ns posi ti vel y charged pl ate
groups that are connected wi th l ead straps to the
posi ti ve termi nal post, and negati vel y charged pl ate
groups that are connected wi th l ead straps to the
negati ve termi nal post. Each pl ate consi sts of a sti ff
mesh framework or gri d coated wi th l ead di oxi de
(posi ti ve pl ate) or sponge l ead (negati ve pl ate). I nsu-
l ators or pl ate separators made of a non-conducti ve
materi al are i nserted between the posi ti ve and nega-
ti ve pl ates to prevent them from contacti ng or short-
i ng agai nst one another. These di ssi mi l ar metal
pl ates are submerged i n a sul furi c aci d and water
sol uti on cal l ed an el ectrol yte.
Some factory-i nstal l ed batteri es have a bui l t-i n test
i ndi cator (hydrometer). The col or vi si bl e i n the si ght
gl ass of the i ndi cator wi l l reveal the battery condi -
ti on. For more i nformati on on the use of the bui l t-i n
test i ndi cator, refer to Standard Procedures The
factory-installed low-maintenance battery has
removable battery cell caps. Di sti l l ed water can
be added to thi s battery. The battery i s not seal ed
and has vent hol es i n the cel l caps. The chemi cal
composi ti on of the metal coated pl ates wi thi n the
l ow-mai ntenance battery reduces battery gassi ng and
water l oss, at normal charge and di scharge rates.
Therefore, the battery shoul d not requi re addi ti onal
water i n normal servi ce. I f the el ectrol yte l evel i n
thi s battery does become l ow, di sti l l ed water must be
added. However, rapi d l oss of el ectrol yte can be
caused by an overchargi ng condi ti on. Be certai n to
MICRO 420 BATTERY AND CHARGING SYSTEM
TESTER
Fig. 4 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - TEST INDICATOR
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
di agnose the chargi ng system after repl eni shi ng the
water i n the battery for a l ow el ectrol yte condi ti on
and before returni ng the vehi cl e to servi ce. Refer to
Charging System for addi ti onal i nformati on.
For battery mai ntenance schedul es and jump start-
i ng procedures, see the owners manual i n the vehi cl e
gl ove box. Opti onal l y, refer to Maintenance Sched-
ules and J ump Starting, Towing and Hoisting i n
the i ndex of thi s servi ce manual for the l ocati on of
the recommended battery mai ntenance schedul es and
the proper battery jump starti ng procedures. Whi l e
battery chargi ng can be consi dered a mai ntenance
procedure, the battery chargi ng procedures and i nfor-
mati on are l ocated i n the servi ce procedures secti on
of thi s servi ce manual . Thi s was done because the
battery must be ful l y-charged before any battery
di agnosi s or testi ng procedures can be performed.
Refer to Standard Procedures i n the i ndex of thi s
servi ce manual for the l ocati on of the proper battery
chargi ng procedures.
OPERATION
The battery i s desi gned to store el ectri cal energy i n
a chemi cal form. When an el ectri cal l oad i s appl i ed to
the termi nal s of the battery, an el ectrochemi cal reac-
ti on occurs. Thi s reacti on causes the battery to di s-
charge el ectri cal current from i ts termi nal s. As the
battery di scharges, a gradual chemi cal change takes
pl ace wi thi n each cel l . The sul furi c aci d i n the el ec-
trol yte combi nes wi th the pl ate materi al s, causi ng
both pl ates to sl owl y change to l ead sul fate. At the
same ti me, oxygen from the posi ti ve pl ate materi al
combi nes wi th hydrogen from the sul furi c aci d, caus-
i ng the el ectrol yte to become mai nl y water. The
chemi cal changes wi thi n the battery are caused by
the movement of excess or free el ectrons between the
posi ti ve and negati ve pl ate groups. Thi s movement of
el ectrons produces a fl ow of el ectri cal current
through the l oad devi ce attached to the battery ter-
mi nal s.
As the pl ate materi al s become more si mi l ar chem-
i cal l y, and the el ectrol yte becomes l ess aci d, the vol t-
age potenti al of each cel l i s reduced. However, by
chargi ng the battery wi th a vol tage hi gher than that
of the battery i tsel f, the battery di schargi ng process
i s reversed. Chargi ng the battery gradual l y changes
the sul fated l ead pl ates back i nto sponge l ead and
l ead di oxi de, and the water back i nto sul furi c aci d.
Thi s acti on restores the di fference i n the el ectron
charges deposi ted on the pl ates, and the vol tage
potenti al of the battery cel l s. For a battery to remai n
useful , i t must be abl e to produce hi gh-amperage cur-
rent over an extended peri od. A battery must al so be
abl e to accept a charge, so that i ts vol tage potenti al
may be restored.
The battery i s vented to rel ease excess hydrogen
gas that i s created when the battery i s bei ng charged
or di scharged. However, even wi th these vents,
hydrogen gas can col l ect i n or around the battery. I f
hydrogen gas i s exposed to fl ame or sparks, i t may
i gni te. I f the el ectrol yte l evel i s l ow, the battery may
arc i nternal l y and expl ode. I f the battery i s equi pped
wi th removabl e cel l caps, add di sti l l ed water when-
ever the el ectrol yte l evel i s bel ow the top of the
pl ates. I f the battery cel l caps cannot be removed, the
battery must be repl aced i f the el ectrol yte l evel
becomes l ow.
The battery must be compl etel y charged and the
termi nal s shoul d be properl y cl eaned and i nspected
before di agnosti c procedures are performed. Refer to
Battery System Cl eani ng for the proper cl eani ng pro-
cedures, and Battery System I nspecti on for the
proper battery i nspecti on procedures. Refer to Stan-
dard Procedures for the proper battery chargi ng pro-
cedures.
MICRO 420 ELECTRICAL SYSTEM TESTER
The Mi cro420 automoti ve battery tester i s desi gned
to hel p the deal ershi p techni ci ans di agnose the cause
of a defecti ve battery. Fol l ow the i nstructi on manual
suppl i ed wi th the tester to properl y di agnose a vehi -
cl e. I f the i nstructi on manual i s not avai l abl e refer to
the standard procedure i n thi s secti on, whi ch
i ncl udes the di recti ons for usi ng the Mi cro420 el ectri -
cal system tester.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
requi red. A ful l y-charged battery must be l oad tested
BATTERY (Continued)
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING
Battery chargi ng i s the means by whi ch the bat-
tery can be restored to i ts ful l vol tage potenti al . A
battery i s ful l y-charged when:
Mi cro 420 el ectri cal system tester i ndi cates bat-
tery i s OK.
Al l of the battery cel l s are gassi ng freel y duri ng
battery chargi ng.
Three hydrometer tests, taken at one-hour i nter-
val s, i ndi cate no i ncrease i n the temperature-cor-
rected speci fi c gravi ty of the battery el ectrol yte.
Open-ci rcui t vol tage of the battery i s 12.4 vol ts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1 C [30 F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING, LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty. Refer to Standard Procedures for
the proper battery l oad test procedures. I f the battery
wi l l endure a l oad test, return the battery to servi ce.
I f the battery wi l l not endure a l oad test, i t i s faul ty
and must be repl aced.
Cl ean and i nspect the battery hol d downs, tray,
termi nal s, posts, and top before compl eti ng battery
servi ce. Refer to Battery System Cl eani ng for the
proper battery system cl eani ng procedures, and Bat-
tery System I nspecti on for the proper battery system
i nspecti on procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 5). I f the
readi ng i s bel ow ten vol ts, the battery chargi ng cur-
rent wi l l be l ow. I t coul d take some ti me before the
battery accepts a current greater than a few mi l l i am-
peres. Such l ow current may not be detectabl e on the
ammeters bui l t i nto many battery chargers.
BATTERY (Continued)
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the battery charger and
the battery from bei ng damaged i f they are i mprop-
erl y connected. I f the battery state-of-charge i s too
l ow for the pol ari ty-sensi ng ci rcui try to detect, the
battery charger wi l l not operate. Thi s makes i t
appear that the battery wi l l not accept chargi ng cur-
rent. See the i nstructi ons provi ded by the manufac-
turer of the battery charger for detai l s on how to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e chargi ng
current at vari ous vol tages i s shown i n the Charge
Rate Tabl e. I f the chargi ng current i s sti l l not mea-
surabl e at the end of the chargi ng ti me, the battery
i s faul ty and must be repl aced. I f the chargi ng cur-
rent i s measurabl e duri ng the chargi ng ti me, the bat-
tery may be good and the chargi ng shoul d be
compl eted i n the normal manner.
CHARGE RATE TABLE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
Battery Capacity - A compl etel y di scharged
heavy-duty battery requi res twi ce the chargi ng ti me
of a smal l capaci ty battery.
Temperature - A l onger ti me wi l l be needed to
charge a battery at -18 C (0 F) than at 27 C (80
F). When a fast battery charger i s connected to a col d
battery, the current accepted by the battery wi l l be
very l ow at fi rst. As the battery warms, i t wi l l accept
a hi gher chargi ng current rate (amperage).
Charger Capacity - A battery charger that
suppl i es onl y fi ve amperes wi l l requi re a l onger
chargi ng ti me. A battery charger that suppl i es
twenty amperes or more wi l l requi re a shorter charg-
i ng ti me.
State-Of-Charge - A compl etel y di scharged bat-
tery requi res more chargi ng ti me than a parti al l y
di scharged battery. El ectrol yte i s nearl y pure water
i n a compl etel y di scharged battery. At fi rst, the
chargi ng current (amperage) wi l l be l ow. As the bat-
tery charges, the speci fi c gravi ty of the el ectrol yte
wi l l gradual l y ri se.
The Battery Chargi ng Ti me Tabl e gi ves an i ndi ca-
ti on of the ti me requi red to charge a typi cal battery
at room temperature based upon the battery state-of-
charge and the charger capaci ty.
BATTERY CHARGING TIME TABLE
Charging
Amperage
5 Amps
10
Amps
20 Amps
Open Circuit
Voltage
Hours Charging @ 21C (70
F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - USING MICRO 420
ELECTRICAL TESTER
Al ways use the Mi cro 420 I nstructi on Manual that
was suppl i ed wi th the tester as a reference. I f the
I nstructi on Manual i s not avai l abl e the fol l owi ng pro-
cedure can be used:
WARNING: ALWAYS WEAR APPROPRIATE EYE
PROTECTION AND USE EXTREME CAUTION WHEN
WORKING WITH BATTERIES.
BATTERY TESTING
(1) I f testi ng the battery OUT-OF-VEHI CLE, cl ean
the battery termi nal s wi th a wi re brush before test-
i ng. I f the battery i s equi pped wi th si de post termi -
nal s, i nstal l and ti ghten the suppl i ed l ead termi nal
stud adapters. Do not use steel bol ts. Fai l ure to prop-
erl y i nstal l the stud adapters, or usi ng stud adapters
that are di rty or worn-out may resul t i n fal se test
readi ngs.
Fig. 5 Voltmeter - Typical
BATTERY (Continued)
(2) I f testi ng the battery I N-THE-VEHI CLE, make
certai n al l of the vehi cl e accessory l oads are OFF,
i ncl udi ng the i gni ti on. The preferred test position
is at the battery terminal. I f the battery i s not
accessi bl e, you may test usi ng both the posi ti ve and
negati ve jumper posts. Sel ect TESTI NG AT JUMPER
POST when connecti ng to that l ocati on.
(3) Connect the tester (Fi g. 6) to the battery or
jumper posts, the red cl amp to posi ti ve (+) and the
bl ack cl amp to negati ve ().
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
(4) Usi ng the ARROW key sel ect in or out of vehi -
cl e testi ng and press ENTER to make a sel ecti on.
(5) I f not sel ected, choose the Col d Cranki ng Amp
(CCA) battery rati ng. Or sel ect the appropri ate bat-
tery rati ng for your area (see menu). The tester wi l l
then run i ts sel f programmed test of the battery and
di spl ay the resul ts. Refer to the test resul t tabl e
noted bel ow.
CAUTION: If REPLACE BATTERY is the result of the
test, this may mean a poor connection between the
vehicles cables and battery exists. After discon-
necting the vehicles battery cables from the bat-
tery, retest the battery using the OUT-OF-VEHICLE
test before replacing.
(6) Whi l e vi ewi ng the battery test resul t, press the
CODE button and the tester wi l l prompt you for the
l ast 4 di gi ts of the VI N. Use the UP/DOWN arrow
buttons to scrol l to the correct character; then press
ENTER to sel ect and move to the next di gi t. Then
press the ENTER button to vi ew the SERVI CE
CODE. Pressi ng the CODE button a second ti me wi l l
return you to the test resul ts.
BATTERY TEST RESULTS
GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system
NOTE: The SERVICE CODE is required on every
warranty claim submitted for battery replacement.
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST
An i ndi cator (hydrometer) bui l t i nto the top of the
battery case provi des vi sual i nformati on for battery
testi ng (Fi g. 7). Li ke a hydrometer, the bui l t-i n i ndi -
cator measures the speci fi c gravi ty of the battery
el ectrol yte. The speci fi c gravi ty of the el ectrol yte
reveal s the battery state-of-charge; however, i t wi l l
not reveal the cranki ng capaci ty of the battery. A l oad
test must be performed to determi ne the battery
cranki ng capaci ty. Refer to Standard Procedures for
the proper battery l oad test procedures.
Fig. 6 MICRO 420 BATTERY AND CHARGING
SYSTEM TESTER
Fig. 7 Built-In Indicator
1 - SIGHT GLASS
2 - BATTERY TOP
3 - GREEN BALL
4 - PLASTIC ROD
BATTERY (Continued)
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n i ndi cator,
i t i s i mportant that the battery be l evel and have a
cl ean si ght gl ass. Addi ti onal l i ght may be requi red to
vi ew the i ndi cator. Do not use open flame as a
source of additional light.
To read the bui l t-i n i ndi cator, l ook i nto the si ght
gl ass and note the col or of the i ndi cati on (Fi g. 8). The
battery condi ti on that each col or i ndi cates i s
descri bed i n the fol l owi ng l i st:
Green - I ndi cates 75% to 100% battery state-of-
charge. The battery i s adequatel y charged for further
testi ng or return to servi ce. I f the starter wi l l not
crank for a mi ni mum of fi fteen seconds wi th a ful l y-
charged battery, the battery must be l oad tested.
Refer to Standard Procedures for the proper battery
l oad test procedures.
Black or Dark - I ndi cates 0% to 75% battery
state-of-charge. The battery i s i nadequatel y charged
and must be charged unti l a green i ndi cati on i s vi si -
bl e i n the si ght gl ass (12.4 vol ts or more), before the
battery i s tested further or returned to servi ce. Refer
to Standard Procedures for the proper battery charg-
i ng procedures. Al so refer to Di agnosi s and Testi ng
for more i nformati on on the possi bl e causes of the
di scharged battery condi ti on.
Clear or Bright - I ndi cates a l ow battery el ec-
trol yte l evel . The el ectrol yte l evel i n the battery i s
bel ow the bui l t-i n i ndi cator. A mai ntenance-free bat-
tery wi th non-removabl e cel l caps must be repl aced i f
the el ectrol yte l evel i s l ow. Water must be added to a
l ow-mai ntenance battery wi th removabl e cel l caps
before i t i s charged. Refer to Standard Procedures for
the proper battery fi l l i ng procedures. A l ow el ectro-
l yte l evel may be caused by an overchargi ng condi -
ti on. Refer to Chargi ng System for the proper
chargi ng system di agnosi s and testi ng procedures.
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the approxi mate state-of-charge of a battery.
Thi s test can be used i n pl ace of the hydrometer test
when a hydrometer i s not avai l abl e, or for mai nte-
nance-free batteri es wi th non-removabl e cel l caps.
Before proceedi ng wi th thi s test, compl etel y charge
the battery (Refer to 8 - ELECTRI CAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the headl amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (see the i nstructi ons provi ded by the manufac-
turer of the vol tmeter), measure the open-ci rcui t vol t-
age (Fi g. 9).
See the Open-Ci rcui t Vol tage Tabl e. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty (Refer to 8 - ELECTRI CAL/BATTERY SYS-
TEM/BATTERY - STANDARD PROCEDURE).
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
Fig. 8 Built-In Indicator Sight Glass Chart
Fig. 9 Testing Open-Circuit Voltage - Typical
BATTERY (Continued)
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term I gni ti on-Off Draw (I OD) i denti fi es a nor-
mal condi ti on where power i s bei ng drai ned from the
battery wi th the i gni ti on swi tch i n the Off posi ti on. A
normal vehi cl e el ectri cal system wi l l draw from fi ve
to thi rty-fi ve mi l l i amperes (0.005 to 0.035 ampere)
wi th the i gni ti on swi tch i n the Off posi ti on, and al l
non-i gni ti on control l ed ci rcui ts i n proper worki ng
order. Up to thi rty-fi ve mi l l i amperes are needed to
enabl e the memory functi ons for the Powertrai n Con-
trol Modul e (PCM), di gi tal cl ock, el ectroni cal l y tuned
radi o, and other modul es whi ch may vary wi th the
vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the Power Di stri buti on Center (PDC). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
El ectri cal i tems l eft on.
Faul ty or i mproperl y adjusted swi tches.
Faul ty or shorted el ectroni c modul es and compo-
nents.
An i nternal l y shorted generator.
I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over thi rty-fi ve mi l l i amperes, the
probl em must be found and corrected before repl ac-
i ng a battery. I n most cases, the battery can be
charged and returned to servi ce after the excessi ve
I OD condi ti on has been corrected.
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th an i l l umi -
nated entry system or an el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes. See the El ectroni c Modul e I gni -
ti on-Off Draw Tabl e for more i nformati on.
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
Module
Time Out?
(If Yes, Interval And Wake-Up Input)
IOD
IOD After Time
Out
Radio No
1 to 3
milliamperes
N/A
Audio Power
Amplifier
No
up to 1
milliampere
N/A
Body Control Module
(BCM)
No
5.90
milliamperes
(max.)
N/A
Powertrain Control
Module (PCM)
No 0.95 milliampere N/A
Transmission Control
Module (TCM) 4.7L
w/45RFE
YES (20 minutes, ignition on) 130 milliamperes 0.64 milliampere
ElectroMechanical
Instrument Cluster
(EMIC)
No 0.44 milliampere N/A
Combination Flasher No 0.08 milliampere N/A
(2) Determi ne that the underhood l amp i s operat-
i ng properl y, then di sconnect the l amp wi re harness
connector or remove the l amp bul b.
(3) Di sconnect the battery negati ve cabl e.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e ter-
mi nal cl amp and the battery negati ve termi nal post.
Make sure that the doors remai n cl osed so that the
i l l umi nated entry system i s not acti vated. The mul ti -
meter amperage readi ng may remai n hi gh for up to
three mi nutes, or may not gi ve any readi ng at al l
whi l e set i n the hi ghest amperage scal e, dependi ng
upon the el ectri cal equi pment i n the vehi cl e. The
mul ti -meter l eads must be securel y cl amped to the
battery negati ve cabl e termi nal cl amp and the bat-
tery negati ve termi nal post. I f conti nui ty between the
battery negati ve termi nal post and the negati ve cabl e
termi nal cl amp i s l ost duri ng any part of the I OD
test, the el ectroni c ti mer functi on wi l l be acti vated
and al l of the tests wi l l have to be repeated.
BATTERY (Continued)
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or nonexi stent, dependi ng upon the el ectri cal
equi pment i n the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove and repl ace each fuse or ci rcui t
breaker i n the Power Di stri buti on Center (PDC) and
then i n the Juncti on Bl ock (JB), one at a ti me unti l
the amperage readi ng becomes very l ow, or nonexi st-
ent. Refer to the appropri ate wi ri ng i nformati on i n
thi s servi ce manual for compl ete PDC and JB fuse,
ci rcui t breaker, and ci rcui t i denti fi cati on. Thi s wi l l
i sol ate each ci rcui t and i denti fy the ci rcui t that i s the
source of the hi gh-amperage I OD. I f the amperage
readi ng remai ns hi gh after removi ng and repl aci ng
each fuse and ci rcui t breaker, di sconnect the wi re
harness from the generator. I f the amperage readi ng
now becomes very l ow or nonexi stent, refer to Charg-
i ng System for the proper chargi ng system di agnosi s
and testi ng procedures. After the hi gh-amperage I OD
has been corrected, swi tch the mul ti -meter to pro-
gressi vel y l ower amperage scal es and, i f necessary,
repeat the fuse and ci rcui t breaker remove-and-re-
pl ace process to i denti fy and correct al l sources of
excessi ve I OD. I t i s now safe to sel ect the l owest mi l -
l i ampere scal e of the mul ti -meter to check the l ow-
amperage I OD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed thi rty-fi ve mi l l i am-
peres (0.035 ampere). I f the current draw exceeds
thi rty-fi ve mi l l i amperes, i sol ate each ci rcui t usi ng the
fuse and ci rcui t breaker remove-and-repl ace process
i n Step 5. The mul ti -meter readi ng wi l l drop to
wi thi n the acceptabl e l i mi t when the source of the
excessi ve current draw i s di sconnected. Repai r thi s
ci rcui t as requi red; whether a wi ri ng short, i ncorrect
swi tch adjustment, or a component fai l ure i s at faul t.
STANDARD PROCEDURE - CHECKING BATTERY
ELECTROLYTE LEVEL
The fol l owi ng procedure can be used to check the
battery el ectrol yte l evel .
(1) Remove the battery cel l caps (Fi g. 10).
(2) Look through the battery cap hol es to deter-
mi ne the l evel of the el ectrol yte i n the battery (Fi g.
11). The el ectrol yte shoul d be approxi matel y 1 centi -
meter above the battery pl ates or unti l the hook
i nsi de the battery cap hol es i s covered.
(3) Add onl y di sti l l ed water unti l the el ectrol yte
l evel i s approx. one centi meter above the pl ates.
Fig. 10 Battery Caps - Export Battery
1 - BATTERY CAP
2 - BATTERY
Fig. 11 Hook Inside Battery Cap Holes - Export
Battery
1 - BATTERY SURFACE COVER
2 - HOOK
BATTERY (Continued)
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post (Fi g. 12).
(4) Loosen the battery posi ti ve cabl e termi nal
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
(6) Remove the battery hol d down from the bat-
tery. Refer to Battery Hold Down i n thi s secti on of
the servi ce manual for the procedure.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(7) Remove the battery from the battery tray.
INSTALLATION
(1) Cl ean and i nspect the battery. Refer to the pro-
cedures i n thi s secti on.
(2) Posi ti on the battery onto the battery tray as a
uni t. Ensure that the battery posi ti ve and negati ve
termi nal posts are correctl y posi ti oned. The battery
cabl e termi nal cl amps must reach the correct battery
termi nal post wi thout stretchi ng the cabl es (Fi g. 13)
or (Fi g. 14).
(3) Rei nstal l the battery hol d downs onto the bat-
tery. Refer to Battery Hold Downs
CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reverse battery polarity may damage
electrical components of the vehicle.
(4) Cl ean the battery cabl e termi nal cl amps and
the battery termi nal posts.
Fig. 12 Remove Battery Cable Terminal Clamp -
Typical
1 - BATTERY
2 - BATTERY TERMINAL PULLER
Fig. 13 Battery Cables - 4.0L Engine
3 - CLIPS
3 - CLIPS
BATTERY (Continued)
(5) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 6.8 Nm (60
i n. l bs.).
(6) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 6.8 Nm (
60 i n. l bs.).
(7) Appl y a thi n coati ng of petrol eum jel l y or chas-
si s grease to the exposed surfaces of the battery cabl e
termi nal cl amps and the battery termi nal posts.
BATTERY HOLDDOWN
DESCRIPTION
The battery hol d down hardware consi sts of (Fi g.
15) a mol ded pl asti c l i p that i s i ntegral to the out-
board edge of the battery tray and support uni t, a
mol ded pl asti c hol d down bracket, a si ngl e hex screw
wi th a coned washer and a U-nut.
When i nstal l i ng a battery i nto the battery tray, be
certai n that the hol d down hardware i s properl y
i nstal l ed and that the fasteners are ti ghtened to the
proper speci fi cati ons. I mproper hol d down fastener
ti ghtness, whether too l oose or too ti ght, can resul t i n
damage to the battery, the vehi cl e or both.
OPERATION
The battery hol ddown secures the battery i n the
battery tray. Thi s hol ddown i s desi gned to prevent
battery movement duri ng the most extreme vehi cl e
operati on condi ti ons. Peri odi c removal and l ubri ca-
ti on of the battery hol ddown hardware i s recom-
mended to prevent hardware sei zure at a l ater date.
CAUTION: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
Al l of the battery hol d down hardware can be ser-
vi ced wi thout removal of the battery or the battery
tray and support uni t.
the termi nal cl amp from the battery post.
(4) Remove the screw wi th washer that secures the
battery hol d down bracket to the U-nut on the
i nboard si de of the battery tray and support uni t
(Fi g. 16).
(5) Remove the battery hol d down bracket from
the battery tray and support uni t.
INSTALLATION
Al l of the battery hol d down hardware can be ser-
vi ced wi thout removal of the battery or the battery
tray and support uni t.
(1) Cl ean and i nspect the battery hol d down hard-
ware. Refer to the procedures i n thi s secti on of the
servi ce manual .
(2) Be certai n that the battery i s properl y posi -
ti oned i n the battery tray and support uni t. The
l edge on the outboard si de of the battery case must
be engaged under the l i p on the outboard si de of the
battery tray and support uni t.
Fig. 15 Battery Hold Downs
1 - SCREW
2 - HOLD DOWN BRACKET
3 - BATTERY SUPPORT
4 - ACCUMULATOR
5 - NUT
6 - U-NUT
7 - STUD
8 - RADIATOR SUPPORT BRACKET
9 - U-NUT
10 - SCREW
11 - BATTERY TEMPERATURE SENSOR
12 - BATTERY
BATTERY (Continued)
(3) Posi ti on the battery hol d down bracket over the
l edge on the i nboard si de of the battery case i n the
battery tray and support uni t. Be certai n that the
l edge on the bottom of the hol d down bracket i s ori -
ented towards the i nboard si de of the battery case.
Proper hol d down bracket ori entati on may al so be
determi ned by noti ng the di recti on of the arrow-l i ke
formati ons of the mol ded rei nforci ng ri bs on the top
of the hol d down bracket. These arrows shoul d be
poi nted towards the battery.
battery hol d down bracket to the U-nut on the
i nboard si de of the battery tray and support uni t.
Ti ghten thew screw to 3.4 Nm (30 i n. l bs.).
(5) Reconnect the battery negati ve cabl e termi nal cl amp
to the battery negati ve termi nal post. Ti ghten the termi nal
cl amp pi nch-bol t hex nut to 8.4 Nm (75 i n. l bs.).
BATTERY CABLE
DESCRIPTION
Fig. 16 Battery Hold Downs Remove/Install
1 - SCREW
3 - BATTERY SUPPORT
4 - ACCUMULATOR
5 - NUT
6 - U-NUT
7 - STUD
9 - U-NUT
10 - SCREW
12 - BATTERY
3 - CLIPS
3 - CLIPS
BATTERY HOLDDOWN (Continued)
The battery cabl es (Fi g. 17) or (Fi g. 18) are l arge
gauge, stranded copper wi res sheathed wi thi n a
heavy pl asti c or syntheti c rubber i nsul ati ng jacket.
The wi re used i n the battery cabl es combi nes excel -
l ent fl exi bi l i ty and rel i abi l i ty wi th hi gh el ectri cal cur-
rent carryi ng capaci ty. Refer to Wiring Diagrams
for battery cabl e wi re gauge i nformati on.
A cl ampi ng type femal e battery termi nal made of
soft l ead i s di e cast onto one end of the battery cabl e
wi re. A square headed pi nch-bol t and hex nut are
i nstal l ed at the open end of the femal e battery termi -
nal cl amp. Large eyel et type termi nal s are cri mped
onto the opposi te end of the battery cabl e wi re and
then sol der-di pped. The battery posi ti ve cabl e wi res
have a red i nsul ati ng jacket to provi de vi sual i denti -
fi cati on and feature a l arger femal e battery termi nal
cl amp to al l ow connecti on to the l arger battery posi -
ti ve termi nal post. The battery negati ve cabl e wi res
have a bl ack i nsul ati ng jacket and a smal l er femal e
battery termi nal cl amp.
The battery cabl es cannot be repai red and, i f dam-
aged or faul ty they must be repl aced. Both the bat-
tery posi ti ve and negati ve cabl es are avai l abl e for
servi ce repl acement onl y as a uni t wi th the battery
wi re harness, whi ch may i ncl ude porti ons of the wi r-
i ng ci rcui ts for the generator and other components
on some model s. Refer to Wiring Diagrams for more
i nformati on on the vari ous wi ri ng ci rcui ts i ncl uded i n
the battery wi re harness for the vehi cl e bei ng ser-
vi ced.
OPERATION
The battery cabl es connect the battery termi nal
posts to the vehi cl e el ectri cal system. These cabl es
al so provi de a path back to the battery for el ectri cal
current generated by the chargi ng system for restor-
i ng the vol tage potenti al of the battery. The femal e
battery termi nal cl amps on the ends of the battery
cabl e wi res provi de a strong and rel i abl e connecti on
of the battery cabl e to the battery termi nal posts.
The termi nal pi nch bol ts al l ow the femal e termi nal
cl amps to be ti ghtened around the mal e termi nal
posts on the top of the battery. The eyel et termi nal s
secured to the opposi te ends of the battery cabl e
wi res from the femal e battery termi nal cl amps pro-
vi de secure and rel i abl e connecti on of the battery
cabl es to the vehi cl e el ectri cal system.
The battery posi ti ve cabl e termi nal cl amp i s di e
cast onto the ends of two wi res. One wi re has an eye-
l et termi nal that connects the battery posi ti ve cabl e
to the B(+) termi nal stud of the Power Di stri buti on
Center (PDC), and the other wi re has an eyel et ter-
mi nal that connects the battery posi ti ve cabl e to the
B(+) termi nal stud of the engi ne starter motor sol e-
noi d. The battery negati ve cabl e termi nal cl amp i s
al so di e cast onto the ends of two wi res. One wi re
has an eyel et termi nal that connects the battery neg-
ati ve cabl e to the vehi cl e powertrai n through a stud
on the ri ght si de of the engi ne cyl i nder bl ock. The
other wi re has an eyel et termi nal that connects the
battery negati ve cabl e to the vehi cl e body through a
ground screw on the ri ght front fender i nner shi el d,
near the battery.
DIAGNOSIS AND TESTING - BATTERY CABLES
A vol tage drop test wi l l determi ne i f there i s exces-
si ve resi stance i n the battery cabl e termi nal connec-
ti ons or the battery cabl e. I f excessi ve resi stance i s
found i n the battery cabl e connecti ons, the connec-
ti on poi nt shoul d be di sassembl ed, cl eaned of al l cor-
rosi on or forei gn materi al , then reassembl ed.
Fol l owi ng reassembl y, check the vol tage drop for the
battery cabl e connecti on and the battery cabl e agai n
to confi rm repai r.
When performi ng the vol tage drop test, i t i s i mpor-
tant to remember that the vol tage drop i s gi vi ng an
i ndi cati on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached. EXAM-
PLE: When testi ng the resi stance of the battery pos-
i ti ve cabl e, touch the vol tmeter l eads to the battery
posi ti ve cabl e termi nal cl amp and to the battery pos-
i ti ve cabl e eyel et termi nal at the starter sol enoi d
B(+) termi nal stud. I f you probe the battery posi ti ve
termi nal post and the battery posi ti ve cabl e eyel et
termi nal at the starter sol enoi d B(+) termi nal stud,
you are readi ng the combi ned vol tage drop i n the
battery posi ti ve cabl e termi nal cl amp-to-termi nal
post connecti on and the battery posi ti ve cabl e.
VOLTAGE DROP TEST
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng thi s
test, be certai n that the fol l owi ng procedures are
accompl i shed:
The battery i s ful l y-charged and l oad tested.
Refer to Standard Procedures for the proper battery
chargi ng and l oad test procedures.
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
Veri fy that al l l amps and accessori es are turned
off.
To prevent the engi ne from starti ng, remove the
Automati c Shut Down (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
BATTERY CABLE (Continued)
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e termi nal cl amp (Fi g. 19). Rotate and hol d the
i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct the poor con-
necti on between the battery negati ve cabl e termi nal
cl amp and the battery negati ve termi nal post.
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
termi nal cl amp (Fi g. 20). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor connecti on
between the battery posi ti ve cabl e termi nal cl amp
and the battery posi ti ve termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve cabl e termi nal cl amp and the starter
sol enoi d B(+) termi nal stud (Fi g. 21). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery posi ti ve cabl e eyel et termi nal con-
necti on at the starter sol enoi d B(+) termi nal stud.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
battery negati ve cabl e termi nal cl amp and a good
cl ean ground on the engi ne bl ock (Fi g. 22). Rotate
and hol d the i gni ti on swi tch i n the Start posi ti on.
Observe the vol tmeter. I f the readi ng i s above 0.2
vol t, cl ean and ti ghten the battery negati ve cabl e
eyel et termi nal connecti on to the engi ne bl ock.
repl ace the faul ty battery negati ve cabl e.
REMOVAL
Both the battery negati ve cabl e and the battery
posi ti ve cabl e are servi ced i n the battery wi re har-
ness. I f ei ther battery cabl e i s damaged or faul ty, the
battery wi re harness uni t must be repl aced.
the termi nal cl amp from the battery post.
Fig. 19 TEST BATTERY NEGATIVE CONNECTION
RESISTANCE - TYPICAL
1 - VOLTMETER
2 - BATTERY
Fig. 20 TEST BATTERY POSITIVE CONNECTION
1 - VOLTMETER
2 - BATTERY
Fig. 21 TEST BATTERY POSITIVE CABLE
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
(4) Loosen the battery posi ti ve cabl e termi nal
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
(6) Unl atch and open the cover on the Power Di s-
tri buti on Center (PDC).
(7) Remove the two nuts that secure the battery
posi ti ve cabl e and generator output cabl e eyel et ter-
mi nal to the B(+) termi nal studs i n the PDC.
(8) Remove the battery posi ti ve cabl e and genera-
tor output cabl e eyel et termi nal from the B(+) termi -
nal studs i n the PDC.
(9) Di sconnect the battery wi re harness connector
from the ri ght headl amp and dash wi re harness con-
nector l ocated near the front of the battery.
(10) Remove the screw that secures the battery
negati ve cabl e eyel et termi nal to the i nner fender
shi el d near the front of the battery.
(11) On model s wi th the 4.7L engi ne, remove the
nut that secures the battery harness cl i p to the stud
on the ri ght si de of the i ntake mani fol d and remove
the cl i p from the stud.
(12) Unl atch and remove the cover from the gener-
ator output termi nal stud housi ng on the back of the
generator.
(13) Remove the nut that secures the generator
output cabl e eyel et termi nal to the generator output
termi nal stud.
(14) Remove the generator output cabl e eyel et ter-
mi nal from the generator output termi nal stud.
from the generator fi el d termi nal connector recepta-
cl e on the back of the generator.
(16) Remove the screw that secures the battery
negati ve cabl e ground eyel et termi nal to the ri ght
si de of the engi ne bl ock.
(17) Remove the nut that secures the battery pos-
i ti ve cabl e eyel et termi nal to the B(+) termi nal stud
on the starter sol enoi d.
(18) Remove the battery posi ti ve cabl e eyel et ter-
mi nal from the B(+) termi nal stud on the starter
sol enoi d.
from the connector receptacl e on the starter sol enoi d.
(20) Remove the battery wi re harness from the
engi ne compartment.
INSTALLATION
Both the battery negati ve cabl e and the battery
posi ti ve cabl e are servi ced i n the battery wi re har-
ness. I f ei ther battery cabl e i s damaged or faul ty, the
battery wi re harness uni t must be repl aced.
(1) Cl ean and i nspect the battery cabl e termi nal
cl amps and the battery termi nal posts.
(2) Posi ti on the battery wi re harness i nto the
engi ne compartment (Fi g. 23) or (Fi g. 24).
(3) Reconnect the battery wi re harness connector
to the connector receptacl e on the starter sol enoi d.
(4) I nstal l the battery posi ti ve cabl e eyel et termi -
nal onto the B(+) termi nal stud on the starter sol e-
noi d.
Fig. 22 TEST GROUND CIRCUIT RESISTANCE -
TYPICAL
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
3 - CLIPS
(5) I nstal l and ti ghten the nut that secures the
battery posi ti ve cabl e eyel et termi nal to the B(+) ter-
mi nal stud on the starter sol enoi d. Ti ghten the nut to
11.3 Nm (100 i n. l bs.).
battery negati ve cabl e ground eyel et termi nal to the
ri ght si de of the engi ne bl ock. Ti ghten the screw to
10.2 Nm (90 i n. l bs.) for 4.0L engi nes, or 13.0 Nm
(115 i n. l bs.) for 4.7L engi nes.
to the generator fi el d termi nal connector receptacl e
on the back of the generator.
(8) I nstal l the generator output cabl e eyel et termi -
nal onto the generator output termi nal stud.
generator output cabl e eyel et termi nal to the genera-
tor output termi nal stud. Ti ghten the nut to 10.7
Nm (95 i n. l bs.).
(10) Posi ti on the cover for the generator output
termi nal stud housi ng onto the back of the generator
and snap i t i nto pl ace.
(11) On model s wi th the 4.7L engi ne, i nstal l the
battery harness cl i p onto the stud on the ri ght si de of
the i ntake mani fol d, then i nstal l and ti ghten the nut
that secures the cl i p to the stud. Ti ghten the nut to
11.3 Nm (100 i n. l bs.).
battery negati ve cabl e eyel et termi nal to the i nner
fender shi el d near the front of the battery. Ti ghten
the screw to 28.2 Nm (250 i n. l bs.).
to the ri ght headl amp and dash wi re harness connec-
tor l ocated near the front of the battery.
(14) I nstal l the battery posi ti ve cabl e and genera-
tor output cabl e eyel et termi nal onto the PDC B(+)
termi nal studs.
(15) I nstal l and ti ghten the two nuts that secure
the battery posi ti ve cabl e and generator output cabl e
eyel et termi nal to the PDC B(+) termi nal studs.
Ti ghten the nuts to 11.3 Nm (100 i n. l bs.).
(16) Cl ose and l atch the PDC cover.
(17) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
i n. l bs.).
(18) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
i n. l bs.).
(19) Appl y a thi n coati ng of petrol eum jel l y or
chassi s grease to the exposed surfaces of the battery
cabl e termi nal cl amps and the battery termi nal
posts.
BATTERY TRAY
DESCRIPTION
The battery i s mounted i n a mol ded pl asti c battery
tray and support uni t (Fi g. 25) l ocated i n the ri ght
front corner of the engi ne compartment. The battery
tray and support uni t i s secured at the rear wi th a
nut to a stud on the front wheel house i nner panel , at
the outboard si de wi th a screw to the si de cowl rei n-
forcement panel , and at the front wi th a screw
through a U-nut on a bracket of the radi ator support.
The battery tray and support uni t al so i ncl udes
three upri ght stanchi ons that are mol ded i nto the
outboard si de of the uni t. These stanchi ons support
the Power Di stri buti on Center (PDC). Refer to
Power Distribution Center i n the Power Di stri bu-
ti on secti on of thi s servi ce manual for more i nforma-
ti on on the PDC.
A hol e i n the bottom of the battery tray i s fi tted
wi th a battery temperature sensor. Refer to Battery
Temperature Sensor i n the Chargi ng secti on of
thi s servi ce manual for more i nformati on on the bat-
tery temperature sensor. Refer to Battery Hold
Down i n thi s secti on of the servi ce manual for more
i nformati on on the battery hol d down hardware.
3 - CLIPS
OPERATION
The battery tray provi des a secure mounti ng l oca-
ti on and supports the battery. On some vehi cl es, the
battery tray al so provi des the anchor poi nt/s for the
battery hol ddown hardware. The battery tray and
the battery hol ddown hardware combi ne to secure
and stabi l i ze the battery i n the engi ne compartment,
whi ch prevents battery movement duri ng vehi cl e
operati on. Unrestrai ned battery movement duri ng
vehi cl e operati on coul d resul t i n damage to the vehi -
cl e, the battery, or both.
REMOVAL
(1) Remove the battery from the battery tray
(Refer to 8 - ELECTRI CAL/BATTERY SYSTEM/BAT-
TERY - REMOVAL).
(2) Remove the Power Di stri buti on Center (PDC)
from the stanchi ons on the outboard si de of the bat-
tery tray and support uni t. Refer to Power Distri-
bution Center i n the Power Di stri buti on secti on of
thi s servi ce manual for PDC removal procedure.
(3) Remove the one screw that secures the front of
the battery tray and support uni t to the bracket on
the ri ght si de of the radi ator support (Fi g. 26).
(4) Remove the one screw that secures the out-
board si de of the battery tray and support uni t to the
ri ght fender si de cowl rei nforcement.
(5) Remove the one nut that secures the rear of
the battery tray and support uni t to the stud on the
ri ght fender front wheel house i nner panel .
(6) Remove the battery temperature sensor from
the battery tray. Refer to Battery Temperature
Sensor i n the Chargi ng secti on of thi s servi ce man-
ual for battery temperature sensor removal proce-
dure.
(7) Remove the battery tray and support uni t from
the ri ght front corner of the engi ne compartment.
Fig. 25 Battery Tray and Support
1 - SCREW
3 - BATTERY SUPPORT
4 - ACCUMULATOR
5 - NUT
6 - U-NUT
7 - STUD
9 - U-NUT
10 - SCREW
12 - BATTERY
Fig. 26 Battery Tray and Support Remove/Install
1 - BATTERY TRAY AND SUPPORT
2 - NUT (1)
3 - STUD
4 - U-NUT (1)
6 - SCREW (1)
7 - SCREW (1)
BATTERY TRAY (Continued)
INSTALLATION
(1) Cl ean and i nspect the battery tray and support
uni t. Refer to the procedures i n thi s secti on of the
servi ce manual .
(2) I nstal l the battery temperature sensor onto the
battery tray. Refer to Battery Temperature Sensor
i n the Chargi ng secti on of thi s servi ce manual for
battery temperature sensor i nstal l ati on procedure.
(3) Posi ti on the battery tray and support uni t i nto
the ri ght front corner of the engi ne compartment. Be
certai n that no hoses or wi re harnesses are trapped
or pi nched by the i nstal l ati on of the tray.
(4) I nstal l and ti ghten the one nut that secures the
rear of the battery tray and support uni t to the stud
on the ri ght fender front wheel house i nner panel .
Ti ghten the nut to 7.3 Nm (65 i n. l bs.).
(5) I nstal l and ti ghten the one screw that secures
the outboard si de of the battery tray and support
uni t to the ri ght fender si de cowl rei nforcement.
Ti ghten the screw to 8.1 Nm (72 i n. l bs.).
the front of the battery tray and support uni t to the
bracket on the ri ght si de of the radi ator support.
(7) I nstal l the Power Di stri buti on Center (PDC)
onto the stanchi ons on the outboard si de of the bat-
tery tray and support uni t. Refer to Power Distri-
bution Center i n the Power Di stri buti on secti on of
thi s servi ce manual for PDC i nstal l ati on procedure.
(8) I nstal l the battery onto the battery tray (Refer
to 8 - ELECTRI CAL/BATTERY SYSTEM/BATTERY -
I NSTALLATI ON).
BATTERY TRAY (Continued)
CHARGING
TABLE OF CONTENTS
page page
CHARGING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING - CHARGING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS
GENERATOR RATINGS - GAS POWERED . . 25
TORQUE - GAS POWERED . . . . . . . . . . . . . 25
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 26
BATTERY TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
GENERATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
VOLTAGE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CHARGING
DESCRIPTION
The chargi ng system consi sts of:
Generator
El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM)
I gni ti on swi tch
Battery (refer to 8, Battery for i nformati on)
Battery temperature sensor
Generator Lamp (i f equi pped)
Check Gauges Lamp (i f equi pped)
Vol tmeter (refer to 8, I nstrument Cl uster for
i nformati on)
Wi ri ng harness and connecti ons (refer to 8, Wi r-
i ng for i nformati on)
OPERATION
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. The system i s on when the engi ne i s
runni ng and the ASD rel ay i s energi zed. When the
ASD rel ay i s on, vol tage i s suppl i ed to the ASD rel ay
sense ci rcui t at the PCM. Thi s vol tage i s connected
through the PCM and suppl i ed to one of the genera-
tor fi el d termi nal s (Gen. Source +) at the back of the
generator.
The amount of DC current produced by the gener-
ator i s control l ed by the EVR (fi el d control ) ci rcui try
contai ned wi thi n the PCM. Thi s ci rcui try i s con-
nected i n seri es wi th the second rotor fi el d termi nal
and ground.
A battery temperature sensor, l ocated i n the bat-
tery tray housi ng, i s used to sense battery tempera-
ture. Thi s temperature data, al ong wi th data from
moni tored l i ne vol tage, i s used by the PCM to vary
the battery chargi ng rate. Thi s i s done by cycl i ng the
ground path to control the strength of the rotor mag-
neti c fi el d. The PCM then compensates and regul ates
generator current output accordi ngl y.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng EVR
(fi el d control ) ci rcui try, are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for certai n fai l ures i t detects. Refer to
Di agnosti c Troubl e Codes i n; Powertrai n Control
Modul e; El ectroni c Control Modul es for more DTC
i nformati on.
The Check Gauges Lamp (i f equi pped) moni tors:
charging system voltage, engi ne cool ant tempera-
ture and engi ne oi l pressure. I f an extreme condi ti on
i s i ndi cated, the l amp wi l l be i l l umi nated. Thi s i s
done as remi nder to check the three gauges. The si g-
nal to acti vate the l amp i s sent vi a the CCD bus ci r-
cui ts. The l amp i s l ocated on the i nstrument panel .
Refer to 8, I nstrument Cl uster for addi ti onal i nfor-
mati on.
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
The fol l owi ng procedures may be used to di agnose
the chargi ng system i f:
the check gauges l amp (i f equi pped) i s i l l umi -
nated wi th the engi ne runni ng
the vol tmeter (i f equi pped) does not regi ster
properl y
an undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
accessori es bei ng l eft on wi th the engi ne not
runni ng
8F - 24 CHARGING WJ
a faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. Refer to I gni ti on-Off Draw
Test i n 8, Battery for more i nformati on.
INSPECTION
The Powertrai n Control Modul e (PCM) moni tors
cri ti cal i nput and output ci rcui ts of the chargi ng sys-
tem, maki ng sure they are operati onal . A Di agnosti c
Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some chargi ng system ci rcui ts are
checked conti nuousl y, and some are checked onl y
under certai n condi ti ons.
Refer to Di agnosti c Troubl e Codes i n; Powertrai n
Control Modul e; El ectroni c Control Modul es for more
DTC i nformati on. Thi s wi l l i ncl ude a compl ete l i st of
DTCs i ncl udi ng DTCs for the chargi ng system.
To perform a compl ete test of the chargi ng system,
refer to the appropri ate Powertrai n Di agnosti c Proce-
dures servi ce manual and the DRB scan tool . Per-
form the fol l owi ng i nspecti ons before attachi ng the
scan tool .
(1) I nspect the battery condi ti on. Refer to 8, Bat-
tery for procedures.
(2) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
(3) I nspect al l fuses i n both the fusebl ock and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n 7, Cool i ng System.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to 7, Cool i ng System for i nformati on.
(7) I nspect generator el ectri cal connecti ons at gen-
erator fi el d, battery output, and ground termi nal (i f
equi pped). Al so check generator ground wi re connec-
ti on at engi ne (i f equi pped). They shoul d al l be cl ean
and ti ght. Repai r as requi red.
SPECIFICATIONS
GENERATOR RATINGS - GAS POWERED
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
BOSCH 56041322 136 4.0L 6-Cylinder 100
DENSO 56041324 136 4.7L V-8 100
TORQUE - GAS POWERED
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Generator Mounting Bolts-4.0L 55 41
Generator Vertical Mounting Bolt-4.7L 40 29
Generator (long) Horizontal Mounting
Bolt-4.7L
55 41
Generator (short) Horizontal Mounting
Bolt-4.7L
55 41
Generator B+ Terminal Nut 11 95
WJ CHARGING 8F - 25
CHARGING (Continued)
SPECIAL TOOLS
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) i s attached
to the battery tray l ocated under the battery.
OPERATION
The BTS i s used to determi ne the battery temper-
ature and control battery chargi ng rate. Thi s temper-
ature data, al ong wi th data from moni tored l i ne
vol tage, i s used by the PCM to vary the battery
chargi ng rate. System vol tage wi l l be hi gher at col der
temperatures and i s gradual l y reduced at warmer
temperatures.
The PCM sends 5 vol ts to the sensor and i s
grounded through the sensor return l i ne. As temper-
ature i ncreases, resi stance i n the sensor decreases
and the detecti on vol tage at the PCM i ncreases.
The BTS i s al so used for OBD I I di agnosti cs. Cer-
tai n faul ts and OBD I I moni tors are ei ther enabl ed
or di sabl ed, dependi ng upon BTS i nput (for exampl e,
di sabl e purge and enabl e Leak Detecti on Pump
(LDP) and O2 sensor heater tests). Most OBD I I
moni tors are di sabl ed bel ow 20 degrees F.
REMOVAL
The battery temperature sensor i s l ocated under
the vehi cl e battery (Fi g. 1) and i s attached to a
mounti ng hol e on the battery tray.
(1) Remove battery. Refer to Group 8A, Battery for
procedures.
(2) Remove battery tray.
(3) Pul l sensor up from battery tray and di scon-
nect engi ne wi re harness.
(4) Remove sensor from battery tray.
INSTALLATION
(1) Posi ti on sensor i nto mounti ng hol e and attach
wi ri ng harness.
(2) Press sensor i nto top of battery tray.
(3) I nstal l battery. Refer to Group 8A, Battery for
procedures.
GENERATOR DECOUPLER TOOL #8433
GENERATOR DECOUPLER TOOL #8823
Fig. 1 Battery Temperature Sensor Location
2 - ENGINE WIRE HARNESS
3 - BATTERY TRAY
8F - 26 CHARGING WJ
CHARGING (Continued)
GENERATOR
DESCRIPTION
The generator i s bel t-dri ven by the engi ne usi ng a
serpenti ne type dri ve bel t. I t i s servi ced onl y as a
compl ete assembl y. I f the generator fai l s for any rea-
son, the enti re assembl y must be repl aced.
OPERATION
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
The Y type stator wi ndi ng connecti ons del i ver the
i nduced AC current to 3 posi ti ve and 3 negati ve
di odes for recti fi cati on. From the di odes, recti fi ed DC
current i s del i vered to the vehi cl e el ectri cal system
through the generator battery termi nal .
Al though the generators appear the same exter-
nal l y, di fferent generators wi th di fferent output rat-
i ngs are used on thi s vehi cl e. Be certai n that the
repl acement generator has the same output rati ng
and part number as the ori gi nal uni t. Refer to Gen-
erator Rati ngs i n the Speci fi cati ons secti on at the
back of thi s group for amperage rati ngs and part
numbers.
Noi se emi tti ng from the generator may be caused
by: worn, l oose or defecti ve beari ngs; a l oose or defec-
ti ve dri ve pul l ey; i ncorrect, worn, damaged or mi sad-
justed fan dri ve bel t; l oose mounti ng bol ts; a
mi sal i gned dri ve pul l ey or a defecti ve stator or di ode.
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
(2) Remove generator dri ve bel t. Refer to Cool i ng
System for procedure.
(3) Unsnap cabl e protector cover from B+ mount-
i ng stud (Fi g. 2) .
(4) Di sconnect (unsnap) 2wi re fi el d connector at
rear of generator (Fi g. 2) .
(5) Remove generator mounti ng bol ts (Fi g. 3) or
(Fi g. 4).
(6) Remove generator from vehi cl e.
Fig. 2 Generator B+ Cable and Field Wire
Connections (Typical4.0L Engine Shown)
1 - FIELD WIRE CONNECTOR
2 - B+ CABLE
3 - GENERATOR
4 - B+ CABLE MOUNTING NUT
5 - CABLE PROTECTOR
Fig. 3 Remove/Install Generator4.7L V-8 Engine
1 - LOWER BOLTS
2 - REAR BOLT
3 - GENERATOR
WJ CHARGING 8F - 27
INSTALLATION
(1) Posi ti on generator to engi ne and i nstal l mount-
i ng bol ts.
(2) Ti ghten generator mounti ng bol ts as fol l ows:
Verti cal mounti ng bol t 4.7L engi ne40 Nm (29
ft. l bs.)
Long hori zontal mounti ng bol t 4.7L engi ne55
Nm (41 ft. l bs.)
Short hori zontal mounti ng bol t 4.7L engi ne55
Nm (41 ft. l bs.)
Generator mounti ng bol ts 4.0L engi ne55 Nm
(41 ft. l bs.)
B+ termi nal nut11 Nm (95 i n. l bs.)
(3) Snap 2wi re fi el d connector i nto rear of gener-
ator.
(4) Snap cabl e protector cover to B+ mounti ng
stud.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in 7, Cool-
ing System.
(5) I nstal l generator dri ve bel t. Refer to 7, Cool i ng
System for procedure.
(6) I nstal l negati ve battery cabl e to battery.
VOLTAGE REGULATOR
DESCRIPTION
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the Powertrai n Control
Modul e (PCM). The EVR i s not servi ced separatel y. I f
repl acement i s necessary, the PCM must be repl aced.
OPERATION
The amount of DC current produced by the gener-
ator i s control l ed by EVR ci rcui try contai ned wi thi n
the PCM. Thi s ci rcui try i s connected i n seri es wi th
the generators second rotor fi el d termi nal and i ts
ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage (B+) and
battery temperature (refer to Battery Temperature
Sensor for more i nformati on). I t then determi nes a
target chargi ng vol tage. I f sensed battery vol tage i s
0.5 vol ts or l ower than the target vol tage, the PCM
grounds the fi el d wi ndi ng unti l sensed battery vol t-
age i s 0.5 vol ts above target vol tage. A ci rcui t i n the
PCM cycl es the ground si de of the generator fi el d up
to 100 ti mes per second (100Hz), but has the capabi l -
i ty to ground the fi el d control wi re 100% of the ti me
(ful l fi el d) to achi eve the target vol tage. I f the charg-
i ng rate cannot be moni tored (l i mp-i n), a duty cycl e
of 25% i s used by the PCM i n order to have some
generator output. Al so refer to Chargi ng System
Operati on for addi ti onal i nformati on.
Fig. 4 Remove/Install Generator4.0L 6Cylinder
Engine
1 - GENERATOR
2 - UPPER BOLT
3 - LOWER BOLT
8F - 28 CHARGING WJ
GENERATOR (Continued)
STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING - STARTING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS
TORQUE - STARTER . . . . . . . . . . . . . . . . . . . 35
STARTER MOTOR - GAS POWERED . . . . . . 35
STARTER MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING - STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
STARTER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - STARTER RELAY . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
STARTING
DESCRIPTION
An el ectri cal l y operated engi ne starti ng system i s
standard factory-i nstal l ed equi pment on thi s model .
The starti ng system i s desi gned to provi de the vehi -
cl e operator wi th a conveni ent, effi ci ent and rel i abl e
means of cranki ng and starti ng the i nternal combus-
ti on engi ne used to power the vehi cl e and al l of i ts
accessory systems from wi thi n the safe and secure
confi nes of the passenger compartment. See the own-
ers manual i n the vehi cl e gl ove box for more i nfor-
mati on and i nstructi ons on the recommended use
and operati on of the factory-i nstal l ed starti ng sys-
tem.
The starti ng system consi sts of the fol l owi ng com-
ponents:
Battery
Starter rel ay
Starter motor (i ncl udi ng an i ntegral starter sol e-
noi d)
I gni ti on swi tch
Park/neutral posi ti on swi tch
Wi re harnesses and connecti ons (i ncl udi ng the
battery cabl es).
Thi s group provi des compl ete servi ce i nformati on
for the starter motor and the starter rel ay. Compl ete
servi ce i nformati on for the other starti ng system
components can be l ocated as fol l ows:
Refer to Battery i n the proper secti on of Group
8A - Battery for compl ete servi ce i nformati on for the
battery.
Refer to Ignition Switch and Key Lock Cyl-
inder i n the proper secti on of Group 8D - I gni ti on
System for compl ete servi ce i nformati on for the i gni -
ti on swi tch.
Refer to Park/Neutral Position Switch i n the
proper secti on of Group 21 - Transmi ssi on for com-
pl ete servi ce i nformati on for the park/neutral posi -
ti on swi tch.
Refer to the proper secti on of Group 8W - Wir-
ing Diagrams for compl ete servi ce i nformati on and
ci rcui t di agrams for the starti ng system wi ri ng com-
ponents.
Group 8A covers the Battery, Group 8B covers the
Starti ng Systems, and Group 8C covers the Chargi ng
System. We have separated these systems to make i t
easi er to l ocate the i nformati on you are seeki ng
wi thi n thi s Servi ce Manual . However, when attempt-
i ng to di agnose any of these systems, i t i s i mportant
that you keep thei r i nterdependency i n mi nd.
The battery, starti ng, and chargi ng systems i n the
vehi cl e operate wi th one another, and must be tested
as a compl ete system. I n order for the vehi cl e to start
and charge properl y, al l of the components that are
used i n these systems must perform wi thi n speci fi ca-
ti ons.
The di agnosti c procedures used i n each of these
groups i ncl ude the most basi c conventi onal di agnosti c
methods, to the more sophi sti cated On-Board Di ag-
nosti cs (OBD) bui l t i nto the Powertrai n Control Mod-
ul e (PCM). Use of an i nducti on-type mi l l i ampere
ammeter, vol t/ohmmeter, battery charger, carbon pi l e
rheostat (l oad tester), and 12-vol t test l amp may be
requi red.
Al l OBD-sensed systems are moni tored by the
PCM. Each moni tored ci rcui t i s assi gned a Di agnos-
ti c Troubl e Code (DTC). The PCM wi l l store a DTC i n
el ectroni c memory for any fai l ure i t detects. Refer to
On-Board Diagnostic Test For Charging System
i n the Di agnosi s and Testi ng secti on of Group 8C -
Chargi ng System for more i nformati on.
WJ STARTING 8F - 29
OPERATION
The starti ng system components form two separate
ci rcui ts. A hi gh-amperage feed ci rcui t that feeds the
starter motor between 150 and 350 amperes, and a
l ow-amperage control ci rcui t that operates on l ess
than 20 amperes. The hi gh-amperage feed ci rcui t
components i ncl ude the battery, the battery cabl es,
the contact di sc porti on of the starter sol enoi d, and
the starter motor. The l ow-amperage control ci rcui t
components i ncl ude the i gni ti on swi tch, the park/
neutral posi ti on swi tch, the starter rel ay, the el ectro-
magneti c wi ndi ngs of the starter sol enoi d, and the
connecti ng wi re harness components.
Battery vol tage i s suppl i ed through the l ow-amper-
age control ci rcui t to the coi l battery termi nal of the
starter rel ay when the i gni ti on swi tch i s turned to
the momentary Start posi ti on. The park/neutral posi -
ti on swi tch i s i nstal l ed i n seri es between the starter
rel ay coi l ground termi nal and ground. Thi s normal l y
open swi tch prevents the starter rel ay from bei ng
energi zed and the starter motor from operati ng
unl ess the automati c transmi ssi on gear sel ector i s i n
the Neutral or Park posi ti ons.
When the starter rel ay coi l i s energi zed, the nor-
mal l y open rel ay contacts cl ose. The rel ay contacts
connect the rel ay common feed termi nal to the rel ay
normal l y open termi nal . The cl osed rel ay contacts
energi ze the starter sol enoi d coi l wi ndi ngs.
The energi zed sol enoi d pul l -i n coi l pul l s i n the sol e-
noi d pl unger. The sol enoi d pl unger pul l s the shi ft
l ever i n the starter motor. Thi s engages the starter
overrunni ng cl utch and pi ni on gear wi th the starter
ri ng gear on the automati c transmi ssi on torque con-
verter dri ve pl ate.
As the sol enoi d pl unger reaches the end of i ts
travel , the sol enoi d contact di sc compl etes the hi gh-
amperage starter feed ci rcui t and energi zes the sol e-
noi d pl unger hol d-i n coi l . Current now fl ows between
the sol enoi d battery termi nal and the starter motor,
energi zi ng the starter.
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter motor from damage by al l owi ng the
starter pi ni on gear to spi n faster than the pi ni on
shaft. When the dri ver rel eases the i gni ti on swi tch to
the On posi ti on, the starter rel ay coi l i s de-energi zed.
Thi s causes the rel ay contacts to open. When the
rel ay contacts open, the starter sol enoi d pl unger
hol d-i n coi l i s de-energi zed.
When the sol enoi d pl unger hol d-i n coi l i s de-ener-
gi zed, the sol enoi d pl unger return spri ng returns the
pl unger to i ts rel axed posi ti on. Thi s causes the con-
tact di sc to open the starter feed ci rcui t, and the shi ft
l ever to di sengage the overrunni ng cl utch and pi ni on
gear from the starter ri ng gear.
DIAGNOSIS AND TESTING - STARTING
SYSTEM
The battery, starti ng, and chargi ng systems oper-
ate wi th one another, and must be tested as a com-
pl ete system. I n order for the vehi cl e to start and
charge properl y, al l of the components i nvol ved i n
these systems must perform wi thi n speci fi cati ons.
Group 8A covers the Battery, Group 8B covers the
Starti ng Systems, and Group 8C covers the Chargi ng
System. We have separated these systems to make i t
easi er to l ocate the i nformati on you are seeki ng
wi thi n thi s Servi ce Manual . However, when attempt-
i ng to di agnose any of these systems, i t i s i mportant
that you keep thei r i nterdependency i n mi nd.
The di agnosti c procedures used i n these groups
i ncl ude the most basi c conventi onal di agnosti c meth-
ods, to the more sophi sti cated On-Board Di agnosti cs
(OBD) bui l t i nto the Powertrai n Control Modul e
(PCM). Use of an i nducti on-type mi l l i ampere amme-
ter, vol t/ohmmeter, battery charger, carbon pi l e rheo-
stat (l oad tester), and 12-vol t test l amp may be
requi red.
Al l OBD-sensed systems are moni tored by the
PCM. Each moni tored ci rcui t i s assi gned a Di agnos-
ti c Troubl e Code (DTC). The PCM wi l l store a DTC i n
el ectroni c memory for any fai l ure i t detects. Refer to
On-Board Diagnostic Test For Charging System
i n the Di agnosi s and Testi ng secti on of Group 8C -
Chargi ng System for more i nformati on.
8F - 30 STARTING WJ
STARTING (Continued)
Starting System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO
OPERATE.
1. Battery discharged or
faulty.
1. Refer to Battery in the Diagnosis and Testing section of
Group 8A - Battery. Charge or replace the battery, if
required.
2. Starting circuit wiring
faulty.
2. Refer to Starting System in Group 8W - Wiring
Diagrams. Test and repair the starter feed and/or control
circuits, if required.
3. Starter relay faulty. 3. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace the starter relay, if
required.
4. Ignition switch faulty. 4. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
5. Park/Neutral position
switch faulty or
misadjusted.
5. Refer to Park/Neutral Position Switch in the Diagnosis
and Testing section of Group 21 - Transmission. Replace
the park/neutral position switch, if required.
6. Starter solenoid faulty. 6. Refer to Starter Motor in the Diagnosis and Testing
section of this group. Replace the starter motor assembly,
if required.
7. Starter motor faulty. 7. If all other starting system components and circuits test
OK, replace the starter motor assembly.
STARTER ENGAGES,
FAILS TO TURN
ENGINE.
1. Battery discharged or
faulty.
1. Refer to Battery in the Diagnosis and Testing section of
Group 8A - Battery. Charge or replace the battery, if
required.
2. Starting circuit wiring
faulty.
2. Refer to Starting System in Group 8W - Wiring
Diagrams. Test and repair the starter feed and/or control
circuits, if required.
4. Engine seized. 4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of Group 9 - Engine.
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.
1. Starter ring gear faulty. 1. Refer to Starter Motor in the Removal and Installation
section of this group. Remove the starter motor to inspect
the starter ring gear. Replace the starter ring gear, if
required.
STARTER DOES NOT
DISENGAGE.
1. Starter motor
improperly installed.
1. Refer to Starter Motor in the Removal and Installation
section of this group. Tighten the starter mounting
hardware to the correct tightness specifications.
2. Starter relay faulty. 2. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace the starter relay, if
required.
3. Ignition switch faulty. 3. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
WJ STARTING 8F - 31
INSPECTION
For compl ete ci rcui t di agrams, refer to Starting
System i n the Contents of Group 8W - Wi ri ng Di a-
grams. Before removi ng any uni t from the starti ng
system for repai r or di agnosi s, perform the fol l owi ng
i nspecti ons:
BAGS, 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 PRE-
INJURY.
Battery - Vi sual l y i nspect the battery for i ndi -
cati ons of physi cal damage and l oose or corroded
cabl e connecti ons. Determi ne the state-of-charge and
cranki ng capaci ty of the battery. Charge or repl ace
the battery, i f requi red. Refer to Battery i n the
proper secti on of Group 8A - Battery for compl ete ser-
vi ce i nformati on for the battery.
Ignition Switch - Vi sual l y i nspect the i gni ti on
swi tch for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons. Refer to Igni-
tion Switch and Key Lock Cylinder i n the proper
secti on of Group 8D - I gni ti on System for compl ete
servi ce i nformati on for the i gni ti on swi tch.
Park/Neutral Position Switch - Vi sual l y
i nspect the park/neutral posi ti on swi tch for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
harness connecti ons. Refer to Park/Neutral Posi-
tion Switch i n the proper secti on of Group 21 -
Transmi ssi on for compl ete servi ce i nformati on for the
park/neutral posi ti on swi tch.
Starter Relay - Vi sual l y i nspect the starter
rel ay for i ndi cati ons of physi cal damage and l oose or
corroded wi re harness connecti ons.
Starter Motor - Vi sual l y i nspect the starter
motor for i ndi cati ons of physi cal damage and l oose or
corroded wi re harness connecti ons.
Starter Solenoid - Vi sual l y i nspect the starter
sol enoi d for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons.
Wiring - Vi sual l y i nspect the wi re harnesses for
damage. Repai r or repl ace any faul ty wi ri ng, as
requi red. Refer to the proper secti on of Group 8W -
Wiring Diagrams for compl ete servi ce i nformati on
and ci rcui t di agrams for the starti ng system wi ri ng
components.
TESTING
COLD CRANKING TEST
For compl ete ci rcui t di agrams, refer to Starting
System i n the Contents of Group 8W - Wi ri ng Di a-
grams. The battery must be ful l y-charged and l oad-
tested before proceedi ng. Refer to Battery i n the
Di agnosi s and Testi ng secti on of Group 8A - Battery
for the procedures.
(1) Connect a sui tabl e vol t-ampere tester to the
battery termi nal s (Fi g. 1). See the i nstructi ons pro-
vi ded by the manufacturer of the vol t-ampere tester
bei ng used.
(2) Ful l y engage the parki ng brake.
(3) Pl ace the automati c transmi ssi on gearshi ft
sel ector l ever i n the Park posi ti on.
(4) Veri fy that al l l amps and accessori es are
turned off.
(5) To prevent the engi ne from starti ng, remove
the Automati c ShutDown (ASD) rel ay. The ASD rel ay
i s l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. Refer to the fuse and rel ay
l ayout l abel affi xed to the undersi de of the PDC cover
(6) Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Note the cranki ng vol tage and current
(amperage) draw readi ngs shown on the vol t-ampere
tester.
(a) I f the vol tage reads bel ow 9.6 vol ts, refer to
Starter Motor i n the Di agnosi s and Testi ng sec-
ti on of thi s group. I f the starter motor i s OK, refer
to Engine Diagnosis i n the Di agnosi s and Testi ng
secti on of Group 9 - Engi ne for further testi ng of
the engi ne. I f the starter motor i s not OK, repl ace
the faul ty starter motor.
Fig. 1 Volts-Amps Tester Connections - Typical
1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP
8F - 32 STARTING WJ
(b) I f the vol tage reads above 9.6 vol ts and the
current (amperage) draw reads bel ow speci fi ca-
ti ons, refer to Feed Circuit Test i n thi s secti on.
(c) I f the vol tage reads 12.5 vol ts or greater and
the starter motor does not turn, refer to Control
Circuit Testing i n thi s secti on.
(d) I f the vol tage reads 12.5 vol ts or greater and
the starter motor turns very sl owl y, refer to Feed
Circuit Test i n thi s secti on.
NOTE: A cold engine will increase the starter cur-
rent (amperage) draw reading, and reduce the bat-
tery voltage reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n the
hi gh-amperage feed ci rcui t. For compl ete ci rcui t di a-
grams, refer to Starting System i n the Contents of
Group 8W - Wi ri ng Di agrams.
When performi ng these tests, i t i s i mportant to
remember that the vol tage drop i s gi vi ng an i ndi ca-
ti on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached.
Example: When testi ng the resi stance of the bat-
tery posi ti ve cabl e, touch the vol tmeter l eads to the
battery posi ti ve cabl e cl amp and the cabl e connector
at the starter sol enoi d. I f you probe the battery pos-
i ti ve termi nal post and the cabl e connector at the
starter sol enoi d, you are readi ng the combi ned vol t-
age drop i n the battery posi ti ve cabl e cl amp-to-termi -
nal post connecti on and the battery posi ti ve cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng the
tests, be certai n that the fol l owi ng procedures are
accompl i shed:
Battery i s ful l y-charged and l oad-tested. Refer to
Battery i n the Di agnosi s and Testi ng secti on of
Group 8A - Battery for the procedures.
Ful l y engage the parki ng brake.
Pl ace the automati c transmi ssi on gearshi ft sel ec-
tor l ever i n the Park posi ti on.
Veri fy that al l l amps and accessori es are turned off.
To prevent the engi ne from starti ng, remove the
Automati c ShutDown (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. Refer to the fuse and rel ay
l ayout l abel affi xed to the undersi de of the PDC cover
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e cl amp (Fi g. 2). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor contact between
the cabl e cl amp and the termi nal post.
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
cl amp (Fi g. 3). Rotate and hol d the i gni ti on swi tch i n
the Start posi ti on. Observe the vol tmeter. I f vol tage
i s detected, correct the poor contact between the
cabl e cl amp and the termi nal post.
battery posi ti ve termi nal post and the starter sol e-
noi d battery termi nal stud (Fi g. 4). Rotate and hol d
ti ghten the battery cabl e connecti on at the sol enoi d.
Fig. 2 Test Battery Negative Connection Resistance
- Typical
1 - VOLTMETER
2 - BATTERY
Fig. 3 Test Battery Positive Connection Resistance -
Typical
1 - VOLTMETER
2 - BATTERY
WJ STARTING 8F - 33
repl ace the faul ty battery posi ti ve cabl e.
battery negati ve termi nal post and a good cl ean
ground on the engi ne bl ock (Fi g. 5). Rotate and hol d
ti ghten the battery negati ve cabl e attachment on the
engi ne bl ock. Repeat the test. I f the readi ng i s sti l l
above 0.2 vol t, repl ace the faul ty battery negati ve
cabl e.
the starter housi ng. Connect the negati ve l ead of the
vol tmeter to the battery negati ve termi nal post (Fi g.
6). Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Observe the vol tmeter. I f the readi ng i s
above 0.2 vol t, correct the poor starter to engi ne
bl ock ground contact.
I f the resi stance tests detect no feed ci rcui t prob-
l ems, refer to Starter Motor i n the Di agnosi s and
Testi ng secti on of thi s group.
CONTROL CIRCUIT TESTING
The starter control ci rcui t components shoul d be
tested i n the order i n whi ch they are l i sted, as fol -
l ows:
Starter Relay - Refer to Starter Relay i n the
Di agnosi s and Testi ng secti on of thi s group for the
procedures.
Starter Solenoid - Refer to Starter Motor i n
the Di agnosi s and Testi ng secti on of thi s group for
the procedures.
Ignition Switch - Refer to Ignition Switch
and Key Lock Cylinder i n the Di agnosi s and Test-
i ng secti on of Group 8D - I gni ti on System for the pro-
cedures.
Park/Neutral Position Switch - Refer to
Park/Neutral Position Switch i n the Di agnosi s
and Testi ng secti on of Group 21 - Transmi ssi on for
the procedures.
Wire harnesses and connections - Refer to
Starting System i n the Contents of Group 8W -
Wi ri ng Di agrams for compl ete ci rcui t di agrams.
Fig. 4 Test Battery Positive Cable Resistance -
Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
Fig. 5 Test Ground Circuit
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 6 Test Starter Ground - Typical
1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER
8F - 34 STARTING WJ
SPECIFICATIONS
TORQUE - STARTER
Stater Motor (B+) Terminal
(Diesel)
27 20
Stater Motor (B+) Terminal
(Except Diesel)
11.3 100
Starter Motor Retaining Bolts
(Diesel)
27 20
Starter Motor Retaining Bolt
(Forward Facing 4.0L)
41 30
(Forward Facing 4.7L)
54 40
(Rearward Facing 4.7L)
54 40
STARTER MOTOR - GAS POWERED
Starter Motor and Solenoid
Manufacturer Mitsubishi
Engine Application 4.0L/4.7L
Power Rating 1.4 Kilowatt (1.9 Horsepower)
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.2 Volts
Free Running Test Maximum Amperage Draw 90 Amperes
Free Running Test Minimum Speed 2400 rpm
Solenoid Closing Maximum Voltage Required 7.8 Volts
*Cranking Amperage Draw Test 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
STARTER MOTOR
DESCRIPTION
The starter motors used for both the 4.0L and the
4.7L engi nes avai l abl e i n thi s model are very si mi l ar,
but are not i nterchangeabl e. Both starter motors are
mounted wi th two screws to the automati c transmi s-
si on torque converter housi ng and are l ocated on the
ri ght si de of the engi ne.
Each of these starter motors i ncorporates several
of the same features to create a rel i abl e, effi ci ent,
compact, l i ghtwei ght and powerful uni t. The el ectri c
motors of both starters feature four el ectromagneti c
fi el d coi l s wound around four pol e shoes, and four
brushes contact the motor commutator. Both starter
motors are rated at 1.4 ki l owatts (about 1.9 horse-
power) output at 12 vol ts.
Both of these starter motors are servi ced onl y as a
uni t wi th thei r starter sol enoi ds, and cannot be
repai red. I f ei ther component i s faul ty or damaged,
the enti re starter motor and starter sol enoi d uni t
must be repl aced.
WJ STARTING 8F - 35
OPERATION
These starter motors are equi pped wi th a pl ane-
tary gear reducti on (i ntermedi ate transmi ssi on) sys-
tem. The pl anetary gear reducti on system consi sts of
a gear that i s i ntegral to the output end of the el ec-
tri c motor armature shaft that i s i n conti nual
engagement wi th a l arger gear that i s spl i ned to the
i nput end of the starter pi ni on gear shaft. Thi s fea-
ture makes i t possi bl e to reduce the di mensi ons of
the starter. At the same ti me, i t al l ows hi gher arma-
ture rotati onal speed and del i vers i ncreased torque
through the starter pi ni on gear to the starter ri ng
gear.
The starter motors for both engi nes are acti vated
by an i ntegral heavy duty starter sol enoi d swi tch
mounted to the overrunni ng cl utch housi ng. Thi s
el ectromechani cal swi tch connects and di sconnects
the feed of battery vol tage to the starter motor and
actuates a shi ft fork that engages and di sengages the
starter pi ni on gear wi th the starter ri ng gear.
Both starter motors use an overrunni ng cl utch and
starter pi ni on gear uni t to engage and dri ve a starter
ri ng gear that i s i ntegral to the torque converter
dri ve pl ate mounted on the rear crankshaft fl ange.
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operati on can be confi rmed
by performi ng the fol l owi ng free runni ng bench test.
Thi s test can onl y be performed wi th the starter
motor removed from the vehi cl e. Refer to Starting
System i n the Speci fi cati ons secti on of thi s group for
the starter motor speci fi cati ons.
(1) Remove the starter motor from the vehi cl e.
Refer to Starter Motor i n the Removal and I nstal -
l ati on secti on of thi s group for the procedures.
(2) Mount the starter motor securel y i n a soft-
jawed bench vi se. The vi se jaws shoul d be cl amped
on the mounti ng fl ange of the starter motor. Never
cl amp on the starter motor by the fi el d frame.
(3) Connect a sui tabl e vol t-ampere tester and a
12-vol t battery to the starter motor i n seri es, and set
the ammeter to the 100 ampere scal e. See the
i nstructi ons provi ded by the manufacturer of the
vol t-ampere tester bei ng used.
(4) I nstal l a jumper wi re from the sol enoi d termi -
nal to the sol enoi d battery termi nal . The starter
motor shoul d operate. I f the starter motor fai l s to
operate, repl ace the faul ty starter motor assembl y.
(5) Adjust the carbon pi l e l oad of the tester to
obtai n the free runni ng test vol tage. Refer to Start-
ing System i n the Speci fi cati ons secti on of thi s
group for the starter motor free runni ng test vol tage
speci fi cati ons.
(6) Note the readi ng on the ammeter and compare
thi s readi ng to the free runni ng test maxi mum
amperage draw. Refer to Starting System i n the
Speci fi cati ons secti on of thi s group for the starter
motor free runni ng test maxi mum amperage draw
speci fi cati ons.
(7) I f the ammeter readi ng exceeds the maxi mum
amperage draw speci fi cati on, repl ace the faul ty
starter motor assembl y.
STARTER SOLENOID
Thi s test can onl y be performed wi th the starter
motor removed from the vehi cl e.
(1) Remove the starter motor from the vehi cl e.
Refer to Starter Motor i n the Removal and I nstal -
l ati on secti on of thi s group for the procedures.
(2) Di sconnect the wi re from the sol enoi d fi el d coi l
termi nal .
(3) Check for conti nui ty between the sol enoi d ter-
mi nal and the sol enoi d fi el d coi l termi nal wi th a con-
ti nui ty tester (Fi g. 7). There shoul d be conti nui ty. I f
OK, go to Step 4. I f not OK, repl ace the faul ty starter
motor assembl y.
(4) Check for conti nui ty between the sol enoi d ter-
mi nal and the sol enoi d case (Fi g. 8). There shoul d be
conti nui ty. I f not OK, repl ace the faul ty starter motor
assembl y.
Fig. 7 Continuity Test Between Solenoid Terminal
and Field Coil Terminal - Typical
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
4 - FIELD COIL TERMINAL
Fig. 8 Continuity Test Between Solenoid Terminal
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
8F - 36 STARTING WJ
STARTER MOTOR (Continued)
REMOVAL
cabl e.
(3) Remove the l ower (forward faci ng) mounti ng
screw securi ng the starter motor to the automati c
transmi ssi on torque converter housi ng (Fi g. 9) or
(Fi g. 10) .
(4) Whi l e supporti ng the starter motor wi th one
hand, use the other hand to remove the upper (rear
faci ng) mounti ng screw securi ng the starter motor to
the automati c transmi ssi on torque converter housi ng.
(5) Lower the starter motor from the front of the
automati c transmi ssi on torque converter housi ng far
enough to access and remove the nut that secures
the battery cabl e eyel et to the sol enoi d battery termi -
nal (Fi g. 11) or (Fi g. 12) . Al ways support the starter
motor duri ng thi s process, do not l et the starter
motor hang from the wi re harness.
(6) Remove the battery cabl e eyel et from the sol e-
noi d battery termi nal . Al ways support the starter
(7) Di sconnect the sol enoi d termi nal wi re harness
connector from the connector receptacl e on the
starter sol enoi d. Al ways support the starter motor
duri ng thi s process, do not l et the starter motor hang
from the wi re harness.
Fig. 9 Starter Motor Remove/Install - 4.0L Engine
1 - SCREW
2 - STARTER MOTOR
3 - SCREW
Fig. 10 Starter Motor Remove/Install - 4.7L Engine
1 - SCREW
2 - STARTER MOTOR
3 - SCREW
Fig. 11 Starter Wire Harness Remove/Install - 4.0L
Engine
1 - BATTERY, STARTER AND GENERATOR WIRE HARNESS
2 - GROUND EYELET
3 - SCREW
4 - NUT
5 - SOLENOID TERMINAL CONNECTOR
6 - SOLENOID BATTERY TERMINAL EYELET
7 - RETAINERS
WJ STARTING 8F - 37
(8) Remove the starter motor from the engi ne com-
partment.
INSTALLATION
(1) Posi ti on the starter motor i n the engi ne com-
partment.
(2) Reconnect the sol enoi d termi nal wi re harness
connector to the connector receptacl e on the starter
sol enoi d. Al ways support the starter motor duri ng
thi s process, do not l et the starter motor hang from
the wi re harness.
(3) I nstal l the battery cabl e eyel et onto the sol e-
noi d battery termi nal . Al ways support the starter
battery cabl e eyel et to the sol enoi d battery termi nal .
Ti ghten the nut to 11.3 Nm (100 i n. l bs.). Al ways
support the starter motor duri ng thi s process, do not
l et the starter motor hang from the wi re harness.
(5) Posi ti on the starter motor to the front of the
automati c transmi ssi on torque converter housi ng and
l oosel y i nstal l both the upper and l ower mounti ng
screws.
(6) Ti ghten the l ower (forward faci ng) starter
motor mounti ng screw. On 4.0L engi nes, ti ghten the
screw to 41 Nm (30 ft. l bs.). On 4.7L engi nes, ti ghten
the screw to 54 Nm (40 ft. l bs.).
(7) Ti ghten the upper (rearward faci ng) starter
mounti ng screw. Ti ghten the screw to 54 Nm (40 ft.
l bs.).
STARTER MOTOR RELAY
DESCRIPTION
The starter rel ay i s an el ectromechani cal devi ce
that swi tches battery current to the pul l -i n coi l of the
starter sol enoi d when the i gni ti on swi tch i s turned to
the Start posi ti on. The starter rel ay i s l ocated i n the
Power Di stri buti on Center (PDC), i n the engi ne com-
partment. See the fuse and rel ay l ayout l abel affi xed
to the i nsi de surface of the PDC cover for starter
rel ay i denti fi cati on and l ocati on.
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO) mi cro-rel ay. Rel ays conformi ng to
the I SO speci fi cati ons have common physi cal di men-
si ons, current capaci ti es, termi nal patterns, and ter-
mi nal functi ons. The I SO mi cro-rel ay termi nal
functi ons are the same as a conventi onal I SO rel ay.
However, the I SO mi cro-rel ay termi nal pattern (or
footpri nt) i s di fferent, the current capaci ty i s l ower,
and the physi cal di mensi ons are smal l er than those
of the conventi onal I SO rel ay.
The starter rel ay cannot be repai red or adjusted
and, i f faul ty or damaged, i t must be repl aced.
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When the el ec-
tromagneti c coi l i s energi zed, i t draws the movabl e
contact away from the normal l y cl osed fi xed contact,
and hol ds i t agai nst the other (normal l y open) fi xed
contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor or di ode i s con-
nected i n paral l el wi th the el ectromagneti c coi l i n the
rel ay, and hel ps to di ssi pate vol tage spi kes that are
produced when the coi l i s de-energi zed.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter rel ay (Fi g. 13) i s l ocated i n the Power
Di stri buti on Center (PDC), i n the engi ne compart-
ment. Refer to the fuse and rel ay l ayout l abel affi xed
to the undersi de of the PDC cover for starter rel ay
i denti fi cati on and l ocati on. For compl ete ci rcui t di a-
grams, refer to Starting System i n the Contents of
Group 8W - Wi ri ng Di agrams.
Fig. 12 Starter Wire Harness Remove/Install - 4.7L
Engine
1 - SOLENOID BATTERY TERMINAL EYELET
2 - NUT
3 - SOLENOID TERMINAL CONNECTOR
4 - BATTERY STARTER AND GENERATOR WIRE HARNESS
5 - RETAINERS
8F - 38 STARTING WJ
(1) Remove the starter rel ay from the PDC. Refer
to Starter Relay i n the Removal and I nstal l ati on
secti on of thi s group for the procedures.
(2) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 3. I f not OK, repl ace the faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
4. I f not OK, repl ace the faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform the Rel ay Ci rcui t Test that
fol l ows. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the fuse i n the PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the starter sol enoi d fi el d coi l s. There shoul d be
conti nui ty between the cavi ty for rel ay termi nal 87
and the starter sol enoi d termi nal at al l ti mes. I f OK,
go to Step 4. I f not OK, repai r the open ci rcui t to the
starter sol enoi d as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s energi zed when
the i gni ti on swi tch i s hel d i n the Start posi ti on.
Check for battery vol tage at the cavi ty for rel ay ter-
mi nal 86 wi th the i gni ti on swi tch i n the Start posi -
ti on, and no vol tage when the i gni ti on swi tch i s
rel eased to the On posi ti on. I f OK, go to Step 5. I f
not OK, check for an open or short ci rcui t to the i gni -
ti on swi tch and repai r, i f requi red. I f the ci rcui t to
the i gni ti on swi tch i s OK, refer to Ignition Switch
and Key Lock Cylinder i n the Di agnosi s and Test-
i ng secti on of Group 8D - I gni ti on System for testi ng
of the i gni ti on swi tch.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. I t i s grounded
through the park/neutral posi ti on swi tch onl y when
the gearshi ft sel ector l ever i s i n the Park or Neutral
posi ti ons. Check for conti nui ty to ground at the cav-
i ty for rel ay termi nal 85. I f not OK, check for an
open or short ci rcui t to the park/neutral posi ti on
swi tch and repai r, i f requi red. I f the ci rcui t to the
park/neutral posi ti on swi tch i s OK, refer to Park/
Neutral Position Switch i n the Di agnosi s and
Testi ng secti on of Group 21 - Transmi ssi on for testi ng
of the park/neutral posi ti on swi tch.
REMOVAL
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 14) .
Fig. 13 Starter Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
Fig. 14 Power Distribution Center
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
WJ STARTING 8F - 39
STARTER MOTOR RELAY (Continued)
(3) See the fuse and rel ay l ayout l abel affi xed to
the undersi de of the PDC cover for starter rel ay i den-
ti fi cati on and l ocati on.
(4) Remove the starter rel ay from the PDC.
INSTALLATION
the undersi de of the PDC cover for the proper starter
rel ay l ocati on.
(2) Posi ti on the starter rel ay i n the proper recep-
tacl e i n the PDC.
(3) Al i gn the starter rel ay termi nal s wi th the ter-
mi nal cavi ti es i n the PDC receptacl e.
(4) Push down fi rml y on the starter rel ay unti l the
termi nal s are ful l y seated i n the termi nal cavi ti es i n
the PDC receptacl e.
(5) I nstal l the cover onto the PDC.
8F - 40 STARTING WJ
STARTER MOTOR RELAY (Continued)
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 8
HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 9
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION - REAR WINDOW DEFOGGER . . 1
OPERATION - REAR WINDOW DEFOGGER . . . . 2
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . 2
REAR WINDOW DEFOGGER GRID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DEFOGGER GRID . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - REAR GLASS
HEATING GRID REPAIR . . . . . . . . . . . . . . . . . 4
REAR WINDOW DEFOGGER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HEATED GLASS
DESCRIPTION - REAR WINDOW DEFOGGER
An el ectri cal l y heated rear wi ndow defogger i s
El ectri cal l y heated outsi de rear vi ew mi rrors are
avai l abl e factory-i nstal l ed opti onal equi pment. When
the rear wi ndow defogger system i s turned on, el ec-
tri c heater gri ds on the l i ftgate fl i p-up gl ass and
behi nd both outsi de rear vi ew mi rror gl asses are
energi zed. These el ectri c heater gri ds produce heat to
hel p cl ear the rear wi ndow gl ass and the outsi de rear
vi ew mi rrors of i ce, snow, or fog. The rear wi ndow
defogger system control ci rcui t uses i gni ti on swi tched
battery current, so the system wi l l onl y operate when
the i gni ti on swi tch i s i n the On posi ti on.
Thi s group covers the fol l owi ng components of the
rear wi ndow defogger system:
Rear gl ass heati ng gri d
Rear wi ndow defogger rel ay
Rear wi ndow defogger swi tch.
Certai n functi ons and features of the rear wi ndow
defogger system rel y upon resources shared wi th
other el ectroni c modul es i n the vehi cl e over the Pro-
network. The PCI data bus network al l ows the shar-
i ng of sensor i nformati on. Thi s hel ps to reduce wi re
harness compl exi ty, i nternal control l er hardware, and
component sensor current l oads. At the same ti me,
thi s system provi des i ncreased rel i abi l i ty, enhanced
di agnosti cs, and al l ows the addi ti on of many new fea-
ture capabi l i ti es. For di agnosi s of these el ectroni c
modul es or of the PCI data bus network, use a
DRBI I I scan tool and (Refer to Appropri ate Di agnos-
ti c I nformati on).
The other el ectroni c modul es that may affect
proper system operati on are:
Body Control Module (BCM) - Refer to El ec-
troni c Control Modul es for more i nformati on.
Driver Door Module (DDM) - Refer to El ec-
troni c Control Modul es for more i nformati on.
WJ HEATED SYSTEMS 8G - 1
Passenger Door Module (PDM) - Refer to
El ectroni c Control Modul es for more i nformati on.
OPERATION - REAR WINDOW DEFOGGER
The rear wi ndow defogger system i s control l ed by a
momentary swi tch that i s i ntegral to the a/c heater
control l ocated i n the center stack area of the i nstru-
ment panel . A Li ght-Emi tti ng Di ode (LED) i n the
swi tch button wi l l l i ght to i ndi cate when the rear
wi ndow defogger system i s turned on. The BCM,
whi ch contai ns the rear wi ndow defogger system
ti mer and control l ogi c, moni tors the status of the
defogger swi tch through a hard-wi red i nput. The
BCM then sends control outputs through a hard
wi red ci rcui t to energi ze or de-energi ze the defogger
rel ay.
The el ectri cal l y heated outsi de rear vi ew mi rror
heati ng gri ds are al so control l ed by the rear wi ndow
defogger swi tch. When the BCM recei ves an i nput
from the swi tch, i t sends a defogger swi tch status
message to the DDM and the PDM over the PCI data
bus. The DDM and PDM respond to the defogger
swi tch status messages by energi zi ng or de-energi z-
i ng the battery current feed to thei r respecti ve out-
si de rear vi ew mi rror heati ng gri ds.
The rear wi ndow defogger system wi l l be automat-
i cal l y turned off after a programmed ti me i nterval of
about ten mi nutes. After the i ni ti al ti me i nterval has
expi red, i f the defogger swi tch i s turned on agai n
duri ng the same i gni ti on cycl e, the defogger system
wi l l automati cal l y turn off after about fi ve mi nutes.
The defogger system wi l l automati cal l y shut off i f the
i gni ti on swi tch i s turned to the Off posi ti on, or i t can
be turned off manual l y by depressi ng the rear wi n-
dow defogger swi tch agai n.
of the rear wi ndow defogger system.
DEFOGGER SYSTEM
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
For compl ete ci rcui t di agrams, (Refer to Appropri -
ate Wi ri ng I nformati on). The operati on of the el ectri -
cal l y heated rear wi ndow defogger system can be
confi rmed i n one of the fol l owi ng manners:
1. Turn the i gni ti on swi tch to the On posi ti on.
Whi l e moni tori ng the i nstrument panel vol tmeter,
depress the rear wi ndow defogger swi tch to the On
posi ti on. When the rear wi ndow defogger swi tch i s
turned On, a di sti nct vol tmeter needl e defl ecti on
shoul d be noted.
2. Turn the i gni ti on swi tch to the On posi ti on.
Depress the rear wi ndow defogger swi tch to the On
posi ti on. The rear wi ndow defogger operati on can be
checked by feel i ng the rear wi ndow or outsi de rear
vi ew mi rror gl ass. A di sti nct di fference i n tempera-
ture between the gri d l i nes and the adjacent cl ear
gl ass or the mi rror gl ass can be detected wi thi n three
to four mi nutes of operati on.
3. Usi ng a 12-vol t DC vol tmeter, contact the rear
gl ass heati ng gri d termi nal A (ri ght si de) wi th the
negati ve l ead, and termi nal B (l eft si de) wi th the pos-
i ti ve l ead (Fi g. 1). The vol tmeter shoul d read battery
vol tage.
The above checks wi l l confi rm rear wi ndow defog-
ger system operati on. I l l umi nati on of the rear wi n-
dow defogger swi tch LED i ndi cator means that there
i s battery current avai l abl e at the output of the rear
wi ndow defogger rel ay, but does not confi rm that bat-
tery current i s reachi ng the rear gl ass heati ng gri d
l i nes.
I f the rear wi ndow defogger system does not oper-
ate, the probl em shoul d be i sol ated i n the fol l owi ng
manner:
Fig. 1 REAR WINDOW GLASS GRID TEST
1 - TERMINAL A
2 - TERMINAL B
3 - FEED WIRE
4 - MID-POINT C (TYPICAL)
5 - HEATED REAR WINDOW DEFOGGER GRID
6 - GROUND WIRE
8G - 2 HEATED GLASS WJ
HEATED GLASS (Continued)
(1) Confi rm that the i gni ti on swi tch i s i n the On
posi ti on.
(2) Ensure that the rear gl ass heati ng gri d feed
and ground termi nal s are connected to the gl ass.
Confi rm that the ground wi re has conti nui ty to
ground.
(3) Check the fused B(+) fuse i n the Power Di stri -
buti on Center (PDC). The fuse must be ti ght i n i ts
receptacl es and al l el ectri cal connecti ons must be
secure.
When the above steps have been compl eted and the
rear gl ass heati ng gri d i s sti l l i noperati ve, one or
more of the fol l owi ng i s faul ty:
Rear wi ndow defogger swi tch
Rear wi ndow defogger rel ay
Body Control Modul e (BCM)
Rear wi ndow gri d l i nes (al l gri d l i nes woul d
have to be broken or one of the feed wi res di scon-
nected for the enti re system to be i noperati ve).
When the above steps have been compl eted and the
heated mi rror gl ass heati ng gri d i s sti l l i noperati ve,
one or more of the fol l owi ng i s faul ty:
Programmabl e Communi cati ons I nterface (PCI )
data bus
Dri ver Door Modul e (DDM) or Passenger Door
Modul e (PDM)
Outsi de rear vi ew mi rror heati ng gri ds.
I f turni ng the rear wi ndow defogger system on pro-
duces a severe vol tmeter defl ecti on, check for a short
ci rcui t between the rear wi ndow defogger rel ay out-
put and the rear gl ass heati ng gri d.
REAR WINDOW DEFOGGER
GRID
DESCRIPTION
The el ectri cal l y heated rear wi ndow gl ass i s stan-
dard equi pment on thi s model . The l i ftgate fl i p-up
gl ass has two el ectri cal l y conducti ve verti cal bus bars
and a seri es of hori zontal gri d l i nes made of a si l ver-
cerami c materi al , whi ch i s baked on and bonded to
the i nsi de surface of the gl ass. These gri d l i nes and
the bus bars compri se a paral l el el ectri cal ci rcui t. A
spade type termi nal near the top of each bus bar
accept the connectors from the two coi l ed l i ftgate
wi re harness take outs.
The gri d l i nes and bus bars are hi ghl y resi stant to
abrasi on. However, i t i s possi bl e for an open ci rcui t
to occur i n an i ndi vi dual gri d l i ne, resul ti ng i n no
current fl ow through the l i ne. The gri d l i nes can be
damaged or scraped off wi th sharp i nstruments. Care
shoul d be taken when cl eani ng the gl ass or removi ng
forei gn materi al s, decal s, or sti ckers from the gl ass.
Normal gl ass cl eani ng sol vents or hot water used
wi th rags or towel i ng i s recommended.
A repai r ki t i s avai l abl e to repai r the gri d l i nes and
bus bars, or to rei nstal l the heated gl ass termi nal s.
(Refer to 8 - ELECTRI CAL/HEATED GLASS/REAR
WI NDOW DEFOGGER GRI D - STANDARD PROCE-
DURE)
OPERATION
The rear gl ass heati ng gri d i s energi zed and de-en-
ergi zed by the rear wi ndow defogger rel ay. The Body
Control Modul e (BCM) moni tors the rear wi ndow
defogger swi tch. When the BCM recei ves an i nput
from the swi tch, i t energi zes or de-energi zes the rear
wi ndow defogger rel ay through a hard wi red control
output. The rear defogger rel ay swi tches fused bat-
tery current to the rear wi ndow gri d l i nes through
the bus bars. The gri d l i nes heat the rear wi ndow
gl ass to cl ear the surface of i ce, snow or fog. Protec-
ti on for the rear gl ass heati ng gri d ci rcui t i s provi ded
by a fuse i n the Power Di stri buti on Center (PDC).
DEFOGGER GRID
For compl ete ci rcui t di agrams, (Refer to Appropri -
ate Wi ri ng I nformati on). To detect breaks i n the rear
gl ass heati ng gri d l i nes, the fol l owi ng procedure i s
requi red:
Turn the rear wi ndow defogger system on. The rear
wi ndow defogger swi tch LED i ndi cator shoul d l i ght.
I f OK, go to Step 2. I f not OK, (Refer to 8 - ELEC-
TRI CAL/HEATED GLASS/REAR WI NDOW DEFOG-
GER RELAY - DI AGNOSI S AND TESTI NG).
(2) Usi ng a 12-vol t DC vol tmeter, contact the rear
gl ass heati ng gri d verti cal bus bar on the ri ght si de
of the vehi cl e wi th the negati ve l ead. Wi th the posi -
ti ve l ead, contact the rear gl ass heati ng gri d verti cal
bus bar on the l eft si de of the vehi cl e. The vol tmeter
shoul d read battery vol tage. I f OK, go to Step 3. I f
not OK, repai r the open rear wi ndow defogger rel ay
output ci rcui t to the rear wi ndow defogger rel ay as
requi red.
(3) Wi th the posi ti ve vol tmeter l ead sti l l contacti ng
the rear gl ass heati ng gri d verti cal bus bar on the
l eft si de of the vehi cl e, move the negati ve l ead of the
vol tmeter to a good body ground poi nt. The vol tage
readi ng shoul d not change. I f OK, go to Step 4. I f not
OK, repai r the ground ci rcui t to ground as requi red.
(4) Connect the negati ve l ead of the vol tmeter to
the ri ght si de bus bar and touch each gri d l i ne at
mi dpoi nt C wi th the posi ti ve l ead (Fi g. 2). A readi ng
of approxi matel y si x vol ts i ndi cates a l i ne i s good. A
readi ng of zero vol ts i ndi cates a break i n the gri d
l i ne between mi dpoi nt C and the l eft si de rear gl ass
heati ng gri d bus bar. A readi ng of ten to fourteen
WJ HEATED GLASS 8G - 3
HEATED GLASS (Continued)
vol ts i ndi cates a break between mi dpoi nt C and the
ri ght si de rear heati ng gri d bus bar. Move the posi -
ti ve l ead on the gri d l i ne towards the break and the
vol tage readi ng wi l l change as soon as the break i s
crossed.
STANDARD PROCEDURE - REAR GLASS
HEATING GRID REPAIR
Repai r of the rear gl ass heati ng gri d l i nes, bus
bars, and termi nal s can be accompl i shed usi ng a
Mopar Rear Wi ndow Defogger Repai r Ki t (Part Num-
ber 4267922) or equi val ent.
WARNING: MATERIALS CONTAINED IN THE REPAIR
KIT MAY CAUSE SKIN OR EYE IRRITATION. THE
KIT CONTAINS EPOXY RESIN AND AMINE TYPE
HARDENER, WHICH ARE HARMFUL IF SWAL-
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) Mask the repai r area on the i nsi de of the rear
gl ass so that the conducti ve epoxy can be appl i ed
neatl y. Extend the epoxy appl i cati on onto the rear
gl ass heati ng gri d bus bar or gri d l i ne on each si de of
the break (Fi g. 3).
(2) Fol l ow the i nstructi ons i n the repai r ki t for
prepari ng the damaged area.
(3) Remove the package separator cl amp and mi x
the two conducti ve epoxy components thoroughl y
wi thi n the packagi ng. Fol d the package i n hal f and
cut the center corner to di spense the epoxy.
(4) For rear gl ass heati ng gri d l i ne repai rs, mask
the area to be repai red wi th maski ng tape or a tem-
pl ate.
(5) Appl y the epoxy through the sl i t i n the mask-
i ng tape or templ ate. Overl ap both ends of the break
by at l east 19 mi l l i meters (0.75 i nch).
(6) For a rear gl ass heati ng gri d termi nal repl ace-
ment, mask the adjacent areas so the epoxy can be
extended onto the adjacent gri d l i ne as wel l as onto
the bus bar. Appl y a thi n l ayer of epoxy to the area
where the termi nal was previ ousl y fastened and onto
the adjacent gri d l i ne.
(7) Appl y a thi n l ayer of conducti ve epoxy to the
termi nal and pl ace i t i n the proper l ocati on on the
rear gl ass heati ng gri d bus bar. To prevent the termi -
nal from movi ng whi l e the epoxy i s curi ng, i t must be
wedged or cl amped.
(8) Careful l y remove the maski ng tape or tem-
pl ate.
CAUTION: Do not allow the glass surface to exceed
204 C (400 F) or the glass may fracture.
(9) Al l ow the epoxy to cure for 24 hours at room
temperature, or use a heat gun wi th a 260 to 371 C
(500 to 700 F) range for fi fteen mi nutes. Hol d the
heat gun approxi matel y 25.4 centi meters (10 i nches)
from the repai r.
(10) After the conducti ve epoxy i s properl y cured,
remove the wedge or cl amp from the termi nal . Do
Fig. 2 REAR WINDOW GLASS GRID TEST
1 - TERMINAL A
2 - TERMINAL B
3 - FEED WIRE
4 - MID-POINT C (TYPICAL)
5 - HEATED REAR WINDOW DEFOGGER GRID
6 - GROUND WIRE
Fig. 3 GRID LINE REPAIR
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
REAR WINDOW DEFOGGER GRID (Continued)
not attach the wi re harness connectors unti l the cur-
i ng process i s compl ete.
(11) Check the operati on of the rear gl ass heati ng
gri d.
RELAY
DESCRIPTION
The rear wi ndow defogger rel ay i s an el ectrome-
chani cal devi ce that swi tches fused battery current to
the rear gl ass heati ng gri d and the Li ght-Emi tti ng
Di ode (LED) i ndi cator of the rear wi ndow defogger
swi tch, when the Body Control Modul e (BCM) rear
wi ndow defogger ti mer and l ogi c ci rcui try grounds
the rel ay coi l . The rear wi ndow defogger rel ay i s
l ocated i n the juncti on bl ock, under the l eft end of
the i nstrument panel i n the passenger compartment.
The rear wi ndow defogger rel ay i s a I nternati onal
Standards Organi zati on (I SO) rel ay. Rel ays conform-
i ng to the I SO speci fi cati ons have common physi cal
di mensi ons, current capaci ti es, termi nal patterns,
and termi nal functi ons.
The rear wi ndow defogger rel ay cannot be repai red
or adjusted and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
contact.
DEFOGGER RELAY
INJURY.
RELAY TEST
The rear wi ndow defogger rel ay (Fi g. 4) i s l ocated
i n the juncti on bl ock, under the l eft end of the i nstru-
ment panel i n the passenger compartment. Remove
the rear wi ndow defogger rel ay from the juncti on
bl ock to perform the fol l owi ng tests:
and 30. I f OK, refer to the Relay Circuit Test. I f
not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
fused B(+) ci rcui t to the Power Di stri buti on Center
(PDC) fuse as requi red.
Fig. 4 REAR WINDOW DEFOGGER RELAY
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
REAR WINDOW DEFOGGER GRID (Continued)
to the rear gl ass heati ng gri d and to the fuse i n the
juncti on bl ock that feeds the rear wi ndow defogger
swi tch LED i ndi cator. There shoul d be conti nui ty
between the cavi ty for rel ay termi nal 87 and the rear
gl ass heati ng gri d and the rear wi ndow defogger
swi tch LED i ndi cator at al l ti mes. I f OK, go to Step
4. I f not OK, repai r the open rear wi ndow defogger
rel ay output ci rcui t as requi red.
the el ectromagnet i n the rel ay. I t i s connected to bat-
tery vol tage and shoul d be hot at al l ti mes. Check for
battery vol tage at the cavi ty for rel ay termi nal 86. I f
OK, go to Step 5. I f not OK, repai r the open fused
B(+) ci rcui t to the PDC fuse as requi red.
the el ectromagnet i n the rel ay. Thi s termi nal i s pro-
vi ded wi th ground by the Body Control Modul e
(BCM) rear wi ndow defogger ti mer and l ogi c ci rcui try
to energi ze the defogger rel ay. There shoul d be conti -
nui ty to the rear wi ndow defogger rel ay control ci r-
cui t cavi ty of the 22-way i nstrument panel wi re
harness connector for the BCM. I f OK, use a DRB
scan tool and refer to the Appropri ate Di agnosti c
I nformati on to test the BCM. I f not OK, repai r the
open rear wi ndow defogger rel ay control ci rcui t as
requi red.
REMOVAL
INJURY.
cabl e.
from the i nstrument panel . Refer to I nstrument
Panel System for the procedures.
(3) The rear wi ndow defogger rel ay i s l ocated on
the ri ght si de of the combi nati on fl asher i n the junc-
ti on bl ock (Fi g. 5).
(4) Remove the rear wi ndow defogger rel ay from
the juncti on bl ock.
INSTALLATION
(1) Posi ti on the rear wi ndow defogger rel ay i n the
proper receptacl e i n the juncti on bl ock.
(2) Al i gn the rear wi ndow defogger rel ay termi nal s
wi th the termi nal cavi ti es i n the juncti on bl ock recep-
tacl e.
(3) Push i n fi rml y on the rear wi ndow defogger
rel ay unti l the termi nal s are ful l y seated i n the ter-
mi nal cavi ti es i n the juncti on bl ock receptacl e.
(4) I nstal l the steeri ng col umn openi ng cover onto
the i nstrument panel . Refer to I nstrument Panel Sys-
tem for the procedures.
SWITCH
DESCRIPTION
The rear wi ndow defogger swi tch i s i ntegral to the
a/c heater control , whi ch i s l ocated i n the i nstrument
panel center stack bel ow the radi o recei ver. Thi s
momentary swi tch provi des a hard wi red ground si g-
nal to the Body Control Modul e (BCM) each ti me i t i s
depressed. A Li ght Emi tti ng Di ode (LED) i n the push
button for the rear wi ndow defogger swi tch i l l umi -
nates to i ndi cate when the rear wi ndow defogger sys-
tem i s turned on.
The rear wi ndow defogger swi tch and the rear wi n-
dow defogger swi tch LED i ndi cator cannot be
Fig. 5 JUNCTION BLOCK
1 - COMBINATION FLASHER
2 - JUNCTION BLOCK
REAR WINDOW DEFOGGER RELAY (Continued)
repai red and, i f faul ty or damaged, the enti re a/c
heater control must be repl aced. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/CONTROLS/A/C
HEATER CONTROL - REMOVAL)
OPERATION
When the rear wi ndow defogger swi tch push but-
ton i s depressed, i t momentari l y cl oses the rear wi n-
dow defogger swi tch sense ci rcui t for the BCM to
ground. The BCM moni tors the rear wi ndow defogger
swi tch sense ci rcui t. Each ti me the BCM rear wi n-
dow defogger ti mer and l ogi c ci rcui try sees another
i nput from the swi tch, i t toggl es a control output to
the rear wi ndow defogger rel ay. Energi zi ng the rear
wi ndow defogger rel ay provi des el ectri cal current to
the rear wi ndow defogger gri d and to the LED i ndi -
cator i n the swi tch, whi ch l i ghts to i ndi cate when the
defogger system i s turned on. A dedi cated fuse i n the
juncti on bl ock protects the rear wi ndow defogger
rel ay output ci rcui t to the LED i ndi cator.
DEFOGGER SWITCH
For compl ete ci rcui t di agrams, refer to the Appro-
pri ate Wi ri ng I nformati on.
INJURY.
cabl e. Remove the a/c heater control from the i nstru-
ment panel and di sconnect the 11-way (manual tem-
perature control ) or 16-way (automati c zone control )
i nstrument panel wi re harness connector from the a/c
heater control receptacl e.
(2) Check for conti nui ty between the ground ci r-
cui t cavi ty of the 11-way or 16-way i nstrument panel
wi re harness connector for the a/c heater control and
a good ground. There shoul d be conti nui ty. I f OK, go
to Step 3. I f not OK, repai r the open ground ci rcui t to
ground as requi red.
(3) Connect two jumper wi res to the a/c heater
control 11-way or 16-way connector receptacl e. Con-
nect one jumper from the ground ci rcui t termi nal i n
the 11-way or 16-way a/c heater control connector
receptacl e to a good ground. Connect the other
jumper from the fused rear wi ndow defogger rel ay
output ci rcui t termi nal of the 11-way or 16-way con-
nector receptacl e to a 12-vol t battery feed. The rear
wi ndow defogger swi tch LED i ndi cator shoul d l i ght.
I f OK, go to Step 4. I f not OK, repl ace the faul ty a/c
heater control .
cui t and rear wi ndow defogger swi tch sense ci rcui t
termi nal s of the 11-way or 16-way a/c heater control
connector receptacl e. There shoul d be momentary
conti nui ty as the rear wi ndow defogger swi tch push
button i s depressed, and then no conti nui ty. I f OK, go
to Step 5. I f not OK, repl ace the faul ty a/c heater
control .
(5) Di sconnect the 22-way i nstrument panel wi re
harness connector from the Body Control Modul e
(BCM) connector receptacl e. Check for conti nui ty
between the rear wi ndow defogger swi tch sense ci r-
cui t cavi ty of the 11-way or 16-way i nstrument panel
wi re harness connector for the a/c heater control and
a good ground. There shoul d be no conti nui ty. I f OK,
go to Step 6. I f not OK, repai r the shorted rear wi n-
dow defogger swi tch sense ci rcui t as requi red.
(6) Check for conti nui ty between the rear wi ndow
defogger swi tch sense ci rcui t cavi ti es of the 11-way or
16-way i nstrument panel wi re harness connector for
the a/c heater control and the 22-way i nstrument
panel wi re harness connector for the BCM. There
shoul d be conti nui ty. I f OK, refer to (Refer to 8 -
ELECTRI CAL/HEATED GLASS/REAR WI NDOW
DEFOGGER RELAY - DI AGNOSI S AND TESTI NG).
REMOVAL
INJURY.
(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
CONTROLS/A/C HEATER CONTROL - REMOVAL)
REAR WINDOW DEFOGGER SWITCH (Continued)
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - HEATED
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HEATED MIRRORS
DESCRIPTION
El ectri cal l y heated outsi de rear vi ew mi rrors are
opti onal equi pment on thi s model . These mi rrors fea-
ture an el ectri c heati ng gri d l ocated behi nd the mi r-
ror gl ass of each power operated outsi de rear vi ew
mi rror. These heati ng gri ds consi st of a si ngl e resi s-
tor wi re routed i n a gri d-l i ke pattern and captured
between two thi n sheets of pl asti c. When el ectri cal
current i s passed through the resi stor wi re, i t pro-
duces enough heat energy to cl ear the outsi de mi rror
gl ass of i ce, snow or fog. Battery current i s di rected
to the outsi de mi rror heati ng gri d onl y when the rear
wi ndow defogger swi tch i s i n the On posi ti on.
I f the outsi de mi rror heati ng gri ds and the rear
wi ndow heati ng gri d are al l i noperati ve, (Refer to 8 -
ELECTRI CAL/HEATED GLASS - DI AGNOSI S AND
TESTI NG - REAR WI NDOW DEFOGGER SYSTEM).
I f the outsi de mi rror heati ng gri ds are i noperati ve,
but the rear wi ndow heati ng gri d i s operati ng as
desi gned, (Refer to 8 - ELECTRI CAL/HEATED MI R-
RORS - DI AGNOSI S AND TESTI NG)
The heati ng gri d behi nd each outsi de mi rror gl ass
cannot be repai red and, i f faul ty or damaged, the
enti re power mi rror uni t must be repl aced. Refer to
Power Mi rrors for the procedures.
OPERATION
The outsi de mi rror heati ng gri ds are energi zed and
de-energi zed by the Dri ver Door Modul e (DDM) and
the Passenger Door Modul e (PDM) based upon the
rear wi ndow defogger swi tch status. The Body Con-
trol Modul e (BCM) moni tors the rear wi ndow defog-
ger swi tch. When the BCM recei ves an i nput from
the swi tch, i t sends a defogger swi tch status message
to the DDM and the PDM over the Programmabl e
Communi cati ons I nterface data bus. The DDM and
PDM respond to the defogger swi tch status messages
by energi zi ng or de-energi zi ng the battery current
feed to thei r respecti ve outsi de rear vi ew mi rror
heati ng gri ds.
DIAGNOSIS AND TESTING - HEATED MIRRORS
For ci rcui t descri pti ons and di agrams, (Refer to
Appropri ate Wi ri ng I nformati on).
(1) I f both mi rror heaters are i noperati ve, check
for proper operati on of the Rear Wi ndow Defogger
System. (Refer to 8 - ELECTRI CAL/HEATED GLASS
- DI AGNOSI S AND TESTI NG - REAR WI NDOW
DEFOGGER SYSTEM). I f Rear Wi ndow Defogger
System operates correctl y, or i f onl y one mi rror
heater i s i noperati ve, go to Step 2.
cabl e. Remove the front door tri m panel on the si de
of the i noperati ve mi rror heater. Go to Step 3.
(3) Di sconnect the door wi re harness connector
from the door modul e connector receptacl e. Check for
conti nui ty between the mi rror heater 12 vol t suppl y,
and the mi rror heater ground. There shoul d be con-
ti nui ty. I f OK, go to Step 4. I f not OK, check for con-
ti nui ty of the i ndi vi dual ci rcui ts between the power
mi rror and the door modul e, and of the mi rror heater
gri d ri ght at the power mi rror.
(4) Use a DRB I I I and (Refer to Appropri ate
Di agnosti c I nformati on) to test the door modul e and
the PCI data bus.
8G - 8 HEATED MIRRORS WJ
HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DRIVER HEATED SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEATED SEAT ELEMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
HEATED SEAT SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PASSENGER HEATED SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - PASSENGER
HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
HEATED SEAT SYSTEM
DESCRIPTION
I ndi vi dual l y control l ed dri ver and passenger si de
el ectri cal l y heated front seats are avai l abl e factory-
i nstal l ed opti onal equi pment on thi s model , when i t
i s al so equi pped wi th the power seat opti on. The
heated seat system al l ows both the dri ver and the
front seat passenger the opti on to sel ect one of two
seat heati ng ranges, Low or Hi gh, or to turn the i ndi -
vi dual seat heaters Off usi ng the heated seat
swi tches l ocated i n the center l ower bezel near the
bottom of the i nstrument panel center stack (Fi g. 1).
The heated seat swi tch ci rcui t operates on i gni ti on
swi tched battery current suppl i ed through a fuse i n
the juncti on bl ock, onl y when the i gni ti on swi tch i s
i n the On posi ti on.
The heated seat system consi sts of the fol l owi ng
components :
Heated seat el ements
Heated seat sensors
Heated seat modul e (or memory heated seat
modul e)
Heated seat swi tches.
The heated seat system al so rel i es upon resources
shared wi th other el ectroni c modul es i n the vehi cl e
over the Programmabl e Communi cati ons I nterface
(PCI ) data bus network. The PCI data bus network
al l ows the shari ng of sensor i nformati on. Thi s hel ps
to reduce wi re harness compl exi ty, i nternal control l er
hardware, and component sensor current l oads. At
the same ti me, thi s system provi des i ncreased rel i -
abi l i ty, enhanced di agnosti cs, and al l ows the addi ti on
of many new feature capabi l i ti es. For di agnosi s of
Fig. 1 HEATED SEAT SWITCHES
1 - HEATED SEAT SWITCHES
WJ HEATED SEAT SYSTEM 8G - 9
these el ectroni c modul es or of the PCI data bus net-
work, the use of a DRB scan tool and the proper
Di agnosti c Procedures manual are recommended.
The el ectroni c modul es that may affect heated seat
Body Control Module (BCM) - Refer to Body
Control Module i n El ectroni c Control Modul es for
more i nformati on.
Heated Seat Module (HSM) - Refer to Heated
Seat Module i n El ectroni c Control Modul es for more
i nformati on.
Memory Heated Seat Module (MHSM) - I f
the vehi cl e i s equi pped wi th the Memory System,
refer to Memory Seat Module i n El ectroni c Control
Modul es for more i nformati on.
Refer to Power Seats Premium I/III i n the Con-
tents of Wi ri ng Di agrams for compl ete ci rcui t di a-
grams. Fol l owi ng are general descri pti ons of the
major components i n the heated seat system.
OPERATION
The heated seat system wi l l onl y operate when the
i gni ti on swi tch i s i n the On posi ti on, and the surface
temperature at the front seat heati ng el ement sen-
sors i s bel ow the desi gned temperature set poi nts of
the system. The heated seat system wi l l not operate
i n ambi ent temperatures greater than about 41 C
(105 F). The front seat heati ng el ements and sensors
are hard wi red to the Heated Seat Modul e (HSM) or
the Memory Heated Seat Modul e (MHSM).
The heated seat swi tches are hard wi red to the
Body Control Modul e (BCM). The BCM moni tors the
heated seat swi tch i nputs, then sends heated seat
swi tch status messages to the HSM or MHSM over
the Programmabl e Communi cati ons I nterface (PCI )
data bus. The HSM or MHSM contai ns the control
l ogi c for the heated seat system. The HSM or MHSM
responds to the heated seat swi tch status messages,
i gni ti on swi tch status messages, and the front seat
heati ng el ement sensor i nputs by control l i ng the out-
put to the front seat heati ng el ements through i nte-
gral sol i d-state rel ays.
When a seat heater i s turned on, the sensor
l ocated on the seat cushi on el ectri c heater el ement
provi des the HSM or MHSM wi th an i nput i ndi cati ng
the surface temperature of the seat cushi on. I f the
surface temperature i nput i s bel ow the temperature
set poi nt for the sel ected Low or Hi gh heated seat
swi tch posi ti on, the HSM or MHSM energi zes the
i ntegral sol i d-state rel ay, whi ch suppl i es battery cur-
rent to the heati ng el ements i n the seat cushi on and
back. When the sensor i nput i ndi cates the correct
temperature set poi nt has been achi eved, the HSM or
MHSM de-energi zes the sol i d-state rel ay. The HSM
or MHSM wi l l conti nue to cycl e the sol i d-state rel ay
as needed to mai ntai n the temperature set poi nt.
The HSM or MHSM and the seat heater el ements
operate on non-swi tched battery current suppl i ed
through the power seat ci rcui t breaker i n the junc-
ti on bl ock. However, the HSM or MHSM wi l l auto-
mati cal l y turn off the heati ng el ements i f i t detects
an open or short i n the sensor ci rcui t, a short or open
i n the heati ng el ement ci rcui t causi ng an excessi ve
current draw, or when the i gni ti on swi tch i s turned
to the Off posi ti on.
of the heated seat system.
SYSTEM
components and ci rcui ts that are hard wi red i nputs
or outputs of the heated seat system. However, these
tests may not prove concl usi ve i n the di agnosi s of
thi s system. I n order to obtai n concl usi ve testi ng of
the heated seat system, the Programmabl e Commu-
ni cati ons I nterface (PCI ) data bus network and al l of
the el ectroni c modul es that provi de i nputs to, or
recei ve outputs from the heated seat system compo-
nents must be checked.
The most rel i abl e, effi ci ent, and accurate means to
di agnose the heated seat system requi res the use of a
DRB scan tool and the proper Di agnosti c Procedures
manual . The DRB scan tool can provi de confi rma-
ti on that the PCI data bus i s functi onal , that al l of
the el ectroni c modul es are sendi ng and recei vi ng the
proper messages on the PCI data bus, and that the
Heated Seat Modul e (HSM) or Memory Heated Seat
Modul e (MHSM) i s recei vi ng the proper hard wi red
i nputs and rel ayi ng the proper hard wi red outputs to
perform i ts heated seat system functi ons.
For compl ete ci rcui t di agrams, refer to Wiring
Diagrams.
NOTE: DO NOT ATTEMPT TO SWAP MEMORY OR
NON-MEMORY HEATED SEAT MODULES FROM
ONE VEHICLE TO ANOTHER. MOST OF THESE
MODULES ARE VEHICLE FEATURE SPECIFIC AND
THEREFORE NOT INTERCHANGEABLE. ALWAYS
USE THE CORRECT PART NUMBERED MODULE
WHEN DIAGNOSING OR REPLACING A MODULE.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
INJURY.
8G - 10 HEATED SEAT SYSTEM WJ
HEATED SEAT SYSTEM (Continued)
PRELIMINARY TEST
Before testi ng the i ndi vi dual components i n the
heated seat system, check the fol l owi ng:
I f the heated seat swi tch LED i ndi cators do not
l i ght wi th the i gni ti on swi tch i n the On posi ti on and
the heated seat swi tch i n the Low or Hi gh posi ti on,
check the fused i gni ti on swi tch output (run) fuse i n
the juncti on bl ock. I f OK, refer to Heated Seat
Switch Diagnosis and Testing i n thi s secti on. I f
not OK, repai r the shorted ci rcui t or component as
I f the heated seat swi tch LED i ndi cators l i ght,
but the heati ng el ements do not heat, check the
power seat ci rcui t breaker i n the juncti on bl ock. I f
OK, refer to Heated Seat Element Diagnosis and
Testing i n thi s secti on of the manual . I f not OK,
repl ace the faul ty power seat ci rcui t breaker.
DRIVER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat swi tches are mounted i n the
i nstrument panel center l ower bezel (Fi g. 2), whi ch i s
l ocated near the bottom of the i nstrument panel cen-
ter stack. The two three-posi ti on rocker-type
swi tches, one swi tch for each front seat, provi de a
resi stor mul ti pl exed si gnal to the Body Control Mod-
ul e (BCM) through separate hard wi red ci rcui ts.
Each swi tch has an Off, Low, and Hi gh posi ti on so
that both the dri ver and the front seat passenger can
sel ect a preferred seat heati ng mode. Each swi tch
has two Li ght-Emi tti ng Di odes (LED), one each for
the Low posi ti on and the Hi gh posi ti on, whi ch l i ght
to i ndi cate that the heater for the seat that the
swi tch control s i s turned on. Each swi tch i s al so back
l i t by a repl aceabl e i ncandescent bul b.
The heated seat swi tches and thei r LEDs cannot
be repai red. I f ei ther swi tch or LED i s faul ty or dam-
aged, the enti re swi tch uni t must be repl aced. The
i ncandescent swi tch i l l umi nati on bul b and bul b
hol der uni ts are avai l abl e for servi ce repl acement.
OPERATION
There are three posi ti ons that can be sel ected wi th
each of the heated seat swi tches: Off, Low, or Hi gh.
When the top of the swi tch rocker i s ful l y depressed,
the Hi gh posi ti on i s sel ected and the hi gh posi ti on
LED i ndi cator i l l umi nates. When the bottom of the
swi tch rocker i s ful l y depressed, the Low posi ti on i s
sel ected and the l ow posi ti on LED i ndi cator i l l umi -
nates. When the swi tch rocker i s moved to i ts neutral
posi ti on, Off i s sel ected and both LED i ndi cators are
exti ngui shed.
Both swi tches provi de separate resi stor mul ti -
pl exed hard wi re i nputs to the BCM to i ndi cate the
sel ected swi tch posi ti on. The BCM moni tors the
swi tch i nputs and sends heated seat swi tch status
messages to the Heated Seat Modul e (HSM) or the
Memory Heated Seat Modul e (MHSM) over the Pro-
grammabl e Communi cati ons I nterface (PCI ) data
bus. The HSM or MHSM responds to the heated seat
swi tch status messages by control l i ng the output to
the seat heater el ements of the sel ected seat. The
Low heat posi ti on set poi nt i s about 36 C (97 F),
and the Hi gh heat posi ti on set poi nt i s about 41 C
(105 F).
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH
Diagrams.
INJURY.
(1) Check the fused i gni ti on swi tch output (run)
fuse i n the juncti on bl ock. I f OK, go to Step 2. I f not
HEATED SEAT SYSTEM (Continued)
output (run) fuse i n the juncti on bl ock. I f OK, go to
Step 3. I f not OK, repai r the open fused i gni ti on
swi tch output (run) ci rcui t to the i gni ti on swi tch as
requi red.
cabl e. Remove the l ower center bezel from the i nstru-
ment panel and di sconnect the i nstrument panel wi re
harness connectors from both heated seat swi tch con-
nector receptacl es. Check for conti nui ty between the
ground ci rcui t cavi ty of the i nstrument panel wi re
harness connector for the i noperati ve heated seat
swi tch(es) and a good ground. There shoul d be conti -
vol tage at the fused i gni ti on swi tch output (run) ci r-
cui t cavi ty of the i nstrument panel wi re harness con-
nector for the i noperati ve heated seat swi tch(es). I f
OK, turn the i gni ti on swi tch to the Off posi ti on, di s-
connect and i sol ate the battery negati ve cabl e, and go
swi tch output (run) ci rcui t to the juncti on bl ock fuse
as requi red.
(5) Test the heated seat swi tch(es) (Fi g. 3) as
shown i n the Heated Seat Swi tch Test chart. I f OK,
go to Step 6. I f not OK, repl ace the faul ty heated seat
swi tch(es).
HEATED SEAT SWITCH TEST
SWITCH
POSITION
RESISTANCE
BETWEEN
RESISTANCE
(OHMS)
Off Pin 1 & 6 55
Low Pin 1 & 6 1430
High Pin 1 & 6 365
All resistance values are 5%.
between the seat heater swi tch sensor ground ci rcui t
cavi ty of the i nstrument panel wi re harness connec-
tor for the i noperati ve heated seat swi tch(es) and a
to Step 7. I f not OK, repai r the shorted seat heater
swi tch sensor ground ci rcui t as requi red.
(7) Check for conti nui ty between the seat heater
swi tch sensor ground ci rcui t cavi ti es of the i nstru-
ment panel wi re harness connector for the i n opera-
ti ve heated seat swi tch(es) and the 22-way
i nstrument panel wi re harness connector for the
BCM. There shoul d be conti nui ty. I f OK, go to Step 8.
I f not OK, repai r the open seat heater swi tch sensor
ground ci rcui t as requi red.
swi tch mux ci rcui t cavi ty of the i nstrument panel
wi re harness connector for the i noperati ve heated
seat swi tch and a good ground. There shoul d be no
shorted seat heater swi tch mux ci rcui t as requi red.
seat swi tch and the 22-way i nstrument panel wi re
harness connector for the BCM. There shoul d be con-
ti nui ty. I f OK, use a DRB scan tool and the proper
Di agnosti c Procedures manual to test the BCM. I f
not OK, repai r the open seat heater swi tch mux ci r-
cui t as requi red.
REMOVAL
INJURY.
cabl e.
Fig. 3 Rear of Heated Seat Switch
1 - LEFT SHOWN (RIGHT TYPICAL)
2 - ILLUMINATION LAMP
3 - CONNECTOR RECEPTACLE
4 - HEATED SEAT SWITCH
DRIVER HEATED SEAT SWITCH (Continued)
(2) Remove the center l ower bezel from the i nstru-
ment panel . Refer to Instrument Panel Center
Lower Bezel i n the Body secti on of thi s manual for
the procedure.
(3) Remove the four screws that secure the heated
seat swi tch to the back of the i nstrument panel cen-
ter l ower bezel (Fi g. 4).
(4) Remove the heated seat swi tch from the back
of the i nstrument panel center l ower bezel .
INSTALLATION
(1) Posi ti on the heated seat swi tch onto the back
the heated seat swi tch to the back of the i nstrument
panel center l ower bezel . Ti ghten the screws to 1.5
Nm (13 i n. l bs.).
(3) I nstal l the center l ower bezel onto the i nstru-
the procedure.
HEATED SEAT ELEMENT
DESCRIPTION
The heated seat system i ncl udes two seat heati ng el e-
ments i n each front seat, one for the seat cushi on (Fi g.
5)and the other for the seat back. One type of heated
seat el ement i s offered. Al l model s use two resi stor wi re
heati ng el ements for each seat that are connected i n
seri es wi th the Heated Seat Modul e (HSM).
The seat heati ng el ements are gl ued to the seat and
seat back cushi ons. The heated seat el ements can be
repl aced i f faul ty or damaged, servi ce repl acement seat
or seat back el ements are avai l abl e. Refer to the pro-
cedure i n thi s secti on for detai l ed i nstructi ons.
OPERATION
The heated seat el ements resi st the fl ow of el ectri -
cal current. When battery current i s passed through
the el ements, the energy l ost by the resi stance of the
el ements to the current fl ow i s rel eased i n the form
of heat. The temperature sensor i s a NTC thermi stor.
When the temperature of the seat cushi on cover
ri ses, the resi stance of the sensor decreases. The
HSM or MHSM suppl i es a fi ve-vol t current to one
si de of each sensor, and moni tors the vol tage drop
through the sensor on a return ci rcui t. The MSM or
MHSM uses thi s temperature sensor i nput to moni -
tor the temperature of the seat, and regul ates the
current fl ow to the seat heati ng el ements accordi ngl y.
Fig. 4 Heated Seat Switch Remove/Install
2 - SCREWS (4)
3 - CENTER LOWER BEZEL
4 - CIGAR LIGHTER
5 - ILLUMINATION LAMPS
6 - POWER OUTLET
Fig. 5 HEATING ELEMENT INSTALLED
1 - SEAT BACK WIRE HARNESS
2 - HEATED SEAT WIRE HARNESS CONNECTOR
3 - HEATED SEAT CUSHION ELEMENT
DRIVER HEATED SEAT SWITCH (Continued)
ELEMENT
RESISTOR WIRE ELEMENT
cabl e. The power seat wi re harness connectors for the
seat cushi on and seat back heati ng el ements are
secured to a bracket l ocated under the rear edge of
the seat cushi on frame. Refer to Wiring for compl ete
ci rcui t schemati cs and connector l ocati ons.
(2) Di sconnect the Heated Seat Modul e (HSM) or
Memory Heated Seat Modul e (MHSM) C2 connector.
Check for conti nui ty between the SEAT HEATER
B(+) DRI VER ci rcui t cavi ty of the C2 connector and
the seat cushi on frame. There shoul d be NO conti nu-
i ty. I f OK, go to Step 3. I f not OK, repai r the shorted
seat heater B(+) dri ver ci rcui t as requi red.
NOTE: WHEN CHECKING HEATED SEAT ELE-
MENTS FOR CONTINUITY, BE CERTAIN TO MOVE
THE HEATING ELEMENT BEING CHECKED. MOV-
ING THE ELEMENT, SUCH AS SITTING IN THE SEAT
WILL ELIMINATE THE POSSIBILITY OF AN INTER-
MITTENT OPEN IN THE ELEMENT WHICH WOULD
ONLY BE EVIDENT IF THE ELEMENT WAS MOVED
IN A CERTAIN DIRECTION. FAILURE TO CHECK
THE ELEMENT IN VARIOUS POSITIONS COULD
RESULT IN AN INCOMPLETE TEST.
(3) Check for conti nui ty between the SEAT
HEATER B(+) DRI VER ci rcui t cavi ty of the C2 con-
nector and the ground ci rcui t cavi ty. There shoul d be
conti nui ty at al l ti mes (even upon movi ng or si tti ng
i n the seat). I f OK, proceed wi th testi ng the other
components i n the heated seat system. I f not OK,
repl ace the open heati ng el ement. Refer to the proce-
dure i n thi s secti on of the manual .
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the appropri ate seat cushi on or seat
back tri m cover. Refer to the Body secti on of the ser-
vi ce manual for the procedures.
(3) Di sconnect the i noperati ve heated seat cushi on
or seat back el ement el ectri cal connectors.
(4) Gentl y peel -off defecti ve heater el ement from
foam cushi on.
INSTALLATION
(1) Peel off the adhesi ve backi ng on the back of the
repl acement heati ng el ement and i nstal l on cushi on
pad i n the same l ocati on as the ori gi nal (Fi g. 6).
CAUTION: During the installation of the replace-
ment heating element, be very careful not to fold or
crease the element assembly. Folds or creases will
cause premature failure.
(2) Connect the new heati ng el ement el ectri cal
connectors (Fi g. 6).
(3) Connect the negati ve battery cabl e.
(4) Veri fy heated seat system operati on.
(5) I nstal l the appropri ate seat cushi on or seat
back tri m cover. Make certai n the seat wi re harness
i s correctl y routed through the seat and seat back.
The excess wi re between the cushi on and back el e-
ments shoul d be securel y tucked between the rear of
the cushi on foam and the rear carpet fl ap of the tri m
cover.
Fig. 6 HEATING ELEMENT INSTALLED
1 - SEAT BACK WIRE HARNESS
2 - HEATED SEAT WIRE HARNESS CONNECTOR
3 - HEATED SEAT CUSHION ELEMENT
HEATED SEAT ELEMENT (Continued)
HEATED SEAT SENSOR
DESCRIPTION
The heated seat temperature sensor i s a Negati ve
Temperature Coeffi ci ent (NTC) thermi stor. One tem-
perature sensor i s used for each seat. Thi s tempera-
ture sensor i s l ocated i n the seat cushi on heati ng
el ement on al l model s.
The heated seat temperature sensor cannot be
repai red or adjusted and must be repl aced i f defec-
ti ve. The heated seat cushi on el ement must be
repl aced i f the temperature sensor i s defecti ve. Refer
to the procedure i n thi s secti on of the servi ce man-
ual .
SENSOR
Diagrams.
(1) Di sconnect the Heated Seat Modul e (HSM) or
Memory Heated Seat Modul e (MHSM) C1 connector.
Check for conti nui ty between the SEAT SENSOR 5V
SUPPLY ci rcui t cavi ty and the seat cushi on frame.
There shoul d be NO conti nui ty. I f OK, go to Step 2.
I f not OK, repai r the shorted seat sensor 5V suppl y
(2) Check for conti nui ty between the SEAT SEN-
SOR 5V SUPPLY ci rcui t cavi ty of the 4-way power
seat wi re harness connector and the C1 connector for
the HSM or MHSM. There shoul d be conti nui ty. I f
OK, go to Step 3. I f not OK, repai r the open seat sen-
sor 5V suppl y ci rcui t as requi red.
(3) Connect the modul e el ectri cal connector. Turn
system ON, usi ng a vol tmeter, backprobe the HSM or
MHSM C1 connector on the SEAT TEMPERATURE
SENSOR I NPUT ci rcui t cavi ty. Vol tage shoul d be
present (2-4 vol ts). I f OK, proceed wi th testi ng the
other components i n the heated seat system. I f not
OK, refer to Heated Seat Modul e Di agnosi s and Test-
i ng i n the el ectroni c control modul es secti on of thi s
manual .
REMOVAL
(1) For heated seat sensor repl acement procedure
(Refer to 8 - ELECTRI CAL/HEATED SEATS/
HEATED SEAT ELEMENT - REMOVAL).
PASSENGER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat swi tches are mounted i n the
i nstrument panel center l ower bezel (Fi g. 7), whi ch i s
l ocated near the bottom of the i nstrument panel cen-
ter stack. The two three-posi ti on rocker-type
swi tches, one swi tch for each front seat, provi de a
resi stor mul ti pl exed si gnal to the Body Control Mod-
ul e (BCM) through separate hard wi red ci rcui ts.
Each swi tch has an Off, Low, and Hi gh posi ti on so
that both the dri ver and the front seat passenger can
sel ect a preferred seat heati ng mode. Each swi tch
has two Li ght-Emi tti ng Di odes (LED), one each for
the Low posi ti on and the Hi gh posi ti on, whi ch l i ght
to i ndi cate that the heater for the seat that the
swi tch control s i s turned on. Each swi tch i s al so back
l i t by a repl aceabl e i ncandescent bul b.
The heated seat swi tches and thei r LEDs cannot
be repai red. I f ei ther swi tch or LED i s faul ty or dam-
aged, the enti re swi tch uni t must be repl aced. The
i ncandescent swi tch i l l umi nati on bul b and bul b
hol der uni ts are avai l abl e for servi ce repl acement.
OPERATION
There are three posi ti ons that can be sel ected wi th
each of the heated seat swi tches: Off, Low, or Hi gh.
When the top of the swi tch rocker i s ful l y depressed,
the Hi gh posi ti on i s sel ected and the hi gh posi ti on
LED i ndi cator i l l umi nates. When the bottom of the
swi tch rocker i s ful l y depressed, the Low posi ti on i s
sel ected and the l ow posi ti on LED i ndi cator i l l umi -
nates. When the swi tch rocker i s moved to i ts neutral
posi ti on, Off i s sel ected and both LED i ndi cators are
exti ngui shed.
Both swi tches provi de separate resi stor mul ti -
pl exed hard wi re i nputs to the BCM to i ndi cate the
sel ected swi tch posi ti on. The BCM moni tors the
swi tch i nputs and sends heated seat swi tch status
messages to the Heated Seat Modul e (HSM) or the
Memory Heated Seat Modul e (MHSM) over the Pro-
bus. The HSM or MHSM responds to the heated seat
swi tch status messages by control l i ng the output to
the seat heater el ements of the sel ected seat. The
Low heat posi ti on set poi nt i s about 36 C (97 F),
and the Hi gh heat posi ti on set poi nt i s about 41 C
(105 F).
HEATED SEAT SWITCH
Diagrams.
INJURY.
(1) Check the fused i gni ti on swi tch output (run)
fuse i n the juncti on bl ock. I f OK, go to Step 2. I f not
output (run) fuse i n the juncti on bl ock. I f OK, go to
Step 3. I f not OK, repai r the open fused i gni ti on
swi tch output (run) ci rcui t to the i gni ti on swi tch as
requi red.
cabl e. Remove the l ower center bezel from the i nstru-
ment panel and di sconnect the i nstrument panel wi re
harness connectors from both heated seat swi tch con-
nector receptacl es. Check for conti nui ty between the
ground ci rcui t cavi ty of the i nstrument panel wi re
harness connector for the i noperati ve heated seat
swi tch(es) and a good ground. There shoul d be conti -
vol tage at the fused i gni ti on swi tch output (run) ci r-
nector for the i noperati ve heated seat swi tch(es). I f
OK, turn the i gni ti on swi tch to the Off posi ti on, di s-
connect and i sol ate the battery negati ve cabl e, and go
swi tch output (run) ci rcui t to the juncti on bl ock fuse
as requi red.
(5) Test the heated seat swi tch(es) (Fi g. 8) as
shown i n the Heated Seat Swi tch Test chart. I f OK,
go to Step 6. I f not OK, repl ace the faul ty heated seat
swi tch(es).
HEATED SEAT SWITCH TEST
SWITCH
POSITION
RESISTANCE
BETWEEN
RESISTANCE
(OHMS)
Off Pin 1 & 6 55
Low Pin 1 & 6 1430
High Pin 1 & 6 365
All resistance values are 5%.
Fig. 8 Rear of Heated Seat Switch
1 - LEFT SHOWN (RIGHT TYPICAL)
2 - ILLUMINATION LAMP
4 - HEATED SEAT SWITCH
PASSENGER HEATED SEAT SWITCH (Continued)
between the seat heater swi tch sensor ground ci rcui t
cavi ty of the i nstrument panel wi re harness connec-
tor for the i noperati ve heated seat swi tch(es) and a
to Step 7. I f not OK, repai r the shorted seat heater
swi tch sensor ground ci rcui t as requi red.
swi tch sensor ground ci rcui t cavi ti es of the i nstru-
ment panel wi re harness connector for the i n opera-
ti ve heated seat swi tch(es) and the 22-way
I f not OK, repai r the open seat heater swi tch sensor
ground ci rcui t as requi red.
seat swi tch and a good ground. There shoul d be no
shorted seat heater swi tch mux ci rcui t as requi red.
seat swi tch and the 22-way i nstrument panel wi re
not OK, repai r the open seat heater swi tch mux ci r-
cui t as requi red.
REMOVAL
INJURY.
cabl e.
the procedure.
(3) Remove the four screws that secure the heated
seat swi tch to the back of the i nstrument panel cen-
ter l ower bezel (Fi g. 9).
(4) Remove the heated seat swi tch from the back
INSTALLATION
(1) Posi ti on the heated seat swi tch onto the back
the heated seat swi tch to the back of the i nstrument
panel center l ower bezel . Ti ghten the screws to 1.5
Nm (13 i n. l bs.).
the procedure.
Fig. 9 Heated Seat Switch Remove/Install
2 - SCREWS (4)
4 - CIGAR LIGHTER
6 - POWER OUTLET
PASSENGER HEATED SEAT SWITCH (Continued)
HORN
TABLE OF CONTENTS
page page
HORN SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - HORN SYSTEM . . . 2
HORN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - HORN . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - HORN RELAY . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HORN SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - HORN SWITCH . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HORN SYSTEM
DESCRIPTION
A dual -note el ectri c horn system i s standard facto-
ry-i nstal l ed equi pment on thi s model . The standard
equi pment horn system features one l ow-note horn
uni t and one hi gh-note horn uni t. The horn system
al l ows the vehi cl e operator to provi de an audi bl e
warni ng of the presence or approach of the vehi cl e to
pedestri ans and the dri vers of other vehi cl es i n near
proxi mi ty. The horn system uses a non-swi tched
source of battery current so that the system wi l l
remai n functi onal , regardl ess of the i gni ti on swi tch
posi ti on.
The horn system can al so be acti vated by the Body
Control Modul e (BCM). The BCM i s programmed to
acti vate the horns i n order to provi de the fol l owi ng
features:
Remote Keyl ess Entry (RKE) system l ock
request audi bl e veri fi cati on (except export)
RKE system pani c mode audi bl e al ert
Vehi cl e Theft Securi ty System (VTSS) audi bl e
al arm.
Thi s vehi cl e al so offers several customer program-
mabl e features, whi ch al l ows the sel ecti on of several
opti onal el ectroni c features to sui t i ndi vi dual prefer-
ences. Refer to Overhead Consol e for more i nforma-
ti on on the customer programmabl e feature opti ons.
Customer programmabl e feature opti ons affecti ng the
horn system i ncl ude:
Sound Horn on Lock - Al l ows the opti on of
havi ng the horn sound a short chi rp as an audi bl e
veri fi cati on that the RKE system recei ved a val i d
Lock request from the RKE transmi tter, or havi ng no
audi bl e veri fi cati on.
The horn system i ncl udes the fol l owi ng compo-
nents:
Cl ockspri ng
Horns
Horn rel ay
Horn swi tch
Certai n functi ons and features of the horn system
are recommended.
The other el ectroni c modul es that may affect horn
Body Control Module (BCM) (Refer to 8 -
Electronic Vehicle Information Center
(EVIC) (Refer to 8 - ELECTRI CAL/OVERHEAD
CONSOLE/ELECTRONI C VEHI CLE I NFO CENTER
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CLOCK-
SPRI NG - DESCRI PTI ON) for more i nformati on on
thi s component. Refer to the appropri ate wi ri ng
i nformati on. The wi ri ng i nformati on i ncl udes wi ri ng
WJ HORN 8H - 1
grounds. Fol l owi ng are general descri pti ons of the
remai ni ng major components i n the horn system.
OPERATION
The horn system i s acti vated by a horn swi tch con-
ceal ed beneath the dri ver si de ai rbag modul e tri m
cover i n the center of the steeri ng wheel . Depressi ng
the center of the dri ver si de ai rbag modul e tri m cover
cl oses the horn swi tch. Cl osi ng the horn swi tch acti -
vates the horn rel ay. The acti vated horn rel ay then
swi tches the battery current needed to energi ze the
horns.
The BCM can al so acti vate the horn system by
energi zi ng the horn rel ay through a si ngl e hard
wi red output ci rcui t. The BCM energi zes and de-en-
ergi zes the horn rel ay i n response to i nternal pro-
grammi ng as wel l as message i nputs recei ved over
data bus network. The BCM can energi ze the horn
rel ay for a si ngl e chi rp (RKE l ock request), or for
extended operati on (RKE pani c mode and VTSS
al arm mode).
Refer to the owners manual i n the vehi cl e gl ove
box for more i nformati on on the features, use and
operati on of the horn system.
DIAGNOSIS AND TESTING - HORN SYSTEM
I n most cases, any probl em i nvol vi ng conti nual l y
soundi ng horns can be qui ckl y al l evi ated by removi ng
the horn rel ay from the Power Di stri buti on Center
(PDC). Refer to Horn Rel ay for the proper removal
procedure. Refer to the appropri ate wi ri ng i nforma-
ti on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
grams, proper wi re and connector repai r procedures,
further detai l s on wi re harness routi ng and reten-
ti on, as wel l as pi n-out and l ocati on vi ews for the
vari ous wi re harness connectors, spl i ces and grounds.
INJURY.
HORN SYSTEM DIAGNOSIS
BOTH HORNS
INOPERATIVE
1. Faulty fuse. 1. Check the fuses in the Power Distribution
Center (PDC) and the Junction Block (JB).
Replace the fuse and repair the shorted circuit or
component, if required.
2. Faulty horn relay. 2. Refer to Horn Relay for the proper horn relay
diagnosis and testing procedures. Replace the
horn relay or repair the open horn relay circuit, if
required.
3. Faulty horn switch. 3. Refer to Horn Switch for the proper horn switch
horn switch or repair the open horn switch circuit,
if required.
4. Faulty horns. 4. Refer to Horn for the proper horn diagnosis
and testing procedures. Replace the horns or
repair the open horn circuit, if required.
ONE HORN INOPERATIVE 1. Faulty horn. 1. Refer to Horn for the proper horn diagnosis
and testing procedures. Replace the horn or
repair the open horn circuit, if required.
8H - 2 HORN WJ
HORN SYSTEM (Continued)
HORN SOUNDS
CONTINUOUSLY
1. Faulty horn relay. 1. Refer to Horn Relay for the proper horn relay
horn relay or repair the shorted horn relay control
2. Faulty horn switch. 2. Refer to Horn Switch for the proper horn switch
horn switch or repair the shorted horn switch
HORN
DESCRIPTION
The dual el ectromagneti c di aphragm-type horns
are standard equi pment on thi s model . Both horns
are secured to a mounti ng bracket. The mounti ng
bracket i s secured wi th a screw to the back si de of
the ri ght extensi on of the radi ator cl osure assembl y,
just ahead of the ri ght front wheel house and bel ow
the front wheel house extensi on. The two horns are
connected i n paral l el . Each horn i s grounded through
i ts wi re harness connector and ci rcui t to an eyel et
secured to the ri ght i nner fender shi el d near the bat-
tery, and recei ves battery feed through the cl osed
contacts of the horn rel ay.
The horns cannot be repai red or adjusted and, i f
faul ty or damaged, they must be i ndi vi dual l y
repl aced.
OPERATION
Wi thi n the two hal ves of the mol ded pl asti c horn
housi ng are a fl exi bl e di aphragm, a pl unger, an el ec-
tromagneti c coi l and a set of contact poi nts. The di a-
phragm i s secured i n suspensi on around i ts
peri meter by the mati ng surfaces of the horn hous-
i ng. The pl unger i s secured to the center of the di a-
phragm and extends i nto the center of the
el ectromagnet. The contact poi nts control the current
fl ow through the el ectromagnet.
When the horn i s energi zed, el ectri cal current
fl ows through the cl osed contact poi nts to the el ectro-
magnet. The resul ti ng el ectromagneti c fi el d draws
the pl unger and di aphragm toward i t unti l that
movement mechani cal l y opens the contact poi nts.
When the contact poi nts open, the el ectromagneti c
fi el d col l apses al l owi ng the pl unger and di aphragm to
return to thei r rel axed posi ti ons and cl osi ng the con-
tact poi nts agai n. Thi s cycl e conti nues repeati ng at a
very rapi d rate produci ng the vi brati on and move-
ment of ai r that creates the sound that i s di rected
through the horn outl et.
DIAGNOSIS AND TESTING - HORN
(1) Di sconnect the wi re harness connector(s) from
the horn connector receptacl e(s). Measure the resi s-
tance between the ground ci rcui t cavi ty of the horn(s)
wi re harness connector(s) and a good ground. There
shoul d be no measurabl e resi stance. I f OK, go to Step
2. I f not OK, repai r the open ground ci rcui t to ground
as requi red.
(2) Check for battery vol tage at the horn rel ay out-
put ci rcui t cavi ty of the horn(s) wi re harness connec-
tor(s). There shoul d be zero vol ts. I f OK, go to Step 3.
I f not OK, repai r the shorted horn rel ay output ci r-
cui t or repl ace the faul ty horn rel ay as requi red.
(3) Depress the horn swi tch. There shoul d now be
battery vol tage at the horn rel ay output ci rcui t cavi ty
of the horn(s) wi re harness connector(s). I f OK,
repl ace the faul ty horns. I f not OK, repai r the open
horn rel ay output ci rcui t to the horn rel ay as
requi red.
REMOVAL
cabl e.
(3) Remove the l ower front hal f of the i nner l i ner
from the ri ght front fender wheel house. (Refer to 23
- BODY/EXTERI OR/FRONT FENDER - REMOVAL).
(4) Reach through the front of the ri ght front
fender wheel house openi ng to access and di sconnect
the two ri ght headl amp and dash wi re harness con-
nectors from the horn connector receptacl es (Fi g. 1).
Be certai n to di sengage the connector l ock tabs
before di sconnecti ng them from the horn connector
receptacl es.
(5) Remove the screw that secures the horn
mounti ng bracket to the ri ght extensi on of the radi -
ator cl osure assembl y.
WJ HORN 8H - 3
HORN SYSTEM (Continued)
(6) Remove both horns and the mounti ng bracket
from the ri ght extensi on of the radi ator cl osure
assembl y as a uni t.
INSTALLATION
(1) Posi ti on both horns and the mounti ng bracket
onto the ri ght extensi on of the radi ator cl osure
assembl y as a uni t.
horn mounti ng bracket to the ri ght extensi on of the
radi ator cl osure assembl y. Ti ghten the screw to 11.3
Nm (100 i n. l bs.).
(3) Reconnect the two ri ght headl amp and dash
wi re harness connectors to the horn connector recep-
tacl es. Be certai n to engage the connector l ock tabs
after reconnecti ng them to the horn connector recep-
tacl es.
(4) I nstal l the l ower front hal f of the i nner l i ner to
the ri ght front fender wheel house. (Refer to 23 -
BODY/EXTERI OR/FRONT FENDER - I NSTALLA-
TI ON) for the procedure.
HORN RELAY
DESCRIPTION
The horn rel ay i s a el ectromechani cal devi ce that
swi tches battery current to the horn when the horn
swi tch grounds the rel ay coi l . The horn rel ay i s
l ocated i n the Power Di stri buti on Center (PDC) i n
the engi ne compartment. I f a probl em i s encountered
wi th a conti nuousl y soundi ng horn, i t can usual l y be
qui ckl y resol ved by removi ng the horn rel ay from the
PDC unti l further di agnosi s i s compl eted. See the
fuse and rel ay l ayout l abel affi xed to the i nsi de sur-
face of the PDC cover for horn rel ay i denti fi cati on
and l ocati on.
The horn rel ay i s a I nternati onal Standards Orga-
ni zati on (I SO) mi cro-rel ay. Rel ays conformi ng to the
I SO speci fi cati ons have common physi cal di mensi ons,
current capaci ti es, termi nal patterns, and termi nal
functi ons. The I SO mi cro-rel ay termi nal functi ons
are the same as a conventi onal I SO rel ay. However,
the I SO mi cro-rel ay termi nal pattern (or footpri nt) i s
di fferent, the current capaci ty i s l ower, and the phys-
i cal di mensi ons are smal l er than those of the conven-
ti onal I SO rel ay.
The horn rel ay cannot be repai red or adjusted and,
i f faul ty or damaged, i t must be repl aced.
OPERATION
contact.
DIAGNOSIS AND TESTING - HORN RELAY
The horn rel ay (Fi g. 2) i s l ocated i n the Power Di s-
tri buti on Center (PDC) between the battery and the
ri ght i nner fender shi el d on the passenger si de of the
engi ne compartment. I f a probl em i s encountered
wi th a conti nuousl y soundi ng horn, i t can usual l y be
qui ckl y resol ved by removi ng the horn rel ay from the
PDC unti l further di agnosi s i s compl eted. See the
fuse and rel ay l ayout l abel affi xed to the i nsi de sur-
face of the PDC cover for horn rel ay i denti fi cati on
and l ocati on. For compl ete ci rcui t di agrams, refer to
Fig. 1 Horns Remove/Install
1 - RADIATOR CLOSURE ASSEMBLY
2 - HORNS AND MOUNTING BRACKET
3 - RIGHT HEADLAMP AND DASH WIRE HARNESS
CONNECTORS
8H - 4 HORN WJ
HORN (Continued)
(1) Remove the horn rel ay from the PDC. (Refer to
8 - ELECTRI CAL/HORN/HORN RELAY -
RELAY CIRCUIT TEST
to the horn(s). There shoul d be conti nui ty between
the cavi ty for rel ay termi nal 87 and the horn rel ay
output ci rcui t cavi ty of each horn wi re harness con-
nector at al l ti mes. I f OK, go to Step 4. I f not OK,
repai r the open ci rcui t to the horn(s) as requi red.
the el ectromagnet i n the rel ay. I t i s connected to bat-
tery vol tage and shoul d be hot at al l ti mes. Check for
battery vol tage at the cavi ty for rel ay termi nal 86. I f
OK, go to Step 5. I f not OK, repai r the open ci rcui t to
the fuse i n the PDC as requi red.
the el ectromagnet i n the rel ay. I t i s grounded
through the horn swi tch when the horn swi tch i s
depressed. The horn rel ay coi l ground termi nal can
al so be grounded by the Body Control Modul e (BCM)
i n response to certai n i nputs rel ated to the RKE sys-
tem or the Vehi cl e Theft Securi ty System. Check for
conti nui ty to ground at the cavi ty for rel ay termi nal
85. There shoul d be conti nui ty wi th the horn swi tch
depressed, and no conti nui ty wi th the horn swi tch
rel eased. I f not OK, (Refer to 8 - ELECTRI CAL/
HORN/HORN SWI TCH - DI AGNOSI S AND TEST-
I NG).
REMOVAL
cabl e.
Center (PDC) (Fi g. 3) .
the undersi de of the PDC cover for horn rel ay i den-
ti fi cati on and l ocati on.
(4) Remove the horn rel ay from the PDC.
INSTALLATION
the undersi de of the PDC cover for the proper horn
rel ay l ocati on.
(2) Posi ti on the horn rel ay i n the proper receptacl e
i n the PDC.
(3) Al i gn the horn rel ay termi nal s wi th the termi -
nal cavi ti es i n the PDC receptacl e.
(4) Push down fi rml y on the horn rel ay unti l the
termi nal s are ful l y seated i n the termi nal cavi ti es i n
the PDC receptacl e.
(5) I nstal l the cover onto the PDC.
Fig. 2 Horn Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
WJ HORN 8H - 5
HORN RELAY (Continued)
HORN SWITCH
DESCRIPTION
A center-bl ow, normal l y open, resi sti ve membrane-
type horn swi tch i s secured i n a pl asti c tray that i s
i nserted i n a pocket sewn on the front of the dri ver
si de ai rbag retai ner strap. The horn swi tch i s con-
ceal ed behi nd the dri ver si de ai rbag modul e tri m
cover i n the center of the steeri ng wheel . The swi tch
consi sts of two pl asti c membranes, one that i s fl at
and one that i s sl i ghtl y convex. These two mem-
branes are secured to each other around the peri me-
ter. I nsi de the swi tch, the centers of the faci ng
surfaces of these membranes each has a gri d made
wi th an el ectri cal l y conducti ve materi al appl i ed to i t.
One of the gri ds i s connected to a ci rcui t that pro-
vi des i t wi th conti nui ty to ground at al l ti mes. The
gri d of the other membrane i s connected to the horn
rel ay control ci rcui t.
The steeri ng wheel and steeri ng col umn must be
properl y grounded i n order for the horn swi tch to
functi on properl y. The horn swi tch and pl asti c tray
are servi ced as a uni t. I f the horn swi tch i s damaged
or faul ty, or i f the dri ver si de ai rbag i s depl oyed, the
horn swi tch and tray must be repl aced as a uni t.
OPERATION
When the center area of the dri ver si de ai rbag tri m
cover i s depressed, the el ectri cal l y conducti ve gri ds
on the faci ng surfaces of the horn swi tch membranes
contact each other, cl osi ng the swi tch ci rcui t. The
compl eted horn swi tch ci rcui t provi des a ground for
the control coi l si de of the horn rel ay, whi ch acti vates
the rel ay. When the horn swi tch i s rel eased, the
resi sti ve tensi on of the convex membrane separates
the two el ectri cal l y conducti ve gri ds and opens the
swi tch ci rcui t.
DIAGNOSIS AND TESTING - HORN SWITCH
cabl e. Remove the steeri ng col umn openi ng cover
from the i nstrument panel .
(2) Check for conti nui ty between the metal steer-
i ng col umn jacket and a good ground. There shoul d
be conti nui ty. I f OK, go to Step 3. I f not OK, refer to
Steeri ng, Col umn for proper i nstal l ati on of the steer-
i ng col umn.
(3) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . Di sconnect the horn swi tch wi re har-
ness connectors from the dri ver si de ai rbag modul e.
(4) Remove the horn rel ay from the Power Di stri -
buti on Center (PDC). Check for conti nui ty between
the steeri ng col umn hal f of the horn swi tch feed wi re
harness connector and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 5. I f not OK,
repai r the shorted horn rel ay control ci rcui t to the
horn rel ay i n the PDC as requi red.
(5) Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and the horn rel ay control ci rcui t cavi ty for
the horn rel ay i n the PDC. There shoul d be conti nu-
horn rel ay control ci rcui t to the horn rel ay i n the
PDC as requi red.
1 - RIGHT FENDER
2 - BATTERY
4 - COVER
8H - 6 HORN WJ
HORN RELAY (Continued)
(6) Check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
dri ver si de ai rbag modul e. There shoul d be no conti -
nui ty. I f OK, go to Step 7. I f not OK, repl ace the
faul ty horn swi tch.
(7) Depress the center of the dri ver si de ai rbag
modul e tri m cover and check for conti nui ty between
the horn swi tch feed wi re and the horn swi tch
ground wi re on the dri ver si de ai rbag modul e. There
shoul d now be conti nui ty. I f not OK, repl ace the
faul ty horn swi tch.
REMOVAL
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO ELECTRICAL, RESTRAINTS BEFORE
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
cabl e.
(2) Remove the tri m cover from the dri ver si de ai r-
bag modul e. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - REMOVAL) for the
procedure.
(3) Remove the horn swi tch and tray as a uni t
from the pouch on the retai ni ng strap of the dri ver
si de ai rbag modul e (Fi g. 4).
INSTALLATION
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO ELECTRICAL, RESTRAINTS BEFORE
PERSONAL INJURY.
THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
RIES.
(1) I nstal l the horn swi tch and tray as a uni t i nto
the pouch on the retai ni ng strap of the dri ver si de
ai rbag modul e. Be certai n that the tray i s faci ng the
ai rbag modul e, that the horn swi tch i s faci ng the
tri m cover, that the horn swi tch feed wi re i s on the
l eft, and that the horn swi tch ground wi re i s on the
ri ght.
(2) I nstal l the tri m cover onto the dri ver si de ai r-
bag modul e. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - I NSTALLATI ON) for
the procedure.
Fig. 4 Horn Switch Remove/Install
1 - HORN SWITCH GROUND WIRE EYELET
2 - HORN SWITCH
3 - AIRBAG RETAINING STRAP
4 - POUCH
5 - DRIVER SIDE AIRBAG MODULE (TRIM COVER REMOVED)
6 - TRAY
7 - HORN SWITCH FEED WIRE CONNECTOR
WJ HORN 8H - 7
HORN SWITCH (Continued)
IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
ENGINE FIRING ORDER - 4.0L 6-CYLINDER
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE FIRING ORDER4.7L V-8 ENGINE . . 2
IGNITION COIL RESISTANCE - 4.0L ENGINE . 2
IGNITION COIL RESISTANCE4.7L V-8
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . 2
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE - IGNITION SYSTEM . . . . . . . . . . . . 3
AUTO SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT . . . . . . . . . . . . . 3
OPERATION
OPERATION - PCM OUTPUT . . . . . . . . . . . . . 3
OPERATION - ASD SENSE - PCM INPUT . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAMSHAFT POSITION SENSOR
DESCRIPTION
DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION - 4.7L . . . . . . . . . . . . . . . . . . . . 5
OPERATION
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . . 5
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . 8
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . . 9
COIL RAIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
IGNITION COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
IGNITION COIL CAPACITOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
KNOCK SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPARK PLUG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
IGNITION CONTROL
DESCRIPTION
Two di fferent i gni ti on systems are used. One type
of system i s for the 4.0L 6cyl i nder engi ne. The other
i s for the 4.7L V-8 engi ne.
OPERATION
The 4.0L 6cyl i nder engi ne uses a one-pi ece coi l
rai l contai ni ng three i ndependent coi l s. Al though cyl -
i nder fi ri ng order i s the same as 4.0L engi nes of pre-
vi ous years, spark pl ug fi ri ng i s not. The 3 coi l s dual -
fi re the spark pl ugs on cyl i nders 16, 25 and/or 34.
When one cyl i nder i s bei ng fi red (on compressi on
stroke), the spark to the opposi te cyl i nder i s bei ng
wasted (on exhaust stroke). The one-pi ece coi l bol ts
di rectl y to the cyl i nder head. Rubber boots seal the
secondary termi nal ends of the coi l s to the top of al l
6 spark pl ugs. One el ectri cal connector (l ocated at
the rear end of the coi l rai l ) i s used for al l three coi l s.
The 4.7L V-8 engi ne uses 8 dedi cated and i ndi vi d-
ual l y fi red coi l for each spark pl ug. Each coi l i s
mounted di rectl y to the top of each spark pl ug. A sep-
arate el ectri cal connector i s used for each coi l .
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used on ei ther engi ne. A distrib-
utor is not used wi th ei ther the 4.0L or 4.7L
engi nes.
WJ IGNITION CONTROL 8I - 1
The i gni ti on system i s control l ed by the powertrai n
control modul e (PCM) on al l engi nes.
The i gni ti on system consi sts of:
Spark Pl ugs
I gni ti on Coi l (s)
Powertrai n Control Modul e (PCM)
Crankshaft Posi ti on Sensor
Camshaft Posi ti on Sensor
The MAP, TPS, I AC and ECT al so have an effect
on the control of the i gni ti on system.
SPECIFICATIONS
ENGINE FIRING ORDER - 4. 0L 6-CYLINDER
ENGINE
ENGINE FIRING ORDER 4. 7L V-8 ENGINE
IGNITION COIL RESISTANCE - 4. 0L ENGINE
PRIMARY RESISTANCE 21-27C (70-80F)
0.71 - 0.88 Ohms
IGNITION COIL RESISTANCE 4. 7L V-8
ENGINE
PRIMARY RESISTANCE
21-27C (70-80F)
SECONDARY
RESISTANCE 21-27C
(70-80F)
0.6 - 0.9 Ohms 6,000 - 9,000 Ohms
IGNITION TIMING
Al l i gni ti on ti mi ng functi ons are control l ed by the
Powertrai n Control Modul e (PCM). Mechani cal
adjustments are not needed and cant be made.
On the 4.0L 6cyl i nder engi ne, do not attempt to
rotate the oi l pump dri ve to adjust ti mi ng. Thi s
adjustment i s used for fuel synchroni zati on after
camshaft posi ti on sensor repl acement.
8I - 2 IGNITION CONTROL WJ
IGNITION CONTROL (Continued)
SPARK PLUGS
ENGINE PLUG TYPE ELECTRODE GAP
4.0L 6-CYL. RC12ECC 0.89 mm (.035 in.)
4.7L V-8 (Exc. HO) RC12MCC4 1.01 mm (.040 in.)
4.7L V-8 High
Output (HO)
RC7PYCB4 1.01 mm (.040 in.)
TORQUE - IGNITION SYSTEM
Crankshaft Position Sensor
Bolts - 4.0L Engine
7 - 60
Bolt - 4.7L V-8 Engine
28 21 -
Camshaft Position
Sensortobase bolts - 4.0L
Engine
2 - 15
Camshaft Position Sensor
Bolt - 4.7L V-8 Engine
12 - 106
Oil Pump Drive Hold-down
Bolt - 4.0L Engine
23 17 -
Ignition Coil Rail Mounting
Bolts - 4.0L Engine
29 - 250
Ignition Coil Mounting Nut -
4.7L V-8 Engine
8 - 70
* Knock Sensor Bolt - 4.7L
HO V-8 Engine
*20 *15 -
Spark Plugs - 4.0L Engine 35-41 26-30 -
Spark Plugs - 4.7L V-8
Engine
24 - 30 18 - 22 -
* Do not apply any sealant,
thread-locker or adhesive to
bolts. Poor sensor
performance may result.
Refer to Removal / Installation
for additional information.
AUTO SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT
The 5pi n, 12vol t, Automati c Shutdown (ASD)
rel ay i s l ocated i n the Power Di stri buti on Center
(PDC). Refer to l abel on PDC cover for rel ay l ocati on.
OPERATION
OPERATION - PCM OUTPUT
The ASD rel ay suppl i es battery vol tage (12+ vol ts)
to the fuel i njectors and i gni ti on coi l (s). Wi th certai n
emi ssi ons packages i t al so suppl i es 12vol ts to the
oxygen sensor heati ng el ements.
The ground ci rcui t for the coi l wi thi n the ASD
rel ay i s control l ed by the Powertrai n Control Modul e
(PCM). The PCM operates the ASD rel ay by swi tch-
i ng i ts ground ci rcui t on and off.
IGNITION CONTROL (Continued)
The ASD rel ay wi l l be shutdown, meani ng the
12vol t power suppl y to the ASD rel ay wi l l be de-ac-
ti vated by the PCM i f:
the i gni ti on key i s l eft i n the ON posi ti on. Thi s
i s i f the engi ne has not been runni ng for approxi -
matel y 1.8 seconds.
there i s a crankshaft posi ti on sensor si gnal to
the PCM that i s l ower than pre-determi ned val ues.
OPERATION - ASD SENSE - PCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The rel ay i s used to
connect the oxygen sensor heater el ement, i gni ti on
coi l and fuel i njectors to 12 vol t + power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the Powertrai n Control Modul e
(PCM) does not see 12 vol ts at thi s i nput when the
ASD shoul d be acti vated, i t wi l l set a Di agnosti c
Troubl e Code (DTC).
REMOVAL
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 1). Refer to l abel on PDC cover
for rel ay l ocati on.
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 1). Refer to l abel on PDC cover
for rel ay l ocati on.
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
DESCRIPTION - 4. 0L
The Camshaft Posi ti on Sensor (CMP) on the 4.0L
6cyl i nder engi ne i s bol ted to the top of the oi l pump
dri ve shaft assembl y (Fi g. 2). The sensor and dri ve
shaft assembl y i s l ocated on the ri ght si de of the
engi ne near the oi l fi l ter (Fi g. 3).
Fig. 1 Power Distribution Center (PDC) Location
1 - PCM
2 - COOLANT TANK
Fig. 2 CMP and Oil Pump Drive Shaft4.0L Engine
1 - CAMSHAFT POSITION SENSOR
3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
5 - OIL PUMP DRIVESHAFT
6 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
AUTO SHUT DOWN RELAY (Continued)
DESCRIPTION - 4. 7L
V8 engi ne i s bol ted to the front/top of the ri ght cyl -
OPERATION
OPERATION - 4. 0L
The CMP sensor contai ns a hal l effect devi ce cal l ed
a sync si gnal generator to generate a fuel sync si g-
nal . Thi s sync si gnal generator detects a rotati ng
pul se ri ng (shutter) on the oi l pump dri ve shaft (Fi g.
2). The pul se ri ng rotates 180 degrees through the
sync si gnal generator. I ts si gnal i s used i n conjunc-
ti on wi th the crankshaft posi ti on sensor to di fferenti -
ate between fuel i njecti on and spark events. I t i s al so
used to synchroni ze the fuel i njectors wi th thei r
respecti ve cyl i nders.
When the l eadi ng edge of the pul se ri ng (shutter)
enters the sync si gnal generator, the fol l owi ng occurs:
The i nterrupti on of magneti c fi el d causes the vol tage
to swi tch hi gh resul ti ng i n a sync si gnal of approxi -
matel y 5 vol ts.
When the trai l i ng edge of the pul se ri ng (shutter)
l eaves the sync si gnal generator, the fol l owi ng occurs:
The change of the magneti c fi el d causes the sync si g-
nal vol tage to swi tch l ow to 0 vol ts.
OPERATION - 4. 7L
The CMP sensor contai ns a hal l effect devi ce cal l ed
a sync si gnal generator to generate a fuel sync si g-
nal . Thi s sync si gnal generator detects notches
l ocated on a tonewheel . The tonewheel i s l ocated at
the front of the camshaft for the ri ght cyl i nder head
(Fi g. 5). As the tonewheel rotates, the notches pass
through the sync si gnal generator. The pattern of the
notches (vi ewed counter-cl ockwi se from front of
engi ne) i s: 1 notch, 2 notches, 3 notches, 3 notches, 2
notches 1 notch, 3 notches and 1 notch. The si gnal
from the CMP sensor i s used i n conjuncti on wi th the
crankshaft posi ti on sensor to di fferenti ate between
fuel i njecti on and spark events. I t i s al so used to syn-
chroni ze the fuel i njectors wi th thei r respecti ve cyl i n-
ders.
Fig. 3 CMP Location4.0L Engine
1 - OIL FILTER
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP
6 - ELEC. CONNECTOR
1 - RIGHT CYLINDER HEAD
3 - MOUNTING BOLT
4 - ELEC. CONNECTOR
CAMSHAFT POSITION SENSOR (Continued)
REMOVAL
REMOVAL - 4. 0L
The rotati onal posi ti on of oi l pump dri ve deter-
mi nes fuel synchroni zati on onl y. I t does not deter-
mi ne i gni ti on ti mi ng.
NOTE: Do not attempt to rotate the oil pump drive
to modify ignition timing.
Two different procedures are used for removal
and i nstal l ati on. The fi rst procedure wi l l detai l
removal and i nstal l ati on of the sensor onl y. The sec-
ond procedure wi l l detai l removal and i nstal l ati on of
the sensor and oi l pump dri ve shaft assembl y. The
second procedure i s to be used i f the engi ne has been
di sassembl ed.
An i nternal oi l seal i s used i n the dri ve shaft hous-
i ng that prevents engi ne oi l at the bottom of the sen-
sor. The seal i s not servi ceabl e.
SENSOR ONLY - 4. 0L
(1) Di sconnect el ectri cal connector at CMP sensor
(Fi g. 7).
(2) Remove 2 sensor mounti ng bol ts (Fi g. 6) or
(Fi g. 7).
(3) Remove sensor from oi l pump dri ve.
OIL PUMP DRIVE AND SENSOR - 4. 0L
If the CMP and oil pump drive are to be
removed and installed, do not allow engine
crankshaft or camshaft to rotate. CMP sensor
relationship will be lost.
(Fi g. 7).
(2) Remove 2 sensor mounti ng bol ts (Fi g. 6) or
(Fi g. 7).
(3) Remove sensor from oi l pump dri ve.
(4) Before proceedi ng to next step, mark and note
rotati onal posi ti on of oi l pump dri ve i n rel ati onshi p
to engi ne bl ock. After i nstal l ati on, the CMP sensor
shoul d face rear of engi ne 0.
(5) Remove hol d-down bol t and cl amp (Fi g. 7).
Fig. 5 CMP Sensor and Tonewheel4.7L Engine
1 - NOTCHES
4 - TONEWHEEL
Fig. 6 CMP and Oil Pump Drive Shaft - 4.0L Engine
3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
5 - OIL PUMP DRIVESHAFT
(6) Whi l e pul l i ng assembl y from engi ne, note di rec-
ti on and posi ti on of pul se ri ng (Fi g. 6). After removal ,
l ook down i nto top of oi l pump and note di recti on and
posi ti on of sl ot at top of oi l pump gear.
(7) Remove and di scard ol d oi l pump dri ve-to-en-
gi ne bl ock gasket.
REMOVAL - 4. 7L
I t i s easi er to remove/i nstal l sensor from under
vehi cl e.
(Fi g. 10).
(3) Remove sensor mounti ng bol t (Fi g. 10).
(4) Careful l y pry sensor from cyl i nder head i n a
rocki ng acti on wi th two smal l screwdri vers. Some
4.7L engines are equipped with a sensor spacer
shim. If equipped, this shim will be located at
sensor bolt hole between cylinder head and
sensor mounting tang (TSB W081800). Save
this shim for sensor installation.
(5) Check condi ti on of sensor o-ri ng.
Fig. 7 CMP Location - 4.0L Engine
1 - OIL FILTER
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP
6 - ELEC. CONNECTOR
Fig. 8 CMP Pulse Ring Alignment - 4.0L Engine
1 - PULSE RING (SHUTTER)
2 - TOOTHPICK
Fig. 9 Align Timing Marks - 4.0L Engine
1 - CRANKSHAFT VIBRATION DAMPER TIMING MARK
INSTALLATION
INSTALLATION - 4. 0L
SENSOR ONLY - 4. 0L
(1) I nstal l sensor to oi l pump dri ve.
(2) I nstal l 2 sensor mounti ng bol ts and ti ghten to
2 Nm (15 i n. l bs.) torque.
(3) Connect el ectri cal connector to CMP sensor.
OIL PUMP DRIVE AND SENSOR - 4. 0L
(1) Cl ean oi l pump dri ve mounti ng hol e area of
engi ne bl ock.
(2) I nstal l new oi l pump dri ve-to-engi ne bl ock gas-
ket.
(3) Temporari l y i nstal l a toothpi ck or si mi l ar tool
through access hol e at si de of oi l pump dri ve housi ng.
Al i gn toothpi ck i nto mati ng hol e on pul se ri ng (Fi g.
8).
(4) I nstal l oi l pump dri ve i nto engi ne whi l e al i gn-
i ng i nto sl ot on oi l pump. Rotate oi l pump dri ve back
to i ts ori gi nal posi ti on and i nstal l hol d-down cl amp
and bol t. Fi nger ti ghten bol t. Do not do a fi nal ti ght-
eni ng of bol t at thi s ti me.
(5) I f engi ne crankshaft or camshaft has been
rotated, such as duri ng engi ne tear-down, CMP sen-
sor rel ati onshi p must be reestabl i shed.
(a) Remove i gni ti on coi l rai l assembl y. Refer to
I gni ti on Coi l Removal /I nstal l ati on.
(b) Remove cyl i nder number 1 spark pl ug.
(c) Hol d a fi nger over the open spark pl ug hol e.
Rotate engi ne at vi brati on dampener bol t unti l
compressi on (pressure) i s fel t.
(d) Sl owl y conti nue to rotate engi ne. Do thi s
unti l ti mi ng i ndex mark on vi brati on damper pul -
l ey al i gns wi th top dead center (TDC) mark (0
degree) on ti mi ng degree scal e (Fi g. 9). Al ways
rotate engi ne i n di recti on of normal rotati on. Do
not rotate engi ne backward to al i gn ti mi ng marks.
(e) I nstal l oi l pump dri ve i nto engi ne whi l e
al i gni ng i nto sl ot on oi l pump. I f pump dri ve wi l l
not drop down fl ush to engi ne bl ock, the oi l pump
sl ot i s not al i gned. Remove oi l pump dri ve and
al i gn sl ot i n oi l pump to shaft at bottom of dri ve.
I nstal l i nto engi ne. Rotate oi l pump dri ve back to
i ts ori gi nal posi ti on and i nstal l hol d-down cl amp
and bol t. Fi nger ti ghten bol t. Do not do a fi nal
ti ghteni ng of bol t at thi s ti me.
(f) Remove toothpi ck from housi ng.
(6) I nstal l sensor to oi l pump dri ve. After i nstal l a-
ti on, the CMP sensor shoul d face rear of engi ne 0.
(7) I nstal l 2 sensor mounti ng bol ts and ti ghten to
(8) Connect el ectri cal connector to CMP sensor.
(9) I f removed, i nstal l spark pl ug and i gni ti on coi l
rai l .
To veri fy correct rotati onal posi ti on of oi l pump
dri ve, the DRB scan tool must be used.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
(10) Connect DRB scan tool to data l i nk connector.
The data l i nk connector i s l ocated i n passenger com-
partment, bel ow and to l eft of steeri ng col umn.
(11) Gai n access to SET SYNC screen on DRB.
(12) Fol l ow di recti ons on DRB screen and start
engi ne. Bri ng to operati ng temperature (engi ne must
be i n cl osed l oop mode).
(13) Wi th engi ne runni ng at idle speed, the words
I N RANGE shoul d appear on screen al ong wi th 0.
Thi s i ndi cates correct posi ti on of oi l pump dri ve.
3 - MOUNTING BOLT
4 - ELEC. CONNECTOR
(14) I f a pl us (+) or a mi nus (-) i s di spl ayed next to
degree number, and/or the degree di spl ayed i s not
zero, l oosen but do not remove hol d-down cl amp bol t.
Rotate oi l pump dri ve unti l I N RANGE appears on
screen. Conti nue to rotate oi l pump dri ve unti l
achi evi ng as cl ose to 0 as possi bl e.
The degree scal e on SET SYNC screen of DRB i s
referri ng to fuel synchroni zati on onl y. It is not
referring to ignition timing. Because of thi s, do
not attempt to adjust i gni ti on ti mi ng usi ng thi s
method. Rotati ng oi l pump dri ve wi l l have no effect
on i gni ti on ti mi ng. Al l i gni ti on ti mi ng val ues are con-
trol l ed by powertrai n control modul e (PCM).
(15) Ti ghten hol d-down cl amp bol t to 23 Nm (17
ft. l bs.) torque.
(1) Cl ean out machi ned hol e i n cyl i nder head.
(2) Appl y a smal l amount of engi ne oi l to sensor
o-ri ng.
(3) I nstal l sensor i nto cyl i nder head wi th a sl i ght
rocki ng acti on. Do not twi st sensor i nto posi ti on as
damage to o-ri ng may resul t.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder head.
If sensor is not flush, damage to sensor mounting
tang may result.
(4) I nstal l mounti ng bol t and ti ghten to 12 Nm
COIL RAIL
DESCRIPTION
A one-pi ece coi l rai l assembl y contai ni ng three
i ndi vi dual coi l s i s used on the 4.0L 6cyl i nder engi ne
(Fi g. 11). The coi l rai l must be repl aced as one
assembl y. The bottom of the coi l i s equi pped wi th 6
i ndi vi dual rubber boots (Fi g. 11) to seal the 6 spark
pl ugs to the coi l . I nsi de each rubber boot i s a spri ng.
The spri ng i s used for a mechani cal contact between
the coi l and the top of the spark pl ug. These rubber
boots and spri ngs are a permanent part of the coi l
and are not servi ced separatel y.
(1) The coi l i s bol ted di rectl y to the cyl i nder head
(Fi g. 12). One el ectri cal connector (l ocated at rear of
coi l ) i s used for al l three coi l s.
Fig. 11 Ignition Coil Assembly4.0L 6Cylinder
Engine
1 - CYL. #6
2 - CYL. #5
3 - CYL. #4
4 - CYL. #3
5 - CYL. #2
6 - CYL. #1
7 - COILS (3)
9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)
Fig. 12 Coil Location4.0L Engine
1 - COIL RAIL
2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION
OPERATION
Al though cyl i nder fi ri ng order i s the same as 4.0L
Jeep engi nes of previ ous years, spark pl ug fi ri ng i s
not. The 3 coi l s dual -fi re the spark pl ugs on cyl i nders
1-6, 2-5 and/or 3-4. When one cyl i nder i s bei ng fi red
(on compressi on stroke), the spark to the opposi te
cyl i nder i s bei ng wasted (on exhaust stroke).
Battery vol tage i s suppl i ed to the three i gni ti on
coi l s from the ASD rel ay. The Powertrai n Control
Modul e (PCM) opens and cl oses the i gni ti on coi l
ground ci rcui t for i gni ti on coi l operati on.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
ary cabl es) are not used. The cabl es are i ntegral
wi thi n the coi l rai l .
REMOVAL
A one-pi ece coi l rai l assembl y contai ni ng three
i ndi vi dual coi l s i s used on the 4.0L engi ne (Fi g. 13).
The coi l rai l must be repl aced as one assembl y. The
bottom of the coi l i s equi pped wi th 6 i ndi vi dual rub-
ber boots (Fi g. 13) to seal the 6 spark pl ugs to the
coi l . I nsi de each rubber boot i s a spri ng. The spri ng
i s used for an el ectri cal contact between the coi l and
the top of the spark pl ug. These rubber boots and
spri ngs are a permanent part of the coi l and are not
servi ced separatel y.
(2) The coi l i s bol ted di rectl y to the cyl i nder head.
Remove 4 coi l mounti ng bol ts (Fi g. 14).
(3) Careful l y pry up coi l assembl y from spark
pl ugs. Do thi s by pryi ng al ternatel y at each end of
coi l unti l rubber boots have di sengaged from al l
spark pl ugs. I f boots wi l l not rel ease from spark
pl ugs, use a commerci al l y avai l abl e spark pl ug boot
removal tool . Twi st and l oosen a few boots from a few
spark pl ugs to hel p remove coi l .
(4) After coi l has cl eared spark pl ugs, posi ti on coi l
for access to pri mary el ectri cal connector. Di sconnect
connector from coi l by pushi ng sl i de tab outwards to
ri ght si de of vehi cl e (Fi g. 15). After sl i de tab has been
posi ti oned outwards, push i n on secondary rel ease
l ock (Fi g. 15) on si de of connector and pul l connector
from coi l .
(5) Remove coi l from vehi cl e.
Fig. 13 Ignition Coil Assembly4.0L 6Cylinder
Engine
1 - CYL. #6
2 - CYL. #5
3 - CYL. #4
4 - CYL. #3
5 - CYL. #2
6 - CYL. #1
7 - COILS (3)
9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)
Fig. 14 Ignition Coil Rail Location4.0L 6Cylinder
Engine
1 - COIL RAIL
2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION
COIL RAIL (Continued)
INSTALLATION
(1) Connect engi ne harness connector to coi l by
snappi ng i nto posi ti on. Move sl i de tab towards
engi ne (Fi g. 15) for a posi ti ve l ock.
(2) Posi ti on i gni ti on coi l rubber boots to al l spark
pl ugs. Push down on coi l assembl y unti l bol t bases
have contacted cyl i nder head
(3) I nstal l 4 coi l mounti ng bol ts. Loosel y ti ghten 4
bol ts just enough to al l ow bol t bases to contact cyl i n-
der head. Do a fi nal ti ghteni ng of each bol t i n steps
down to 29 Nm (250 i n. l bs.) torque. Do not appl y
ful l torque to any bol t fi rst.
IGNITION COIL
DESCRIPTION
The 4.7L V8 engi ne uses 8 dedi cated, and i ndi vi d-
ual l y fi red coi l (Fi g. 16) for each spark pl ug. Each
coi l i s mounted di rectl y to the top of each spark pl ug
(Fi g. 17).
Fig. 15 Ignition Coil Electrical Connector4.0L
6Cylinder Engine
1 - REAR OF VALVE COVER
2 - COIL RAIL
3 - SLIDE TAB
4 - RELEASE LOCK
5 - COIL CONNECTOR
Fig. 16 Ignition Coil4.7L Engine
1 - O-RING
2 - IGNITION COIL
Fig. 17 Ignition Coil Location4.7L Engine
1 - IGNITION COIL
2 - COIL ELECTRICAL CONNECTOR
3 - COIL MOUNTING STUD/NUT
COIL RAIL (Continued)
OPERATION
Battery vol tage i s suppl i ed to the 8 i gni ti on coi l s
from the ASD rel ay. The Powertrai n Control Modul e
(PCM) opens and cl oses each i gni ti on coi l ground ci r-
cui t at a determi ned ti me for i gni ti on coi l operati on.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
ary cabl es) are not used.
REMOVAL
An i ndi vi dual i gni ti on coi l i s used for each spark
pl ug (Fi g. 18). The coi l fi ts i nto machi ned hol es i n the
cyl i nder head. A mounti ng stud/nut secures each coi l
to the top of the i ntake mani fol d (Fi g. 19). The bot-
tom of the coi l i s equi pped wi th a rubber boot to seal
the spark pl ug to the coi l . I nsi de each rubber boot i s
a spri ng. The spri ng i s used for a mechani cal contact
between the coi l and the top of the spark pl ug. These
rubber boots and spri ngs are a permanent part of the
coi l and are not servi ced separatel y. An o-ri ng (Fi g.
18) i s used to seal the coi l at the openi ng i nto the cyl -
i nder head.
(1) Dependi ng on whi ch coi l i s bei ng removed, the
throttl e body ai r i ntake tube or i ntake box may need
to be removed to gai n access to coi l .
(2) Di sconnect el ectri cal connector (Fi g. 19) from
coi l by pushi ng downward on rel ease l ock on top of
connector and pul l connector from coi l .
(3) Cl ean area at base of coi l wi th compressed ai r
before removal .
(4) Remove coi l mounti ng nut from mounti ng stud
(Fi g. 19).
(5) Careful l y pul l up coi l from cyl i nder head open-
i ng wi th a sl i ght twi sti ng acti on.
(6) Remove coi l from vehi cl e.
INSTALLATION
(1) Usi ng compressed ai r, bl ow out any di rt or con-
tami nants from around top of spark pl ug.
(2) Check condi ti on of coi l o-ri ng and repl ace as
necessary. To ai d i n coi l i nstal l ati on, appl y si l i cone to
coi l o-ri ng.
(3) Posi ti on i gni ti on coi l i nto cyl i nder head openi ng
and push onto spark pl ug. Do thi s whi l e gui di ng coi l
base over mounti ng stud.
(4) I nstal l mounti ng stud nut and ti ghten to 8 Nm
(5) Connect el ectri cal connector to coi l by snappi ng
i nto posi ti on.
(6) I f necessary, i nstal l throttl e body ai r tube or
box.
Fig. 18 Ignition Coil4.7L V8
1 - O-RING
2 - IGNITION COIL
Fig. 19 Ignition Coil
1 - IGNITION COIL
IGNITION COIL (Continued)
IGNITION COIL CAPACITOR
DESCRIPTION
Two coi l capaci tors are used. One of them i s
l ocated near the center of, and on the l eft si de of the
i ntake mani fol d (Fi g. 20). The other capaci tor i s
l ocated near the center of, and on the ri ght si de of
the i ntake mani fol d.
OPERATION
The 2 coi l capaci tors are used to prevent hi gh-vol t-
age spi kes from i nterferi ng wi th the operati on of cer-
tai n powertrai n sensors. They are al so used to hel p
prevent radi o i nterference.
REMOVAL
Two coi l capaci tors are used. One of them i s
l ocated near the center of, and on the l eft si de of the
i ntake mani fol d (Fi g. 21). The other capaci tor i s
l ocated near the center of, and on the ri ght si de of
the i ntake mani fol d.
(1) Di sconnect el ectri cal connector at coi l capaci tor
(Fi g. 21).
(2) Remove mounti ng nut.
(3) Remove capaci tor from mounti ng stud.
INSTALLATION
(1) Posi ti on capaci tor to mani fol d mounti ng stud.
(2) I nstal l nut and ti ghten to 8 Nm (70 i n. l bs.)
torque.
(3) Connect el ectri cal connector to capaci tor (Fi g.
21).
KNOCK SENSOR
DESCRIPTION
4. 7L High-Output Engine
The 2 knock sensors are bol ted i nto the cyl i nder
bl ock under the i ntake mani fol d.
OPERATION
4. 7L High-Output Engine
Two knock sensors are used on the 4.7L V-8 engi ne
i f equi pped wi th the hi gh-output package; one for
each cyl i nder bank. When the knock sensor detects a
knock i n one of the cyl i nders on the correspondi ng
bank, i t sends an i nput si gnal to the Powertrai n Con-
trol Modul e (PCM). I n response, the PCM retards
i gni ti on ti mi ng for al l cyl i nders by a schedul ed
amount.
Knock sensors contai n a pi ezoel ectri c materi al
whi ch constantl y vi brates and sends an i nput vol tage
(si gnal ) to the PCM whi l e the engi ne operates. As the
i ntensi ty of the crystal s vi brati on i ncreases, the
knock sensor output vol tage al so i ncreases.
Fig. 20 Coil Capacitor (Left Side Shown)
2 - COIL CAPACITOR
3 - MOUNTING NUT
Fig. 21 Coil Capacitor (Left Side Shown)
2 - COIL CAPACITOR
3 - MOUNTING NUT
The vol tage si gnal produced by the knock sensor
i ncreases wi th the ampl i tude of vi brati on. The PCM
recei ves the knock sensor vol tage si gnal as an i nput.
I f the si gnal ri ses above a predetermi ned l evel , the
PCM wi l l store that val ue i n memory and retard
i gni ti on ti mi ng to reduce engi ne knock. I f the knock
sensor vol tage exceeds a preset val ue, the PCM
retards i gni ti on ti mi ng for al l cyl i nders. I t i s not a
sel ecti ve cyl i nder retard.
The PCM i gnores knock sensor i nput duri ng engi ne
i dl e condi ti ons. Once the engi ne speed exceeds a
speci fi ed val ue, knock retard i s al l owed.
Knock retard uses i ts own short term and l ong
term memory program.
Long term memory stores previ ous detonati on
i nformati on i n i ts battery-backed RAM. The maxi -
mum authori ty that l ong term memory has over ti m-
i ng retard can be cal i brated.
Short term memory i s al l owed to retard ti mi ng up
to a preset amount under al l operati ng condi ti ons (as
l ong as rpm i s above the mi ni mum rpm) except at
Wi de Open Throttl e (WOT). The PCM, usi ng short
term memory, can respond qui ckl y to retard ti mi ng
when engi ne knock i s detected. Short term memory
i s l ost any ti me the i gni ti on key i s turned off.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors.
REMOVAL
4. 7L High-Output Engine Only
The 2 knock sensors are bol ted i nto the cyl i nder
bl ock under the i ntake mani fol d (Fi g. 22).
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Di sconnect knock sensor dual pi gtai l harness
connector from engi ne wi ri ng harness connector. Thi s
connecti on i s made near the ri ght/rear of i ntake man-
i fol d (Fi g. 23).
(2) Remove i ntake mani fol d. Refer to Engi ne sec-
ti on.
(3) Remove sensor mounti ng bol ts (Fi g. 22). Note
foam stri p on bol t threads. Thi s foam i s used onl y to
retai n the bol ts to sensors for pl ant assembl y. I t i s
not used as a seal ant. Do not appl y any adhesi ve,
seal ant or thread l ocki ng compound to these bol ts.
(4) Remove sensors from engi ne.
Fig. 22 KNOCK SENSOR LOCATION - 4.7L H.O.
1 - KNOCK SENSORS (2)
2 - MOUNTING BOLTS
3 - INTAKE MANIFOLD (CUTAWAY)
4 - PIGTAIL CONNECTOR
Fig. 23 KNOCK SENSOR ELEC. CONNECTOR - 4.7L
H.O.
1 - KNOCK SENSOR PIGTAIL HARNESS CONNECTOR
2 - ENGINE WIRING HARNESS
KNOCK SENSOR (Continued)
INSTALLATION
4. 7L High-Output Engine Only
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Thoroughl y cl ean knock sensor mounti ng hol es.
(2) I nstal l sensors (Fi g. 22) i nto cyl i nder bl ock.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) I nstal l and ti ghten mounti ng bol ts. Bolt
torque is critical. Refer to torque speci fi cati on.
(4) I nstal l i ntake mani fol d. Refer to Engi ne sec-
ti on.
(5) Connect knock sensor pi gtai l wi ri ng harness to
engi ne wi ri ng harness near ri ght / rear of i ntake
mani fol d (Fi g. 23).
SPARK PLUG
DESCRIPTION
Both the 4.0L 6-cyl i nder and the 4.7L V-8 engi ne
use resi stor type spark pl ugs. Standard 4.7L V-8
engi nes are equi pped wi th fi red i n suppressor seal
type spark pl ugs usi ng a copper core ground el ec-
trode. Hi gh-Output (H.O.) 4.7L V-8 engi nes are
equi pped wi th uni que pl ugs usi ng a pl ati num ri vet
l ocated on the ti p of the center el ectrode.
Because of the use of an al umi num cyl i nder head
on the 4.7L engi ne, spark pl ug torque i s very cri ti cal .
To prevent possi bl e pre-i gni ti on and/or mechani cal
engi ne damage, the correct type/heat range/number
spark pl ug must be used. Do not substitute any
other spark plug on the 4.7L H.O. engine. Seri-
ous engine damage may occur.
Pl ugs on both engi nes have resi stance val ues rang-
i ng from 6,000 to 20,000 ohms (when checked wi th at
l east a 1000 vol t spark pl ug tester). Do not use an
ohmmeter to check the resistance values of the
spark plugs. Inaccurate readings will result.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken por-
cel ai n i nsul ators. Keep pl ugs arranged i n the order
i n whi ch they were removed from the engi ne. A si n-
gl e pl ug di spl ayi ng an abnormal condi ti on i ndi cates
that a probl em exi sts i n the correspondi ng cyl i nder.
Repl ace spark pl ugs at the i nterval s recommended i n
Group O, Lubri cati on and Mai ntenance.
EXCEPT 4.7L H.O. ENGINE : Spark pl ugs that
have l ow mi l eage may be cl eaned and reused i f not
otherwi se defecti ve, carbon or oi l foul ed. Al so refer to
Spark Pl ug Condi ti ons. 4.7L H.O. ENGINE : Never
cl ean spark pl ugs on the 4.7L H.O. engi ne. Damage
to the pl ati num ri vet wi l l resul t.
CAUTION: EXCEPT 4.7L H.O. ENGINE : Never use a
motorized wire wheel brush to clean the spark
plugs. Metallic deposits will remain on the spark
plug insulator and will cause plug misfire.
H.O. Gap Adjustment: I f equi pped wi th the 4.7L
H.O. engi ne, do not use a wi re-type gappi ng tool as
damage to the pl ati num ri vet on the center el ectrode
may occur. Use a tapered-type gauge (Fi g. 24).
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
Fig. 24 PLUG GAP - 4.7L H.O.
1 - TAPER GAUGE
KNOCK SENSOR (Continued)
(Fi g. 25). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than
approxi matel y 0.025 mm (.001 i n) per 3200 km (2000
mi l es) of operati on.
Spark pl ugs except platinum tipped that have
normal wear can usual l y be cl eaned, have the el ec-
trodes fi l ed, have the gap set and then be i nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance may be
affected by MMT deposi ts.
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 25). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 26), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 27).
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 28). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
Fig. 25 NORMAL OPERATION AND COLD (CARBON)
FOULING
1 - NORMAL
2 - DRY BLACK DEPOSITS
3 - COLD (CARBON) FOULING
Fig. 26 OIL OR ASH ENCRUSTED
SPARK PLUG (Continued)
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 29). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PRE-IGNITION DAMAGE
Pre-i gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 30). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
CAUTION: If the engine is equipped with copper
core ground electrode, or platinum tipped spark
plugs, they must be replaced with the same type/
number spark plug as the original. If another spark
plug is substituted, pre-ignition will result.
Fig. 27 ELECTRODE GAP BRIDGING
1 - GROUND ELECTRODE
2 - DEPOSITS
3 - CENTER ELECTRODE
Fig. 28 SCAVENGER DEPOSITS
1 - GROUND ELECTRODE COVERED WITH WHITE OR
YELLOW DEPOSITS
Fig. 29 CHIPPED ELECTRODE INSULATOR
1 - GROUND ELECTRODE
3 - CHIPPED INSULATOR
Fig. 30 PRE-IGNITION DAMAGE
1 - GROUND ELECTRODE STARTING TO DISSOLVE
2 - CENTER ELECTRODE DISSOLVED
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
31). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 2000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
CAUTION: If the engine is equipped with copper
core ground electrode, or platinum tipped spark
plugs, they must be replaced with the same type/
REMOVAL
CAUTION: If equipped with a 4.7L H.O. (High-Out-
put) engine, never substitute the original platinum
tipped spark plug with a different part number. Seri-
ous engine damage may result.
On the 4.0L 6cyl i nder engi ne, the spark pl ugs are
l ocated bel ow the coi l rai l assembl y. On the 4.7L V8
engi ne, each i ndi vi dual spark pl ug i s l ocated under
each i gni ti on coi l .
(1) 4.0L 6Cyl i nder Engi ne: Pri or to removi ng
spark pl ug, spray compressed ai r around spark pl ug
hol e and area around spark pl ug. Thi s wi l l hel p pre-
vent forei gn materi al from enteri ng combusti on
chamber.
(2) 4.7L V8 Engi ne: Pri or to removi ng spark pl ug,
spray compressed ai r around base of i gni ti on coi l at
cyl i nder head. Thi s wi l l hel p prevent forei gn materi al
from enteri ng combusti on chamber.
(3) On the 4.0L engi ne the coi l rai l assembl y must
be removed to gai n access to any/al l spark pl ug.
Refer to I gni ti on Coi l Removal /I nstal l ati on. On the
4.7L V-8 engi ne each i ndi vi dual i gni ti on coi l must be
removed to gai n access to each spark pl ug. Refer to
I gni ti on Coi l Removal /I nstal l ati on.
(4) Remove spark pl ug from cyl i nder head usi ng a
qual i ty socket wi th a rubber or foam i nsert. I f
equi pped wi th a 4.7L V-8 engi ne, al so check condi ti on
of coi l o-ri ng and repl ace as necessary.
(5) I nspect spark pl ug condi ti on. Refer to Spark
Pl ug Condi ti ons.
CLEANING
Except 4.7L H.O. Engine: The pl ugs may be
cl eaned usi ng commerci al l y avai l abl e spark pl ug
cl eani ng equi pment. After cl eani ng, fi l e center el ec-
trode fl at wi th a smal l poi nt fi l e or jewel ers fi l e
before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean spark plugs. Metallic deposits will remain
on spark plug insulator and will cause plug misfire.
4.7L H.O. Engine: Never cl ean spark pl ugs on the
4.7L H.O. engi ne. Damage to the pl ati num ri vet on
the center el ectrode wi l l resul t.
INSTALLATION
CAUTION: The standard 4.7L V-8 engine is
equipped with copper core ground electrode spark
plugs. They must be replaced with the same type/
CAUTION: If equipped with a 4.7L H.O. (High-Out-
put) engine, never substitute the original platinum
tipped spark plug with a different type/part number.
Serious engine damage may result.
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto cyl i nder head spark pl ug wel l s. Be sure
pl ugs do not drop i nto pl ug wel l s as ground straps
may be bent resul ti ng i n a change i n pl ug gap, or
el ectrodes can be damaged.
Al ways ti ghten spark pl ugs to speci fi ed torque. Over
ti ghteni ng can cause di storti on resul ti ng i n a change
i n spark pl ug gap or a cracked porcel ai n i nsul ator.
(1) Start spark pl ug i nto cyl i nder head by hand to
avoi d cross threadi ng.
(2) 4.0L 6Cyl i nder Engi ne: Ti ghten spark pl ugs to
35-41 Nm (26-30 ft. l bs.) torque.
(3) 4.7L V8 Engi ne: Ti ghten spark pl ugs to 27
Nm (20 ft. l bs.) torque.
(4) 4.7L V8 Engi ne: Before i nstal l i ng coi l (s), check
condi ti on of coi l o-ri ng and repl ace as necessary. To ai d
i n coi l i nstal l ati on, appl y si l i cone to coi l o-ri ng.
(5) I nstal l i gni ti on coi l (s). Refer to I gni ti on Coi l
Removal /I nstal l ati on.
Fig. 31 SPARK PLUG OVERHEATING
1 - BLISTERED WHITE OR GRAY COLORED INSULATOR
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
ABS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AIRBAG INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE/PARK BRAKE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - BRAKE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CHECK GAUGES INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
COOLANT LOW INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CRUISE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE TEMPERATURE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FRONT FOG LAMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HIGH BEAM INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LOW FUEL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ODOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OIL PRESSURE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OVERDRIVE OFF INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REAR FOG LAMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SEATBELT INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SHIFT INDICATOR (TRANSFER CASE)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SKIS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SPEEDOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TACHOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TRANS TEMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TURN SIGNAL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSIS AND TESTING - TURN SIGNAL
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 33
VOLTAGE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
WAIT-TO-START INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
WATER-IN-FUEL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
WJ INSTRUMENT CLUSTER 8J - 1
INSTRUMENT CLUSTER
DESCRIPTION
The i nstrument cl uster for thi s model i s an El ec-
troMechani cal I nstrument Cl uster (EMI C) modul e
that i s l ocated i n the i nstrument panel above the
steeri ng col umn openi ng, di rectl y i n front of the
dri ver (Fi g. 1). The remai nder of the EMI C, i ncl udi ng
the mounts and the el ectri cal connecti ons, are con-
ceal ed behi nd the cl uster bezel . The EMI C gauges
and i ndi cators are protected by an i ntegral cl ear
pl asti c cl uster l ens, and are vi si bl e through a dedi -
cated hooded openi ng i n the i nstrument panel top
pad. Just behi nd and i ntegral to the cl uster l ens are
the cl uster hood and cl uster mask, whi ch are con-
structed of mol ded bl ack pl asti c. Two cl uster masks
are used: A base versi on features a bl ack matte face
and no tri m ri ng around the peri meter of each gauge
openi ng, whi l e a premi um versi on features a bl ack
matte face and a rai sed tri m ri ng around the peri m-
eter of each gauge openi ng. The cl uster hood serves
as a vi sor and shi el ds the face of the cl uster from
ambi ent l i ght and refl ecti ons to reduce gl are, whi l e
the cl uster mask serves to separate and defi ne the
i ndi vi dual gauges of the EMI C. On the l ower edge of
the cl uster l ens just ri ght of the speedometer, the
bl ack pl asti c odometer/tri p odometer swi tch button
protrudes through dedi cated hol es i n the cl uster
mask and the cl uster l ens. The mol ded pl asti c EMI C
l ens, hood and mask uni t has four i ntegral mounti ng
tabs, two tabs extend down verti cal l y from the l ower
edge of the uni t and two tabs extend hori zontal l y
rearward from the upper surface of the hood. The
two l ower mounti ng tabs are used to secure the
EMI C to the mol ded pl asti c i nstrument panel cl uster
carri er wi th two screws, whi l e the two upper tabs are
secured to the undersi de of the hood formati on of the
i nstrument panel top pad wi th two screws. A si ngl e
mol ded connector receptacl e l ocated on the EMI C
el ectroni c ci rcui t board i s accessed from the back of
the cl uster housi ng and i s connected to the vehi cl e
el ectri cal system through a si ngl e dedi cated take out
and connector of the i nstrument panel wi re harness.
The cl uster mask features two l arge round open-
i ngs near i ts center through whi ch the two major
gauges are vi si bl e, and two smal l er round openi ngs
stacked at the outboard si de of each of the l arge
openi ngs through whi ch the four mi nor gauges are
vi si bl e. The cl uster mask and the di al faces of the
gauges are l ami nated pl asti c uni ts. The dark, vi si bl e
surface of the mask and the gauge di al faces are the
outer l ayer or overl ay, whi ch i s transl ucent. The
darkness of thi s outer l ayer prevents the cl uster from
appeari ng too cl uttered or busy by conceal i ng the
cl uster i ndi cators that are not i l l umi nated, whi l e the
transl ucence of thi s l ayer al l ows those i ndi cators and
i cons that are i l l umi nated to be readi l y vi si bl e. The
underl yi ng l ayer of the cl uster mask overl ay i s
opaque and al l ows l i ght from the vari ous i ndi cators
behi nd i t to be vi si bl e through the outer l ayer of the
mask and gauge di al faces onl y through predeter-
mi ned cutouts. On the base i nstrument cl usters the
graphi cs, i ncrements, and numeral s on the gauge
faces are al so transl ucent and i l l umi nated from
behi nd, whi l e the orange gauge poi nters are i l l umi -
nated i nternal l y. On the premi um i nstrument cl us-
ters the graphi cs, i ncrements, numeral s and gauge
needl es are opaque whi l e the remai nder of the gauge
faces are transl ucent and i l l umi nated from behi nd by
an el ectro-l umi nescent l amp. The EMI C el ectroni c
ci rcui try i s protected by a mol ded pl asti c rear cover
that features several round access hol es for servi ce of
the i ncandescent cl uster i ndi cator and i l l umi nati on
l i ghti ng l amps and a l arge rectangul ar access hol e
for the EMI C connector receptacl e. The EMI C rear
cover i s secured to the cl uster housi ng wi th screws,
whi l e the cl uster l ens, hood, and mask uni t i s
secured to the cl uster housi ng wi th several i ntegral
pl asti c l atch features.
Twel ve versi ons of the EMI C modul e are offered on
thi s model , two base and ten premi um. These ver-
si ons accommodate al l of the vari ati ons of opti onal
equi pment and regul atory requi rements for the vari -
ous markets i n whi ch the vehi cl e wi l l be offered. Thi s
modul e uti l i zes i ntegrated ci rcui try and i nformati on
carri ed on the Programmabl e Communi cati ons I nter-
face (PCI ) data bus network for control of al l gauges
and many of the i ndi cators. (Refer to 8 - ELECTRI -
CAL/ELECTRONI C CONTROL MODULES/COM-
MUNI CATI ON - DESCRI PTI ON - PCI BUS). The
Fig. 1 Instrument Cluster
1 - INSTRUMENT PANEL TOP PAD HOOD FORMATION
2 - INSTRUMENT CLUSTER
3 - CLUSTER BEZEL
8J - 2 INSTRUMENT CLUSTER WJ
EMI C al so uses several hard wi red i nputs i n order to
perform i ts many functi ons. The EMI C modul e i ncor-
porates a bl ue-green di gi tal Vacuum Fl uorescent Di s-
pl ay (VFD) for di spl ayi ng odometer and tri p
odometer i nformati on.
The EMI C houses si x anal og gauges and has pro-
vi si ons for up to twenty i ndi cators (Fi g. 2). The
EMI C i ncl udes the fol l owi ng anal og gauges:
Coolant Temperature Gauge
Fuel Gauge
Oil Pressure Gauge
Speedometer
Tachometer
Voltage Gauge
Some of the EMI C i ndi cators are automati cal l y
confi gured when the EMI C i s connected to the vehi -
cl e el ectri cal system for compati bi l i ty wi th certai n
opti onal equi pment or equi pment requi red for regul a-
tory purposes i n certai n markets. Whi l e each EMI C
may have provi si ons for i ndi cators to support every
avai l abl e opti on, the confi gurabl e i ndi cators wi l l not
be functi onal i n a vehi cl e that does not have the
equi pment that an i ndi cator supports. The EMI C
i ncl udes provi si ons for the fol l owi ng i ndi cators (Fi g.
2):
Airbag Indicator (with Airbags only)
Antilock Brake System (ABS) Indicator
Brake Indicator
Check Gauges Indicator
Coolant Low Indicator (with Diesel Engine
only)
Cruise Indicator
Four-Wheel Drive Part Time Indicator
(with Selec-Trac NVG-242 Transfer Case only)
Front Fog Lamp Indicator (with Front Fog
Lamps only)
High Beam Indicator
Low Fuel Indicator
Malfunction Indicator Lamp (MIL)
Overdrive-Off Indicator (except Diesel
Engine)
Rear Fog Lamp Indicator (with Rear Fog
Lamps only)
Seatbelt Indicator
Sentry Key Immobilizer System (SKIS)
Indicator
Transmission Overtemp Indicator (except
Diesel Engine)
Turn Signal (Right and Left) Indicators
Wait-To-Start Indicator (with Diesel Engine
only)
Water-In-Fuel Indicator (with Diesel Engine
only)
Many i ndi cators i n the EMI C are i l l umi nated by a
dedi cated Li ght Emi tti ng Di ode (LED) that i s sol -
dered onto the EMI C el ectroni c ci rcui t board. The
LEDs are not avai l abl e for servi ce repl acement and,
i f damaged or faul ty, the enti re EMI C must be
repl aced. Base cl uster i l l umi nati on i s accompl i shed
by di mmabl e i ncandescent back l i ghti ng, whi ch i l l u-
mi nates the gauges for vi si bi l i ty when the exteri or
l i ghti ng i s turned on. Premi um cl uster i l l umi nati on
i s accompl i shed by a di mmabl e el ectro-l umi nescent
l amp that i s servi ced onl y as a uni t wi th the EMI C.
Each of the i ncandescent bul bs i s secured by an i nte-
gral bul b hol der to the el ectroni c ci rcui t board from
the back of the cl uster housi ng. The i ncandescent
bul b/bul b hol der uni ts are avai l abl e for servi ce
repl acement.
Hard wi red ci rcui try connects the EMI C to the
el ectri cal system of the vehi cl e. These hard wi red ci r-
cui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system
and to the EMI C through the use of a combi nati on of
sol dered spl i ces, spl i ce bl ock connectors, and many
di fferent types of wi re harness termi nal connectors
and i nsul ators. Refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
The EMI C modul es for thi s model are servi ced onl y
as compl ete uni ts. The EMI C modul e cannot be
adjusted or repai red. I f a gauge, an LED i ndi cator,
the VFD, the el ectroni c ci rcui t board, the ci rcui t
board hardware, the cl uster overl ay, the el ectro-l umi -
nescent l amp (premi um model onl y) or the EMI C
housi ng are damaged or faul ty, the enti re EMI C mod-
ul e must be repl aced. The cl uster l ens, hood and
mask uni t and the i ndi vi dual i ncandescent l amp
bul bs wi th hol ders are avai l abl e for servi ce repl ace-
ment.
INSTRUMENT CLUSTER (Continued)
OPERATION
The El ectroMechani cal I nstrument Cl uster (EMI C)
i s desi gned to al l ow the vehi cl e operator to moni tor
the condi ti ons of many of the vehi cl e components and
operati ng systems. The gauges and i ndi cators i n the
EMI C provi de val uabl e i nformati on about the vari ous
standard and opti onal powertrai ns, fuel and emi s-
si ons systems, cool i ng systems, l i ghti ng systems,
safety systems and many other conveni ence i tems.
The EMI C i s i nstal l ed i n the i nstrument panel so
that al l of these moni tors can be easi l y vi ewed by the
vehi cl e operator when dri vi ng, whi l e sti l l al l owi ng
rel ati ve ease of access for servi ce. The mi croproces-
sor-based EMI C hardware and software uses vari ous
i nputs to control the gauges and i ndi cators vi si bl e on
the face of the cl uster. Some of these i nputs are hard
wi red, but most are i n the form of el ectroni c mes-
sages that are transmi tted by other el ectroni c mod-
ul es over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. (Refer to 8 -
ULES/COMMUNI CATI ON - OPERATI ON).
The EMI C mi croprocessor smooths the i nput data
usi ng al gori thms to provi de gauge readi ngs that are
accurate, stabl e and responsi ve to operati ng condi -
ti ons. These al gori thms are desi gned to provi de
gauge readi ngs duri ng normal operati on that are con-
si stent wi th customer expectati ons. However, when
abnormal condi ti ons exi st, such as l ow or hi gh bat-
tery vol tage, l ow oi l pressure or hi gh cool ant temper-
ature, the al gori thm can dri ve the gauge poi nter to
an extreme posi ti on and the mi croprocessor turns on
the Check Gauges i ndi cator to provi de a di sti nct
vi sual i ndi cati on of a probl em to the vehi cl e operator.
The i nstrument cl uster ci rcui try al so sends el ectroni c
chi me tone request messages over the PCI data bus
to the Body Control Modul e (BCM) when i t moni tors
Fig. 2 EMIC Gauges & Indicators
1 - BRAKE INDICATOR 15 - TRANSMISSION OVERTEMP INDICATOR
2 - REAR FOG LAMP INDICATOR 16 - PART TIME 4WD INDICATOR
3 - WATER-IN-FUEL INDICATOR 17 - CHECK GAUGES INDICATOR
4 - VOLTAGE GAUGE 18 - ENGINE TEMPERATURE GAUGE
5 - LEFT TURN INDICATOR 19 - ODOMETER/TRIP ODOMETER SWITCH BUTTON
6 - TACHOMETER 20 - ODOMETER/TRIP ODOMETER DISPLAY
7 - HIGH BEAM INDICATOR 21 - WAIT-TO-START INDICATOR
8 - AIRBAG INDICATOR 22 - OVERDRIVE-OFF INDICATOR
9 - SPEEDOMETER 23 - SEATBELT INDICATOR
10 - RIGHT TURN INDICATOR 24 - ABS INDICATOR
11 - OIL PRESSURE GAUGE 25 - FUEL GAUGE
12 - SKIS INDICATOR 26 - FRONT FOG LAMP INDICATOR
13 - MALFUNCTION INDICATOR LAMP (MIL) 27 - LOW FUEL INDICATOR
14 - CRUISE INDICATOR 28 - COOLANT LOW INDICATOR
certai n condi ti ons or i nputs to provi de the vehi cl e
operator wi th an audi bl e al ert to suppl ement a vi sual
i ndi cati on.
The EMI C ci rcui try operates on battery current
recei ved through fused B(+) fuses i n the Power Di s-
tri buti on Center (PDC) and the Juncti on Bl ock (JB)
on a non-swi tched fused B(+) ci rcui t, and on battery
current recei ved through a fused i gni ti on swi tch out-
put (run-start) fuse i n the JB on a fused i gni ti on
swi tch output (run-start) ci rcui t. Thi s arrangement
al l ows the EMI C to provi de some features regardl ess
of the i gni ti on swi tch posi ti on, whi l e other features
wi l l operate onl y wi th the i gni ti on swi tch i n the On
or Start posi ti ons. The EMI C ci rcui try i s grounded
through two separate ground ci rcui ts of the i nstru-
ment panel wi re harness. These ground ci rcui ts
recei ve ground through take outs of the i nstrument
panel wi re harness wi th eyel et termi nal connectors
that are secured by a nut to a ground stud l ocated on
the fl oor panel transmi ssi on tunnel beneath the cen-
ter fl oor consol e, just forward of the Ai rbag Control
Modul e (ACM).
The EMI C al so has a sel f-di agnosti c actuator test
capabi l i ty, whi ch wi l l test each of the PCI bus mes-
sage-control l ed functi ons of the cl uster by l i ghti ng
the appropri ate i ndi cators (except the ai rbag i ndi ca-
tor), sweepi ng the gauge needl es across the gauge
faces from thei r mi ni mum to thei r maxi mum read-
i ngs, and steppi ng the odometer di spl ay sequenti al l y
from al l zeros through al l ni nes. (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG). The sel f-di agnosti c actuator test
can be i ni ti al i zed manual l y or usi ng a DRBI I I scan
of the EMI C.
GAUGES
Al l gauges recei ve battery current through the
EMI C ci rcui try when the i gni ti on swi tch i s i n the On
or Start posi ti ons. Wi th the i gni ti on swi tch i n the Off
posi ti on battery current i s not suppl i ed to any
gauges, and the EMI C ci rcui try i s programmed to
move al l of the gauge needl es back to the l ow end of
thei r respecti ve scal es. Therefore, the gauges do not
accuratel y i ndi cate any vehi cl e condi ti on unl ess the
i gni ti on swi tch i s i n the On or Start posi ti ons. Al l of
the EMI C gauges, except the odometer, are ai r core
magneti c uni ts. Two fi xed el ectromagneti c coi l s are
l ocated wi thi n each gauge. These coi l s are wrapped
at ri ght angl es to each other around a movabl e per-
manent magnet. The movabl e magnet i s suspended
wi thi n the coi l s on one end of a pi vot shaft, whi l e the
gauge needl e i s attached to the other end of the
shaft. One of the coi l s has a fi xed current fl owi ng
through i t to mai ntai n a constant magneti c fi el d
strength. Current fl ow through the second coi l
changes, whi ch causes changes i n i ts magneti c fi el d
strength. The current fl owi ng through the second coi l
i s changed by the EMI C ci rcui try i n response to mes-
sages recei ved over the PCI data bus. The gauge nee-
dl e moves as the movabl e permanent magnet al i gns
i tsel f to the changi ng magneti c fi el ds created around
i t by the el ectromagnets.
The gauges are di agnosed usi ng the EMI C sel f-di -
agnosti c actuator test. (Refer to 8 - ELECTRI CAL/
I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). Proper testi ng of the PCI data bus, and
the data bus message i nputs to the EMI C that con-
trol each gauge requi res the use of a DRBI I I scan
Speci fi c operati on detai l s for each gauge may be
found el sewhere i n thi s servi ce i nformati on.
VACUUM-FLUORESCENT DISPLAY
The Vacuum-Fl uorescent Di spl ay (VFD) modul e i s
sol dered to the EMI C ci rcui t board. The di spl ay i s
acti ve wi th the i gni ti on swi tch i n the On or Start
posi ti ons, and i nacti ve when the i gni ti on swi tch i s i n
any other posi ti on. The i l l umi nati on i ntensi ty of the
VFD i s control l ed by the EMI C ci rcui try based upon
el ectroni c di mmi ng l evel messages recei ved from the
BCM over the PCI data bus, and i s synchroni zed
wi th the i l l umi nati on i ntensi ty of other VFDs i n the
vehi cl e. The BCM provi des di mmi ng l evel messages
based upon i nternal programmi ng and i nputs i t
recei ves from the control knob and control ri ng on
the control stal k of the l eft (l i ghti ng) mul ti -functi on
swi tch on the steeri ng col umn.
The VFD has several di spl ay capabi l i ti es i ncl udi ng
odometer and tri p odometer i nformati on. An odome-
ter/tri p odometer swi tch on the EMI C ci rcui t board i s
used to control the di spl ay modes. Thi s swi tch i s
actuated manual l y by depressi ng the odometer/tri p
odometer swi tch button that extends through the
l ower edge of the cl uster l ens, just ri ght of the speed-
ometer. Actuati ng thi s swi tch momentari l y wi th the
i gni ti on swi tch i n the On posi ti on wi l l toggl e the
VFD between the odometer and tri p odometer modes.
The EMI C mi croprocessor remembers whi ch di spl ay
mode i s acti ve when the i gni ti on swi tch i s turned to
the Off posi ti on, and returns the di spl ay to that
mode when the i gni ti on swi tch i s turned On agai n.
Depressi ng the swi tch button for about two seconds
whi l e the VFD i s i n the tri p odometer mode wi l l
reset the tri p odometer val ue to zero. Hol di ng thi s
swi tch depressed whi l e turni ng the i gni ti on swi tch
from the Off posi ti on to the On posi ti on wi l l i ni ti ate
the EMI C sel f-di agnosti c actuator test. Refer to the
appropri ate di agnosti c i nformati on for addi ti onal
detai l s on thi s VFD functi on.
The VFD i s di agnosed usi ng the EMI C sel f-di ag-
nosti c actuator test. (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). Proper testi ng of the PCI data bus and
the data bus message i nputs to the EMI C that con-
trol the VFD functi ons requi res the use of a DRBI I I
scan tool . Refer to the appropri ate di agnosti c i nfor-
mati on. Speci fi c operati on detai l s for the odometer
and tri p odometer functi ons of the VFD may be found
el sewhere i n thi s servi ce i nformati on.
INDICATORS
I ndi cators are l ocated i n vari ous posi ti ons wi thi n
the EMI C and are al l connected to the EMI C ci rcui t
board. The turn si gnal i ndi cators are hard wi red. The
brake i ndi cator i s control l ed by PCI data bus mes-
sages from the Control l er Anti l ock Brake (CAB) as
wel l as by hard wi red park brake swi tch and brake
fl ui d l evel swi tch i nputs to the EMI C. The Mal func-
ti on I ndi cator Lamp (MI L) i s normal l y control l ed by
PCI data bus messages from the Powertrai n Control
Modul e (PCM); however, i f the EMI C l oses PCI data
bus communi cati on, the EMI C ci rcui try wi l l automat-
i cal l y turn the MI L on unti l PCI data bus communi -
cati on i s restored. The EMI C uses PCI data bus
messages from the Ai rbag Control Modul e (ACM), the
BCM, the PCM, the CAB, the Sentry Key I mmobi -
l i zer Modul e (SKI M), and the Transmi ssi on Control
Modul e (TCM) to control al l of the remai ni ng i ndi ca-
tors.
The vari ous i ndi cators are control l ed by di fferent
strategi es; some recei ve fused i gni ti on swi tch output
from the EMI C ci rcui try and have a swi tched ground,
others are grounded through the EMI C ci rcui try and
have a swi tched battery feed, whi l e sti l l others are
compl etel y control l ed by the EMI C mi croprocessor
based upon vari ous hard wi red and el ectroni c mes-
sage i nputs. Some i ndi cators are i l l umi nated at a
fi xed i ntensi ty, whi l e the i l l umi nati on i ntensi ty of
others i s synchroni zed wi th that of the EMI C general
i l l umi nati on l amps.
The hard wi red i ndi cators are di agnosed usi ng con-
venti onal di agnosti c methods. The EMI C and PCI
bus message control l ed i ndi cators are di agnosed
usi ng the EMI C sel f-di agnosti c actuator test. (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
DI AGNOSI S AND TESTI NG). Proper testi ng of the
PCI data bus and the el ectroni c data bus message
i nputs to the EMI C that control each i ndi cator
requi re the use of a DRBI I I scan tool . Refer to the
appropri ate di agnosti c i nformati on. Speci fi c detai l s of
the operati on for each i ndi cator may be found el se-
where i n thi s servi ce i nformati on.
CLUSTER ILLUMINATION
Two types of general cl uster i l l umi nati on are avai l -
abl e i n thi s model . Base versi ons of the EMI C have
several i ncandescent i l l umi nati on l amps, whi l e pre-
mi um versi ons of the EMI C have a si ngl e el ectro-l u-
mi nescent l amp. Both types of l amps provi de cl uster
back l i ghti ng whenever the exteri or l i ghti ng i s
turned On wi th the control knob on the l eft (l i ghti ng)
mul ti -functi on swi tch control stal k. The i l l umi nati on
i ntensi ty of these l amps i s adjusted by the EMI C
mi croprocessor based upon el ectroni c di mmi ng l evel
messages recei ved from the Body Control Modul e
(BCM) over the PCI data bus. The BCM provi des
el ectroni c di mmi ng l evel messages to the EMI C
based upon i nternal programmi ng and i nputs i t
recei ves when the control ri ng on the l eft (l i ghti ng)
mul ti -functi on swi tch control stal k i s rotated (down
to di m, up to bri ghten) to one of si x avai l abl e mi nor
detent posi ti ons.
The i ncandescent i l l umi nati on l amps recei ve bat-
tery current at al l ti mes, whi l e the ground for these
l amps i s control l ed by a 12-vol t Pul se Wi dth Modu-
l ated (PWM) output of the EMI C el ectroni c ci rcui try.
The i l l umi nati on i ntensi ty of these bul bs and of the
vacuum-fl uorescent el ectroni c di spl ay are control l ed
by the i nstrument cl uster mi croprocessor based upon
di mmi ng l evel messages recei ved from the Body Con-
trol Modul e (BCM) over the PCI data bus. The BCM
uses i nputs from the headl amp and panel di mmer
swi tches wi thi n the l eft (l i ghti ng) mul ti -functi on
swi tch control stal k and i nternal programmi ng to
deci de what di mmi ng l evel message i s requi red. The
BCM then sends the proper di mmi ng l evel messages
to the EMI C over the PCI data bus.
The el ectro-l umi nescent l amp uni t consi sts of l ay-
ers of phosphor, carbon, i di um ti n oxi de, and di el ec-
tri c appl i ed by a si l k-screen process between two
pol yester membranes and i ncl udes a short pi gtai l
wi re and connector. The l amp pi gtai l wi re i s con-
nected to a smal l connector receptacl e on the EMI C
ci rcui t board through a smal l cl earance hol e i n the
cl uster housi ng rear cover. The EMI C el ectroni c ci r-
cui try al so uses a PWM strategy to control the i l l u-
mi nati on i ntensi ty of thi s l amp; however, the EMI C
powers thi s l amp wi th an Al ternati ng Current (AC)
rated at 80 vol ts rms (root mean squared) and 415
Hertz, whi ch exci tes the phosphor parti cl es causi ng
them to l umi nesce.
The BCM al so has several hard wi red panel l amp
dri ver outputs and sends the proper panel l amps
di mmi ng l evel messages over the PCI data bus to
coordi nate the i l l umi nati on i ntensi ty of al l of the
i nstrument panel l i ghti ng and the VFDs of other
el ectroni c modul es on the PCI data bus. Vehi cl es
equi pped wi th the Auto Headl amps opti on have an
automati c parade mode. I n thi s mode, the BCM uses
an i nput from the auto headl amp l i ght sensor to
determi ne the ambi ent l i ght l evel s. I f the BCM
deci des that the exteri or l i ghti ng i s turned on i n the
dayl i ght, i t overri des the sel ected panel di mmer
swi tch si gnal by sendi ng a message over the PCI
data bus to i l l umi nate al l vacuum fl uorescent di s-
pl ays at ful l bri ghtness for i mproved vi si bi l i ty i n day-
ti me l i ght l evel s. The automati c parade mode has no
effect on the i ncandescent bul b i l l umi nati on i ntensi ty.
The hard wi red cl uster i l l umi nati on ci rcui ts
between the l eft (l i ghti ng) mul ti -functi on swi tch and
the BCM may be di agnosed usi ng conventi onal di ag-
nosti c tool s and methods. The el ectro-l umi nescent
l amp i s di agnosed usi ng the EMI C sel f-di agnosti c
actuator test. (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG).
However, proper testi ng of the EMI C and the el ec-
troni c di mmi ng l evel messages sent by the BCM over
the PCI data bus requi res the use of a DRBI I I scan
CHIME SERVICE
The EMI C i s programmed to request chi me servi ce
from the Body Control Modul e (BCM) when certai n
i ndi cators are i l l umi nated. The EMI C chi me request
for i l l umi nati on of the l ow fuel i ndi cator i s a cus-
tomer programmabl e feature. When the programmed
condi ti ons are met, the EMI C generates an el ectroni c
chi me request message and sends i t over the PCI
data bus to the BCM. Upon recei vi ng the proper
chi me request, the BCM acti vates an i ntegral chi me
tone generator to provi de the audi bl e chi me tone to
the vehi cl e operator. (Refer to 8 - ELECTRI CAL/
CHI ME WARNI NG SYSTEM - OPERATI ON). Proper
testi ng of the PCI data bus and the el ectroni c chi me
request message outputs from the EMI C requi res the
use of a DRBI I I scan tool . Refer to the appropri ate
di agnosti c i nformati on.
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER
I f al l of the i nstrument cl uster gauges and/or i ndi -
cators are i noperati ve, refer to PRELI MI NARY
DI AGNOSI S . I f an i ndi vi dual gauge or Programma-
bl e Communi cati ons I nterface (PCI ) data bus mes-
sage-control l ed i ndi cator i s i noperati ve, refer to
ACTUATOR TEST . I f an i ndi vi dual hard wi red i ndi -
cator i s i noperati ve, refer to the di agnosi s and testi ng
i nformati on for that speci fi c i ndi cator. I f the base
i nstrument cl uster i ncandescent i l l umi nati on l i ghti ng
i s i noperati ve, refer to CLUSTER I LLUMI NATI ON
DI AGNOSI S . I f the premi um i nstrument cl uster
el ectro-l umi nescent i l l umi nati on l i ghti ng i s i nopera-
ti ve, refer to ACTUATOR TEST . Refer to the appro-
NOTE: Occasionally, a condition may be encoun-
tered where the gauge pointer for the speedometer
or the tachometer becomes caught on the wrong
side of the pointer stop. To correct this condition,
the technician should use a DRBIII scan tool and
the appropriate diagnostic information to perform
the instrument cluster self-diagnostic actuator test
procedure. When performed, the actuator test pro-
cedure will automatically return the pointer to the
correct side of the pointer stop.
PRELIMINARY DIAGNOSIS
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PERSONAL INJURY.
WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
(1) Check the fused B(+) fuse (Fuse 17 - 10
ampere) i n the Juncti on Bl ock (JB). I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
(Fuse 17 - 10 ampere) i n the JB. I f OK, go to Step 3.
I f not OK, repai r the open fused B(+) ci rcui t between
the JB and the Power Di stri buti on Center (PDC) as
requi red.
(3) Check the fused i gni ti on swi tch output (run-
start) fuse (Fuse 22 - 10 ampere) i n the JB. I f OK, go
to Step 4. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
output (run-start) fuse (Fuse 22 - 10 ampere) i n the
JB. I f OK, go to Step 5. I f not OK, repai r the open
fused i gni ti on swi tch output (run-start) ci rcui t
between the JB and the i gni ti on swi tch as requi red.
Remove the i nstrument cl uster. Reconnect the bat-
tery negati ve cabl e. Check for battery vol tage at the
fused B(+) ci rcui t cavi ty of the i nstrument panel wi re
harness connector for the i nstrument cl uster. I f OK,
go to Step 6. I f not OK, repai r the open fused B(+)
ci rcui t between the i nstrument cl uster and the JB as
requi red.
output (run-start) ci rcui t cavi ty of the i nstrument
panel wi re harness connector for the i nstrument cl us-
ter. I f OK, go to Step 7. I f not OK, repai r the open
fused i gni ti on swi tch output (run-start) ci rcui t
between the i nstrument cl uster and the JB as
requi red.
Check for conti nui ty between each of the ground ci r-
cui t cavi ti es of the i nstrument panel wi re harness
connector for the i nstrument cl uster and a good
ground. There shoul d be conti nui ty. I f OK, refer to
the ACTUATOR TEST . I f not OK, repai r the open
ground ci rcui t(s) between the i nstrument cl uster and
ground (G200) as requi red.
ACTUATOR TEST
PERSONAL INJURY.
INJURY.
The i nstrument cl uster actuator test wi l l put the
i nstrument cl uster i nto i ts sel f-di agnosti c mode. I n
thi s mode the i nstrument cl uster can perform a sel f-
di agnosti c test that wi l l confi rm that the i nstrument
cl uster ci rcui try, the gauges, the PCI data bus mes-
sage control l ed i ndi cators, and the el ectro-l umi nes-
cent i l l umi nati on l amp (i f equi pped) are capabl e of
operati ng as desi gned. Duri ng the actuator test the
i nstrument cl uster ci rcui try wi l l sweep each of the
gauge needl es across the gauge faces, i l l umi nate each
of the segments i n the Vacuum-Fl uorescent Di spl ay
(VFD), turn al l of the PCI data bus message-con-
trol l ed i ndi cators on and off agai n, and turn the el ec-
tro-l umi nescent i l l umi nati on l amp (i f equi pped) on
and off agai n.
Successful compl eti on of the actuator test wi l l con-
fi rm that the i nstrument cl uster i s operati onal . How-
ever, there may sti l l be a probl em wi th the PCI data
bus, the Powertrai n Control Modul e, the Ai rbag Con-
trol Modul e (ACM), the Body Control Modul e (BCM),
the Control l er Anti -l ock Brake (CAB), the Sentry Key
I mmobi l i zer Modul e (SKI M), or the i nputs to one of
these el ectroni c control modul es. Use a DRBI I I scan
tool to di agnose these components. Refer to the
I f an i ndi vi dual i ndi cator l amp or the el ectro-l umi -
nescent i l l umi nati on l amp do not i l l umi nate duri ng
the actuator test, the i nstrument cl uster shoul d be
removed. However, check that the i ncandescent l amp
bul b i s not faul ty, that the bul b hol der i s properl y
i nstal l ed on the i nstrument cl uster el ectroni c ci rcui t
board, or that the el ectro-l umi nescent l amp pi gtai l
wi re connector i s properl y connected to the i nstru-
ment cl uster el ectroni c ci rcui t board before consi der-
i ng i nstrument cl uster repl acement. I f the bul b and
bul b hol der, or the el ectro-l umi nescent l amp connec-
ti on check OK, repl ace the faul ty i nstrument cl uster
uni t.
(1) Begi n the test wi th the i gni ti on swi tch i n the
Off posi ti on.
(2) Depress the odometer/tri p odometer swi tch but-
ton.
(3) Whi l e sti l l hol di ng the odometer/tri p odometer
swi tch button depressed, turn the i gni ti on swi tch to
the On posi ti on, but do not start the engi ne.
(4) Rel ease the odometer/tri p odometer swi tch but-
ton.
(5) The i nstrument cl uster wi l l automati cal l y
begi n the actuator test sequence, as fol l ows:
(a) The cl uster wi l l turn on, then off agai n each
of the PCI data bus message control l ed i ndi cators
(except Ai rbag) to confi rm the functi onal i ty of the
i ndi cator and the cl uster control ci rcui try:
(b) The cl uster wi l l sweep the needl es for each of
the gauges from mi ni mum to maxi mum and back
to mi ni mum to confi rm the functi onal i ty of the
gauge and the cl uster control ci rcui try:
(c) Onl y on model s wi th a premi um versi on of
the cl uster, the cl uster wi l l i l l umi nate the el ectro-
l umi nescent l amp and turn i t off agai n to confi rm
the functi onal i ty of the l amp and the cl uster con-
trol ci rcui try.
(d) The cl uster wi l l sequenti al l y step the odome-
ter/tri p odometer VFD di spl ay from al l zeros
(000000) through al l ni nes (999999) to confi rm the
functi onal i ty of al l VFD segments and thei r control
ci rcui try, then di spl ay the software versi on number,
fol l owed by DONE.
(6) The actuator test i s now compl eted. The i nstru-
ment cl uster wi l l automati cal l y exi t the sel f-di agnos-
ti c mode and return to normal operati on at the
compl eti on of the test, i f the i gni ti on swi tch i s turned
to the Off posi ti on duri ng the test, or i f a vehi cl e
speed message i ndi cati ng that the vehi cl e i s movi ng
i s recei ved from the PCM over the PCI data bus dur-
i ng the test.
(7) Go back to Step 1 to repeat the test, i f
requi red.
CLUSTER ILLUMINATION DIAGNOSIS
On model s equi pped wi th a base versi on of the
i nstrument cl uster, the EMI C has several i ncandes-
cent i l l umi nati on l amps that are i l l umi nated when-
ever the exteri or l i ghti ng i s turned On. I f the
probl em bei ng di agnosed i s a si ngl e i noperati ve i l l u-
mi nati on l amp, be certai n that the bul b and bul b
hol der uni t are properl y i nstal l ed i n the i nstrument
cl uster el ectroni c ci rcui t board. I f no i nstal l ati on
probl ems are found repl ace the faul ty bul b and bul b
hol der uni t. I f al l of the cl uster i l l umi nati on l amps
are i noperati ve, the most rel i abl e, effi ci ent, and accu-
rate means to di agnose the cl uster i l l umi nati on func-
ti on of the i nstrument cl uster requi res the use of a
ti c i nformati on.
REMOVAL
PERSONAL INJURY.
INJURY.
cabl e.
(2) Remove the cl uster bezel from the i nstrument
CLUSTER BEZEL - REMOVAL).
(3) Remove the two screws that secure the upper
mounti ng tabs of the i nstrument cl uster to the
undersi de of the i nstrument cl uster hood formati on of
the i nstrument panel top pad.
(4) Remove the two screws that secure the l ower
mounti ng tabs of the i nstrument cl uster to the
(5) Pul l the upper mounti ng tabs of the i nstrument
cl uster downward, then pul l the i nstrument cl uster
rearward far enough to access the i nstrument panel
wi re harness connector for the i nstrument cl uster
(Fi g. 3).
connector for the i nstrument cl uster from the connec-
tor receptacl e on the back of the i nstrument cl uster
housi ng.
(7) Remove the i nstrument cl uster from the i nstru-
ment panel .
DISASSEMBLY
Some of the components for the i nstrument cl uster
used i n thi s vehi cl e are servi ced i ndi vi dual l y. The
servi ced components i ncl ude: the i ncandescent
i nstrument cl uster i ndi cator and i l l umi nati on l amp
bul bs (i ncl udi ng the i ntegral bul b hol ders), the cl us-
ter l ens, hood and mask uni t, and the cl uster housi ng
rear cover. Fol l owi ng are the procedures for di sas-
sembl i ng these components from the i nstrument cl us-
ter uni t.
PERSONAL INJURY.
INJURY.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp or i ndi cator bul b and bul b
hol der uni ts. However, the i l l umi nati on l amps and
the i ndi cators use di fferent bul b and bul b hol der uni t
si zes. They must never be i nterchanged. Be certai n
that any bul b hol der removed from the el ectroni c ci r-
cui t board i s rei nstal l ed i n the correct posi ti on.
cabl e.
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Turn the bul b hol der countercl ockwi se about
si xty degrees on the cl uster el ectroni c ci rcui t board
(Fi g. 4).
(4) Pul l the bul b and bul b hol der strai ght back to
remove i t from the bul b mounti ng hol e i n the cl uster
el ectroni c ci rcui t board.
CLUSTER LENS, HOOD AND MASK
cabl e.
(3) Work around the peri meter of the cl uster hous-
i ng to di sengage each of the ei ght l atches that secure
the cl uster l ens, hood and mask uni t to the cl uster
housi ng (Fi g. 5).
(4) Gentl y pul l the cl uster l ens, hood and mask
uni t away from the cl uster housi ng.
CLUSTER HOUSING REAR COVER
cabl e.
Fig. 3 Instrument Cluster Remove/Install
1 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR
(3) On model s wi th a premi um cl uster onl y, di scon-
nect the el ectro-l umi nescent i l l umi nati on l amp pi g-
tai l wi re connector from the receptacl e on the cl uster
el ectroni c ci rcui t board and di sengage the pi gtai l
wi re from the i ntegral routi ng cl i p on the rear cover
(Fi g. 6).
(4) Remove the seven screws that secure the rear
cover to the back of the cl uster housi ng.
(5) Di sengage the ei ght l atch features (four on top,
four on the bottom) that secure the upper and l ower
edges of the rear cover to the top and bottom of the
cl uster housi ng.
(6) Remove the rear cover from the back of the
cl uster housi ng.
ASSEMBLY
PERSONAL INJURY.
Fig. 4 Cluster Bulb Locations - Typical
1 - ILLUMINATION LAMP BULBS AND HOLDERS (5)
2 - CLUSTER HOUSING REAR COVER
3 - CLUSTER HOUSING
Fig. 5 Instrument Cluster Components
1 - MINOR GAUGE SETS
2 - HOUSING REAR COVER
3 - TRIP ODOMETER RESET KNOB
4 - LENS, HOOD AND MASK
5 - MAJOR GAUGES
6 - CLUSTER HOUSING
Fig. 6 Cluster Housing Rear Cover Screws
1 - ELECTRO-LUMINESCENT LAMP PIGTAIL WIRE
CONNECTOR
2 - REAR COVER
3 - SCREW (7)
INJURY.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp or i ndi cator bul b and bul b
hol der uni ts. However, the i l l umi nati on l amps and
the i ndi cators use di fferent bul b and bul b hol der uni t
si zes. They must never be i nterchanged.
CAUTION: Be certain that any bulb and bulb holder
unit removed from the cluster electronic circuit
board is reinstalled in the correct position. Always
use the correct bulb size and type for replacement.
An incorrect bulb size or type may overheat and
cause damage to the instrument cluster, the elec-
tronic circuit board and/or the gauges.
(1) I nsert the bul b and bul b hol der strai ght i nto
the correct bul b mounti ng hol e i n the cl uster el ec-
troni c ci rcui t board (Fi g. 4).
(2) Wi th the bul b hol der ful l y seated agai nst the
cl uster el ectroni c ci rcui t board, turn the bul b hol der
cl ockwi se about si xty degrees to l ock i t i nto pl ace.
(3) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
CLUSTER LENS, HOOD AND MASK
(1) Posi ti on the cl uster l ens, hood and mask uni t
over the face of the i nstrument cl uster (Fi g. 5). Be
certai n that the odometer/tri p odometer swi tch but-
ton i s i nserted through the proper cl earance hol es i n
the mask and the l ens.
(2) Press fi rml y and evenl y on the cl uster l ens,
hood and mask uni t to i nstal l i t onto the cl uster
housi ng.
(3) Work around the peri meter of the cl uster hous-
i ng to be certai n that each of the ei ght l atches that
secure the cl uster l ens, hood and mask uni t to the
cl uster housi ng i s ful l y engaged.
(4) Rei nstal l the i nstrument cl uster i nto the
CLUSTER HOUSING REAR COVER
(1) Posi ti on the rear cover onto the back of the
cl uster housi ng (Fi g. 6).
(2) Press fi rml y and evenl y on the rear cover unti l
each of the ei ght l atches (four on top, four on the bot-
tom) that secure the upper and l ower edges of the
rear cover to the top and bottom of the cl uster hous-
i ng are ful l y engaged.
(3) I nstal l and ti ghten the seven screws that
secure the rear cover to the back of the cl uster hous-
i ng. Ti ghten the screws to 2 Nm (20 i n. l bs.).
(4) On model s wi th a premi um cl uster onl y, recon-
nect the el ectro-l umi nescent i l l umi nati on l amp pi g-
tai l wi re connector to the receptacl e on the cl uster
el ectroni c ci rcui t board and engage the pi gtai l wi re
under the i ntegral routi ng cl i p on the rear cover.
INSTALLATION
PERSONAL INJURY.
INJURY.
(1) Posi ti on the i nstrument cl uster to the i nstru-
ment panel .
connector for the i nstrument cl uster to the connector
receptacl e on the back of the i nstrument cl uster
housi ng (Fi g. 7).
(3) Posi ti on the l ower mounti ng tabs of the i nstru-
ment cl uster to the mounti ng hol es on the i nstru-
ment panel structural duct, then ti l t the top of the
i nstrument cl uster forward unti l the upper mounti ng
tabs are posi ti oned to the mounti ng hol es on the
undersi de of the i nstrument cl uster hood formati on of
the i nstrument panel top pad.
the upper mounti ng tabs of the i nstrument cl uster to
the undersi de of the i nstrument cl uster hood forma-
ti on of the i nstrument panel top pad. Ti ghten the
the l ower mounti ng tabs of the i nstrument cl uster to
the i nstrument panel structural duct. Ti ghten the
(6) Rei nstal l the cl uster bezel onto the i nstrument
CLUSTER BEZEL - I NSTALLATI ON).
ABS INDICATOR
DESCRIPTION
An Anti -l ock Brake System (ABS) i ndi cator i s stan-
dard equi pment on al l i nstrument cl usters. The ABS
i ndi cator i s l ocated on the l ower l eft edge of the
i nstrument cl uster, to the l eft of the tachometer. The
ABS i ndi cator consi sts of a I nternati onal Control and
Di spl ay Symbol i con for Fai l ure of Anti -l ock Braki ng
System i mpri nted on an amber l ens. The l ens i s
l ocated behi nd a cutout i n the opaque l ayer of the
i nstrument cl uster overl ay. The dark outer l ayer of
the overl ay prevents the i ndi cator from bei ng cl earl y
vi si bl e when i t i s not i l l umi nated. The i con appears
si l houetted agai nst an amber fi el d through the trans-
l ucent outer l ayer of the overl ay when the i ndi cator
i s i l l umi nated from behi nd by a repl aceabl e i ncandes-
cent bul b and bul b hol der uni t l ocated on the i nstru-
ment cl uster el ectroni c ci rcui t board. The ABS
i ndi cator l ens i s servi ced as a uni t wi th the i nstru-
ment cl uster l ens, hood and mask uni t.
OPERATION
The ABS i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the ABS system i s faul ty or i nop-
erati ve. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster ci rcui t board based upon cl us-
ter programmi ng and el ectroni c messages recei ved by
the cl uster from the Control l er Anti -l ock Brake
(CAB) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The ABS i ndi cator bul b i s
compl etel y control l ed by the i nstrument cl uster l ogi c
ci rcui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
operate when the i nstrument cl uster recei ves a bat-
tery current i nput on the fused i gni ti on swi tch out-
put (run-start) ci rcui t. Therefore, the i ndi cator wi l l
al ways be off when the i gni ti on swi tch i s i n any posi -
ti on except On or Start. The bul b onl y i l l umi nates
when i t i s provi ded a path to ground by the i nstru-
ment cl uster transi stor. The i nstrument cl uster wi l l
turn on the ABS i ndi cator for the fol l owi ng reasons:
Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the CAB sends an el ec-
troni c ABS l amp-on message to the cl uster whi ch wi l l
i l l umi nate the ABS i ndi cator for about four seconds
as a bul b test. The enti re four second bul b test i s a
functi on of the CAB.
ABS Indicator Lamp-On Message - Each ti me
the cl uster recei ves an ABS i ndi cator l amp-on mes-
sage from the CAB, the ABS i ndi cator wi l l be i l l umi -
nated. The i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves an ABS i ndi cator l amp-off message
from the CAB, or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst.
Communication Error - I f the cl uster recei ves
no ABS i ndi cator l amp-on or l amp-off messages from
the CAB for si x consecuti ve seconds, the ABS i ndi ca-
tor i s i l l umi nated. The i ndi cator remai ns i l l umi nated
unti l the cl uster recei ves a val i d l amp-on or l amp-off
message from the CAB, or unti l the i gni ti on swi tch i s
turned to the Off posi ti on, whi chever occurs fi rst.
Actuator Test - Each ti me the i nstrument cl us-
ter i s put through the actuator test, the ABS i ndi ca-
Fig. 7 Instrument Cluster Remove/Install
tor wi l l be turned on for the durati on of the test to
confi rm the functi onal i ty of the bul b and the cl uster
control ci rcui try.
ABS Diagnostic Test - The ABS i ndi cator i s
bl i nked on and off based upon l amp-on and l amp-off
messages from the CAB duri ng the performance of
the ABS di agnosti c tests.
The CAB conti nual l y moni tors the ABS ci rcui ts
and sensors to deci de whether the system i s i n good
operati ng condi ti on. The CAB then sends the proper
ABS i ndi cator l amp-on or l amp-off messages to the
i nstrument cl uster. I f the ABS i ndi cator fai l s to l i ght
duri ng the bul b test, repl ace the bul b wi th a known
good uni t. I f the CAB sends an ABS i ndi cator
l amp-on message after the bul b test, i t i ndi cates that
the CAB has detected a system mal functi on and/or
that the ABS system has become i noperati ve. The
CAB wi l l store a Di agnosti c Troubl e Code (DTC) for
any mal functi on i t detects. Each ti me the ABS i ndi -
cator fai l s to i l l umi nate due to an open or short i n
the cl uster ABS i ndi cator ci rcui t or bul b, the cl uster
sends a message noti fyi ng the CAB of the condi ti on,
then the i nstrument cl uster and the CAB wi l l each
store a DTC. For proper di agnosi s of the anti -l ock
brake system, the CAB, the PCI data bus, or the
el ectroni c message i nputs to the i nstrument cl uster
that control the ABS i ndi cator, a DRBI I I scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
AIRBAG INDICATOR
DESCRIPTION
An ai rbag i ndi cator i s standard equi pment on al l
i nstrument cl usters. However, the i nstrument cl uster
i s programmed to automati cal l y enabl e thi s i ndi cator
onl y on vehi cl es equi pped wi th the ai rbag system,
whi ch i s not avai l abl e i n some markets. The ai rbag
i ndi cator i s l ocated on the upper edge of the i nstru-
ment cl uster, between the speedometer and the
tachometer. The ai rbag i ndi cator consi sts of the
words AI R BAG i mpri nted on a red l ens. The l ens
i s l ocated behi nd a cutout i n the opaque l ayer of the
vi si bl e when i t i s not i l l umi nated. The AI R BAG
text appears si l houetted agai nst a red fi el d through
the transl ucent outer l ayer of the overl ay when the
i ndi cator i s i l l umi nated from behi nd by a Li ght Emi t-
ti ng Di ode (LED), whi ch i s sol dered onto the i nstru-
ment cl uster el ectroni c ci rcui t board. The ai rbag
OPERATION
The ai rbag i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the ai rbag system i s faul ty or
i noperati ve. The ai rbag i ndi cator i s control l ed by a
transi stor on the i nstrument cl uster ci rcui t board
based upon cl uster programmi ng and el ectroni c mes-
sages recei ved by the cl uster from the Ai rbag Control
Modul e (ACM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The ai rbag i ndi cator
Li ght Emi tti ng Di ode (LED) i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l onl y al l ow thi s i ndi cator to operate when the
i nstrument cl uster recei ves a battery current i nput
on the fused i gni ti on swi tch output (run-start) ci r-
cui t. Therefore, the i ndi cator wi l l al ways be off when
the i gni ti on swi tch i s i n any posi ti on except On or
Start. The LED onl y i l l umi nates when i t i s swi tched
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the ai rbag i ndi cator
for the fol l owi ng reasons:
turned to the On posi ti on the ACM sends an el ec-
troni c ai rbag i ndi cator l amp-on message to the cl us-
ter whi ch wi l l i l l umi nate the ai rbag i ndi cator for
about si x seconds as a bul b test. The enti re si x sec-
ond bul b test i s a functi on of the ACM.
Airbag Indicator Lamp-On Message - Each
ti me the cl uster recei ves an ai rbag i ndi cator l amp-on
message from the ACM, the ai rbag i ndi cator wi l l be
i l l umi nated. The i ndi cator remai ns i l l umi nated for
about twel ve seconds or unti l the cl uster recei ves an
ai rbag i ndi cator l amp-off message from the ACM,
whi chever i s l onger.
no ai rbag i ndi cator l amp-on or l amp-off messages for
si x consecuti ve seconds, the ai rbag i ndi cator i s i l l u-
mi nated. The i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves a si ngl e val i d ai rbag i ndi cator l amp-
off message from the ACM.
Actuator Test - Each ti me the cl uster i s put
through the actuator test, the ai rbag i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
ti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try. The actuator
test i l l umi nati on of the ai rbag i ndi cator i s al so a
functi on of the ACM.
The ACM conti nual l y moni tors the ai rbag system
ci rcui ts and sensors to deci de whether the system i s
i n good operati ng condi ti on. The ACM then sends the
proper ai rbag i ndi cator l amp-on or l amp-off messages
to the i nstrument cl uster. I f the ACM sends an ai r-
bag i ndi cator l amp-on message after the bul b test, i t
i ndi cates that the ACM has detected a system mal -
functi on. Such a mal functi on coul d mean that the
ai rbags may not depl oy when requi red, or may
depl oy when not requi red. The ACM wi l l store a
ABS INDICATOR (Continued)
Di agnosti c Troubl e Code (DTC) for any mal functi on i t
detects. Each ti me the ai rbag i ndi cator fai l s to i l l u-
mi nate due to an open or short i n the cl uster ai rbag
i ndi cator ci rcui t, the cl uster sends a message noti fy-
i ng the ACM of the condi ti on, then the i nstrument
cl uster and the ACM wi l l each store a DTC. For
proper di agnosi s of the ai rbag system, the ACM, the
PCI data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the ai rbag i ndi cator,
a DRBI I I scan tool i s requi red. Refer to the appro-
pri ate di agnosti c i nformati on.
BRAKE/PARK BRAKE
INDICATOR
DESCRIPTION
A brake i ndi cator i s standard equi pment on al l
i nstrument cl usters. The brake i ndi cator i s l ocated
near the l eft edge of the i nstrument cl uster, to the
l eft of the tachometer. There are two versi ons of the
brake i ndi cator. The versi on used depends upon the
market for whi ch the vehi cl e i s manufactured. The
versi on of the brake i ndi cator used for vehi cl es man-
ufactured for the Uni ted States consi sts of the word
BRAKE i mpri nted on a red l ens. The Rest-Of-Worl d
(ROW) market versi on of thi s i ndi cator has two
I nternati onal Control and Di spl ay Symbol i cons
i mpri nted on the red l ens; one i s the i con for Brake
Fai l ure, and the other i s the i con for Parki ng
Brake. I n ei ther case, the l ens i s l ocated behi nd a
cutout i n the opaque l ayer of the i nstrument cl uster
overl ay. The dark outer l ayer of the overl ay prevents
the i ndi cator from bei ng cl earl y vi si bl e when i t i s not
i l l umi nated. The BRAKE text or the two i cons
appear si l houetted agai nst a red fi el d through the
transl ucent outer l ayer of the overl ay when the i ndi -
cator i s i l l umi nated from behi nd by a Li ght Emi tti ng
Di ode (LED), whi ch i s sol dered onto the i nstrument
cl uster el ectroni c ci rcui t board. The brake i ndi cator
l ens i s servi ced as a uni t wi th the i nstrument cl uster
l ens, hood and mask uni t.
OPERATION
The brake i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the parki ng brake i s appl i ed, when
the fl ui d l evel of the brake hydraul i c system i s l ow,
or i f there are certai n mal functi ons of the Anti -l ock
Brake System (ABS). Thi s i ndi cator i s control l ed by a
transi stor on the i nstrument cl uster el ectroni c ci rcui t
board based upon cl uster programmi ng, el ectroni c
messages recei ved by the cl uster from the Control l er
Anti -l ock Brake (CAB) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus, and a hard
wi red i nput to the cl uster from the park brake
swi tch. The brake i ndi cator Li ght Emi tti ng Di ode
(LED) i s compl etel y control l ed by the i nstrument
cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow
thi s i ndi cator to operate when the i nstrument cl uster
recei ves a battery current i nput on the fused i gni ti on
swi tch output (run-start) ci rcui t. Therefore, the i ndi -
cator wi l l al ways be off when the i gni ti on swi tch i s i n
any posi ti on except On or Start. The LED onl y i l l u-
mi nates when i t i s provi ded a path to ground by the
i nstrument cl uster transi stor. The i nstrument cl uster
wi l l turn on the brake i ndi cator for the fol l owi ng rea-
sons:
turned to the On posi ti on the brake i ndi cator i s i l l u-
mi nated by the i nstrument cl uster for about three
seconds as a bul b test.
Brake Indicator Lamp-On Message - Each
ti me the cl uster recei ves a brake i ndi cator l amp-on
message from the CAB, the brake i ndi cator wi l l be
i l l umi nated. The i ndi cator remai ns i l l umi nated unti l
the cl uster recei ves a brake i ndi cator l amp-off mes-
sage from the CAB.
Park Brake Switch Input - Each ti me the
cl uster l ogi c ci rcui t detects ground on the park brake
swi tch sense ci rcui t (park brake swi tch cl osed = park
brake appl i ed or not ful l y rel eased) the brake i ndi ca-
unti l the park brake swi tch sense i nput to the cl uster
i s an open ci rcui t (park brake swi tch open = park
brake ful l y rel eased), or unti l the i gni ti on swi tch i s
no brake i ndi cator l amp-on or l amp-off messages
from the CAB for si x consecuti ve seconds, the brake
i ndi cator i s i l l umi nated. The i ndi cator remai ns i l l u-
mi nated unti l the cl uster recei ves a si ngl e val i d
brake i ndi cator l amp-off message from the CAB.
through the actuator test, the brake i ndi cator wi l l be
turned on for the durati on of the test to confi rm the
functi onal i ty of the LED and the cl uster control ci r-
cui try.
The park brake swi tch on the park brake pedal
mechani sm provi des a hard wi red ground i nput to
the i nstrument cl uster ci rcui try through the red
brake warni ng i ndi cator dri ver ci rcui t whenever the
park brake i s appl i ed or not ful l y rel eased. The CAB
conti nual l y moni tors the i nput from the brake fl ui d
l evel swi tch and the ci rcui ts of the anti -l ock brake
system, then sends the proper brake i ndi cator
l amp-on or l amp-off messages to the i nstrument cl us-
ter. I f the CAB sends a brake i ndi cator l amp-on mes-
sage after the bul b test, i t i ndi cates that the CAB
has detected a brake hydraul i c system mal functi on
and/or that the ABS system has become i noperati ve.
The CAB wi l l store a Di agnosti c Troubl e Code (DTC)
for any mal functi on i t detects.
AIRBAG INDICATOR (Continued)
For further di agnosi s of the brake i ndi cator or the
i nstrument cl uster ci rcui try that control s the i ndi ca-
tor, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). The park
brake swi tch i nput to the i nstrument cl uster can be
di agnosed usi ng conventi onal di agnosti c tool s and
methods. For proper di agnosi s of the brake fl ui d l evel
swi tch i nput to the CAB, the anti -l ock brake system,
the CAB, the PCI data bus, or the el ectroni c message
i nputs to the i nstrument cl uster that control the
brake i ndi cator, a DRBI I I scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
DIAGNOSIS AND TESTING - BRAKE INDICATOR
The di agnosi s found here addresses an i noperati ve
park brake i ndi cator condi ti on. I f there are probl ems
wi th several i ndi cators i n the i nstrument cl uster,
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG). I f the brake
i ndi cator stays on wi th the i gni ti on swi tch i n the On
posi ti on and the park brake rel eased, or comes on
whi l e dri vi ng, (Refer to 5 - BRAKES - DI AGNOSI S
AND TESTI NG). I f no brake system probl em i s
found, the fol l owi ng procedures wi l l hel p to l ocate a
shorted or open ci rcui t, or a faul ty park brake swi tch
i nput. Refer to the appropri ate wi ri ng i nformati on.
The wi ri ng i nformati on i ncl udes wi ri ng di agrams,
proper wi re and connector repai r procedures, detai l s
of wi re harness routi ng and retenti on, connector pi n-
out i nformati on and l ocati on vi ews for the vari ous
wi re harness connectors, spl i ces and grounds.
PERSONAL INJURY.
INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES
NOT WHEN PARK BRAKE APPLIED
cabl e. Di sconnect the i nstrument panel wi re harness
connector for the park brake swi tch from the swi tch
termi nal . Appl y the parki ng brake. Check for conti -
nui ty between the park brake swi tch termi nal and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 2. I f not OK, repl ace the faul ty park brake
swi tch.
connector for the i nstrument cl uster from the cl uster
connector receptacl e. Check for conti nui ty between
the red brake warni ng i ndi cator dri ver ci rcui t cavi -
ti es of the i nstrument panel wi re harness connector
for the park brake swi tch and the i nstrument panel
wi re harness connector for the i nstrument cl uster.
There shoul d be conti nui ty. I f not OK, repai r the
open red brake warni ng i ndi cator dri ver ci rcui t
between the park brake swi tch and the i nstrument
cl uster as requi red.
INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM
CHECKS OK
connector for the park brake swi tch from the park
brake swi tch termi nal . Check for conti nui ty between
the termi nal of the park brake swi tch and a good
ground. There shoul d be no conti nui ty wi th the park
brake rel eased, and conti nui ty wi th the park brake
appl i ed. I f OK, go to Step 2. I f not OK, repl ace the
faul ty park brake swi tch.
connector for the i nstrument cl uster from the cl uster
connector receptacl e. Check for conti nui ty between
the red brake warni ng i ndi cator dri ver ci rcui t cavi ty
of the i nstrument panel wi re harness connector for
the park brake swi tch and a good ground. There
shoul d be no conti nui ty. I f not OK, repai r the shorted
red brake warni ng i ndi cator dri ver ci rcui t between
the park brake swi tch and the i nstrument cl uster as
requi red.
CHECK GAUGES INDICATOR
DESCRIPTION
A check gauges i ndi cator i s standard equi pment on
al l i nstrument cl usters. The check gauges i ndi cator i s
l ocated on the ri ght edge of the i nstrument cl uster, to
the ri ght of the speedometer. The check gauges i ndi -
cator consi sts of the words CHECK GAGES
i mpri nted on a red l ens. The l ens i s l ocated behi nd a
i l l umi nated. The CHECK GAGES text appears si l -
houetted agai nst a red fi el d through the transl ucent
outer l ayer of the overl ay when the i ndi cator i s i l l u-
mi nated from behi nd by a Li ght Emi tti ng Di ode
(LED), whi ch i s sol dered onto the i nstrument cl uster
el ectroni c ci rcui t board. The check gauges i ndi cator
BRAKE/PARK BRAKE INDICATOR (Continued)
l ens i s servi ced as a uni t wi th the i nstrument cl uster
l ens, hood and mask uni t.
OPERATION
The check gauges i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when certai n i nstrument cl uster
gauge readi ngs refl ect a condi ti on requi ri ng i mmedi -
ate attenti on. Thi s i ndi cator i s control l ed by a tran-
si stor on the i nstrument cl uster ci rcui t board based
upon cl uster programmi ng and el ectroni c messages
recei ved by the cl uster from the Powertrai n Control
Modul e (PCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The check gauges
i ndi cator Li ght Emi tti ng Di ode (LED) i s compl etel y
control l ed by the i nstrument cl uster l ogi c ci rcui t, and
that l ogi c wi l l onl y al l ow thi s i ndi cator to operate
when the i nstrument cl uster recei ves a battery cur-
rent i nput on the fused i gni ti on swi tch output (run-
start) ci rcui t. Therefore, the i ndi cator wi l l al ways be
off when the i gni ti on swi tch i s i n any posi ti on except
On or Start. The LED onl y i l l umi nates when i t i s
provi ded a path to ground by the i nstrument cl uster
transi stor. The i nstrument cl uster wi l l turn on the
check gauges i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the check gauges i ndi cator
i s i l l umi nated for about three seconds as a bul b test.
Engine Temperature High/Critical Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the engi ne cool ant temperature i s
hi gh or cri ti cal [above about 127 C (261 F) for gas-
ol i ne engi nes except Gul f Coast Country (GCC), 129
C (264 F) for GCC gasol i ne engi nes, and 118 C
(244 F) for di esel engi nes], the check gauges i ndi ca-
unti l the cl uster recei ves a message i ndi cati ng the
engi ne cool ant temperature i s not hi gh or cri ti cal
[about 125 C (255 F) or bel ow for al l gasol i ne
engi nes, or 115 C (239 F) for al l di esel engi nes].
Engine Oil Pressure Low Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne oi l pressure i s about 0.28
kg/cm or l ower (about 4 psi or l ower), the check
gauges i ndi cator i s i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a mes-
sage from the PCM i ndi cati ng that the engi ne oi l
pressure i s about 0.56 kg/cm or hi gher (about 8 psi
or hi gher). The cl uster wi l l onl y turn the i ndi cator on
i n response to an engi ne oi l pressure l ow message i f
the i gni ti on swi tch i s i n the On posi ti on and the
engi ne speed i s 300 rpm or greater.
System Voltage Low Message - Each ti me the
cl uster recei ves a message from the PCM i ndi cati ng
a l ow system vol tage condi ti on (system vol tage i s
about el even vol ts or l ower), the check gauges i ndi ca-
unti l the cl uster recei ves a message from the PCM
i ndi cati ng there i s no l ow system vol tage condi ti on
(system vol tage i s above about el even vol ts, but l ower
than about si xteen vol ts).
System Voltage High Message - Each ti me
the cl uster recei ves a message from the PCM i ndi cat-
i ng a hi gh system vol tage condi ti on (system vol tage
i s about si xteen vol ts or hi gher), the check gauges
i ndi cator i s i l l umi nated. The i ndi cator remai ns i l l u-
mi nated unti l the cl uster recei ves a message from
the PCM i ndi cati ng there i s no hi gh system vol tage
condi ti on (system vol tage i s bel ow about si xteen
vol ts, but hi gher than about el even vol ts).
through the actuator test, the check gauges i ndi cator
wi l l be turned on for the durati on of the test to con-
fi rm the functi onal i ty of the LED and the cl uster con-
trol ci rcui try.
The PCM conti nual l y moni tors the engi ne temper-
ature, oi l pressure, and el ectri cal system vol tage,
then sends the proper messages to the i nstrument
cl uster. For further di agnosi s of the check gauges
i ndi cator or the i nstrument cl uster ci rcui try that con-
trol s the i ndi cator, (Refer to 8 - ELECTRI CAL/I N-
TESTI NG). For proper di agnosi s of the PCM, the PCI
data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the check gauges
i ndi cator, a DRBI I I scan tool i s requi red. Refer to
the appropri ate di agnosti c i nformati on.
COOLANT LOW INDICATOR
DESCRIPTION
A cool ant l ow i ndi cator i s onl y found i n the i nstru-
ment cl usters of vehi cl es equi pped wi th an opti onal
di esel engi ne. The cool ant l ow i ndi cator shoul d not be
confused wi th the cool ant l evel l ow i ndi cati on pro-
vi ded by the El ectroni c Vehi cl e I nformati on Center
(EVI C) of vehi cl es equi pped wi th a gasol i ne engi ne,
al though they do perform the same functi on. The
cool ant l ow i ndi cator i s l ocated i n the l ower l eft cor-
ner of the i nstrument cl uster, to the l eft of the
tachometer. The cool ant l ow i ndi cator consi sts of an
I nternati onal Control and Di spl ay Symbol i con for
Low Cool ant i mpri nted on an amber l ens. The l ens
ment cl uster el ectroni c ci rcui t board. When the
CHECK GAUGES INDICATOR (Continued)
exteri or l i ghti ng i s turned On, the i l l umi nati on i nten-
si ty of the cool ant l ow i ndi cator i s di mmabl e, whi ch
i s adjusted usi ng the panel l amps di mmer control
ri ng on the control stal k of the l eft mul ti -functi on
swi tch. The cool ant l ow i ndi cator l ens i s servi ced as a
uni t wi th the i nstrument cl uster l ens, hood and mask
uni t.
OPERATION
The cool ant l ow i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the di esel engi ne cool ant l evel
i s l ow. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster ci rcui t board based upon cl us-
the cl uster from the Body Control Modul e (BCM)
(PCI ) data bus. The cool ant l ow i ndi cator bul b i s
turn on the cool ant l ow i ndi cator for the fol l owi ng
reasons:
turned to the On posi ti on the cool ant l ow i ndi cator i s
i l l umi nated for about three seconds as a bul b test.
Coolant Low Indicator Lamp-On Message -
Each ti me the cl uster recei ves a cool ant l ow i ndi cator
l amp-on message from the BCM i ndi cati ng the
engi ne cool ant i s bel ow the mi ni mum l evel i n the
cool ant reservoi r, the cool ant l ow i ndi cator wi l l be
the cl uster recei ves a cool ant l ow i ndi cator l amp-off
message from the BCM i ndi cati ng that the engi ne
cool ant l evel i s above the mi ni mum l evel .
through the actuator test, the cool ant l ow i ndi cator
fi rm the functi onal i ty of the bul b and the cl uster con-
trol ci rcui try.
The BCM conti nual l y moni tors the i nput from the
cool ant l evel swi tch, then sends the proper cool ant
l ow i ndi cator l amp-on and l amp-off messages to the
i nstrument cl uster. I f the cool ant l ow i ndi cator fai l s
to l i ght duri ng the bul b test, repl ace the bul b wi th a
known good uni t. For further di agnosi s of the cool ant
l ow i ndi cator or the i nstrument cl uster ci rcui try that
control s the i ndi cator, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). For proper di agnosi s of the cool ant l evel
swi tch, the BCM, the PCI data bus, or the el ectroni c
message i nputs to the i nstrument cl uster that control
the cool ant l ow i ndi cator, a DRBI I I scan tool i s
mati on.
CRUISE INDICATOR
DESCRIPTION
A crui se i ndi cator i s standard equi pment on al l
i nstrument cl usters, but i s onl y functi onal on vehi -
cl es equi pped wi th the opti onal speed control system.
The crui se i ndi cator i s l ocated on the ri ght edge of
the i nstrument cl uster, to the ri ght of the speedome-
ter. The crui se i ndi cator consi sts of the word
CRUI SE i mpri nted on a bl ue/green l ens. The l ens i s
vi si bl e when i t i s not i l l umi nated. The CRUI SE text
appears si l houetted agai nst a bl ue/green fi el d
through the transl ucent outer l ayer of the overl ay
when the i ndi cator i s i l l umi nated from behi nd by a
repl aceabl e bul b and bul b hol der uni t l ocated on the
i nstrument cl uster el ectroni c ci rcui t board. When the
exteri or l i ghti ng i s turned On, the i l l umi nati on i nten-
si ty of the crui se i ndi cator i s di mmabl e, whi ch i s
adjusted usi ng the panel l amps di mmer control ri ng
on the control stal k of the l eft mul ti -functi on swi tch.
The crui se i ndi cator l ens i s servi ced as a uni t wi th
the i nstrument cl uster l ens, hood and mask uni t.
OPERATION
The crui se i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the speed control system i s turned
On, regardl ess of whether the speed control i s
engaged. Thi s i ndi cator i s control l ed by a transi stor
on the i nstrument cl uster el ectroni c ci rcui t board
sages recei ved by the cl uster from the Powertrai n
Control Modul e (PCM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus. The crui se
i ndi cator bul b i s compl etel y control l ed by the i nstru-
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y
al l ow thi s i ndi cator to operate when the i nstrument
cl uster recei ves a battery current i nput on the fused
i gni ti on swi tch output (run-start) ci rcui t. Therefore,
the i ndi cator wi l l al ways be off when the i gni ti on
swi tch i s i n any posi ti on except On or Start. The bul b
onl y i l l umi nates when i t i s provi ded a path to ground
by the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the crui se i ndi cator for the fol -
l owi ng reasons:
Cruise Indicator Lamp-On Message - Each
ti me the cl uster recei ves a crui se i ndi cator l amp-on
message from the PCM i ndi cati ng the speed control
COOLANT LOW INDICATOR (Continued)
system has been turned On, the crui se i ndi cator i s
the cl uster recei ves a crui se i ndi cator l amp-off mes-
sage from the PCM or unti l the i gni ti on swi tch i s
through the actuator test, the crui se i ndi cator wi l l be
functi onal i ty of the bul b and the cl uster control ci r-
cui try.
The PCM conti nual l y moni tors the speed control
swi tches to determi ne the proper outputs to the
speed control servo. The PCM then sends the proper
crui se i ndi cator l amp-on and l amp-off messages to
the i nstrument cl uster. I f the crui se i ndi cator fai l s to
l i ght duri ng the actuator test, repl ace the bul b wi th a
known good uni t. For further di agnosi s of the crui se
TESTI NG). For proper di agnosi s of the speed control
swi tches, the PCM, the PCI data bus, or the el ec-
troni c message i nputs to the i nstrument cl uster that
control the crui se i ndi cator, a DRBI I I scan tool i s
mati on.
ENGINE TEMPERATURE
GAUGE
DESCRIPTION
An engi ne cool ant temperature gauge i s standard
equi pment on al l i nstrument cl usters. The engi ne
cool ant temperature gauge i s l ocated i n the l ower
ri ght corner of the i nstrument cl uster, to the ri ght of
the speedometer. The engi ne cool ant temperature
gauge consi sts of a movabl e gauge needl e or poi nter
control l ed by the i nstrument cl uster ci rcui try and a
fi xed 90 degree scal e on the gauge di al face that
reads l eft-to-ri ght from 40 C to 125 C, or from 100
F to 260 F, dependi ng upon the market for whi ch
the vehi cl e i s manufactured. An I nternati onal Con-
trol and Di spl ay Symbol i con for Engi ne Cool ant
Temperature i s l ocated on the gauge di al face.
The engi ne cool ant temperature gauge graphi cs are
ei ther whi te, gray and orange agai nst a bl ack gauge
di al face (base cl uster) or bl ack, gray and red agai nst
a taupe gauge di al face (premi um cl uster), maki ng
them cl earl y vi si bl e wi thi n the i nstrument cl uster i n
dayl i ght. When i l l umi nated from behi nd by the panel
l amps di mmer control l ed cl uster i l l umi nati on l i ghti ng
wi th the exteri or l amps turned On, the base cl uster
whi te gauge graphi cs appear bl ue-green and the
orange graphi cs sti l l appear orange, whi l e the pre-
mi um cl uster taupe gauge di al face appears bl ue-
green wi th the bl ack graphi cs si l houetted agai nst the
i l l umi nated background and the red graphi cs sti l l
appear red. The gray gauge graphi cs for both ver-
si ons of the cl uster are not i l l umi nated. The orange
gauge needl e i n the base cl uster gauge i s i nternal l y
i l l umi nated, whi l e the bl ack gauge needl e i n the pre-
mi um cl uster gauge i s not.
Base cl uster gauge i l l umi nati on i s provi ded by
repl aceabl e i ncandescent bul b and bul b hol der uni ts
l ocated on the i nstrument cl uster el ectroni c ci rcui t
board. Premi um cl uster gauge i l l umi nati on i s pro-
vi ded by an i ntegral el ectro-l umi nescent l amp that i s
servi ced as a uni t wi th the i nstrument cl uster. The
engi ne cool ant temperature gauge i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The engi ne cool ant temperature gauge gi ves an
i ndi cati on to the vehi cl e operator of the engi ne cool -
ant temperature. Thi s gauge i s control l ed by the
i nstrument cl uster ci rcui t board based upon cl uster
programmi ng and el ectroni c messages recei ved by
the cl uster from the Powertrai n Control Modul e
(PCM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The engi ne cool ant temper-
ature gauge i s an ai r core magneti c uni t that i s com-
pl etel y control l ed by the i nstrument cl uster el ectroni c
ci rcui t board. The cl uster i s programmed to move the
gauge needl e back to the l ow end of the scal e after
the i gni ti on swi tch i s turned to the Off posi ti on. The
i nstrument cl uster ci rcui try control s the gauge nee-
dl e posi ti on and provi des the fol l owi ng features:
Engine Temperature Normal Message - Each
i ndi cati ng the engi ne cool ant temperature i s wi thi n
the normal operati ng range [up to about 124 C (255
F) for gasol i ne engi nes, and 115 C (239 F) for di esel
engi nes], the gauge needl e i s moved to the rel ati ve
temperature posi ti on of the gauge scal e.
Engine Temperature High Message - Each
i ndi cati ng the engi ne cool ant temperature i s hi gh
[above about 127 C (260 F) for gasol i ne engi nes
except Gul f Coast Country (GCC), 129 C (264 F) for
GCC gasol i ne engi nes, and 118 C (244 F) for di esel
engi nes], the gauge needl e i s moved to the center of
the red warni ng zone on the gauge scal e.
Engine Temperature Critical Message -
Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the engi ne cool ant temperature i s
cri ti cal [about 132 C (270 F) or hi gher for al l gaso-
l i ne engi nes, and 126 C (259 F) for al l di esel
engi nes], the gauge needl e i s moved to the hi gh end
of the red warni ng zone on the gauge scal e.
Communication Error - I f the cl uster fai l s to
recei ve an engi ne temperature message, i t wi l l hol d
CRUISE INDICATOR (Continued)
the gauge needl e at the l ast i ndi cati on for about
twel ve seconds or unti l a new engi ne temperature
message i s recei ved, whi chever occurs fi rst. After
twel ve seconds, the cl uster wi l l return the gauge nee-
dl e to the l ow end of the gauge scal e.
through the actuator test, the gauge needl e wi l l be
swept across the enti re gauge scal e and back i n order
to confi rm the functi onal i ty of the gauge and the
cl uster control ci rcui try.
The PCM conti nual l y moni tors the engi ne cool ant
temperature sensor to determi ne the engi ne operat-
i ng temperature. The PCM then sends the proper
engi ne cool ant temperature messages to the i nstru-
ment cl uster. For further di agnosi s of the engi ne cool -
ant temperature gauge or the i nstrument cl uster
ci rcui try that control s the gauge, (Refer to 8 - ELEC-
AND TESTI NG). I f the i nstrument cl uster moves the
engi ne cool ant temperature gauge needl e to i ndi cate
a hi gh or cri ti cal engi ne temperature, i t may i ndi cate
that the engi ne or the engi ne cool i ng system requi res
servi ce. For proper di agnosi s of the engi ne cool ant
temperature sensor, the PCM, the PCI data bus, or
the el ectroni c message i nputs to the i nstrument cl us-
ter that control the engi ne cool ant temperature
gauge, a DRBI I I scan tool i s requi red. Refer to the
FRONT FOG LAMP INDICATOR
DESCRIPTION
A front fog l amp i ndi cator i s standard equi pment
on al l i nstrument cl usters, but i s onl y functi onal on
vehi cl es equi pped wi th the opti onal front fog l amps.
The front fog l amp i ndi cator i s l ocated on the l eft
edge of the i nstrument cl uster, to the l eft of the
tachometer. The front fog l amp i ndi cator consi sts of
an I nternati onal Control and Di spl ay Symbol i con for
Front Fog Li ght i mpri nted on a green l ens. The
l ens i s l ocated behi nd a cutout i n the opaque l ayer of
the i nstrument cl uster overl ay. The dark outer l ayer
of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. The i con
appears si l houetted agai nst a green fi el d through the
cator i s i l l umi nated from behi nd by a repl aceabl e
i ncandescent bul b and bul b hol der uni t l ocated on
the i nstrument cl uster el ectroni c ci rcui t board. When
the exteri or l i ghti ng i s turned On, the i l l umi nati on
i ntensi ty of the front fog l amp i ndi cator i s di mmabl e,
whi ch i s adjusted usi ng the panel l amps di mmer con-
trol ri ng on the control stal k of the l eft mul ti -func-
ti on swi tch. The front fog l amp i ndi cator l ens i s
servi ced as a uni t wi th the i nstrument cl uster l ens,
hood and mask uni t.
OPERATION
The front fog l amp i ndi cator gi ves an i ndi cati on to
the vehi cl e operator whenever the front fog l amps
are i l l umi nated. Thi s i ndi cator i s control l ed by a
sages recei ved by the cl uster from the Body Control
Modul e (BCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The front fog l amp
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l al l ow
thi s i ndi cator to operate whenever the i nstrument
B(+) ci rcui t. Therefore, the i ndi cator can be i l l umi -
nated regardl ess of the i gni ti on swi tch posi ti on. The
bul b onl y i l l umi nates when i t i s provi ded a path to
ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the front fog l amp
i ndi cator for the fol l owi ng reasons:
Front Fog Lamp Indicator Lamp-On Mes-
sage - Each ti me the cl uster recei ves a front fog
l amp i ndi cator l amp-on message from the BCM i ndi -
cati ng that the front fog l amps are turned On, the
front fog l amp i ndi cator wi l l be i l l umi nated. The i ndi -
cator remai ns i l l umi nated unti l the cl uster recei ves a
front fog l amp i ndi cator l amp-off message from the
BCM.
through the actuator test, the front fog l amp i ndi ca-
tor wi l l be turned on for the durati on of the test to
confi rm the functi onal i ty of the bul b and the cl uster
The BCM conti nual l y moni tors the exteri or l i ght-
i ng (l eft mul ti -functi on) swi tch to determi ne the
proper outputs to the front fog l amp rel ay. The BCM
then sends the proper front fog l amp i ndi cator
l amp-on and l amp-off messages to the i nstrument
cl uster. I f the front fog l amp i ndi cator fai l s to l i ght
duri ng the actuator test, repl ace the bul b wi th a
known good uni t. For further di agnosi s of the front
fog l amp i ndi cator or the i nstrument cl uster ci rcui try
that control s the i ndi cator, (Refer to 8 - ELECTRI -
CAL/I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the front fog
l amp system, the BCM, the PCI data bus, or the el ec-
control the front fog l amp i ndi cator, a DRBI I I scan
tool i s requi red. Refer to the appropri ate di agnosti c
i nformati on.
ENGINE TEMPERATURE GAUGE (Continued)
FUEL GAUGE
DESCRIPTION
A fuel gauge i s standard equi pment on al l i nstru-
ment cl usters. The fuel gauge i s l ocated i n the l ower
l eft corner of the i nstrument cl uster, to the l eft of the
tachometer. The fuel gauge consi sts of a movabl e
gauge needl e or poi nter control l ed by the i nstrument
cl uster ci rcui try and a fi xed 90 degree scal e on the
gauge di al face that reads l eft-to-ri ght from E (or
Empty) to F (or Ful l ). An I nternati onal Control and
Di spl ay Symbol i con for Fuel i s l ocated on the
gauge di al face. An arrowhead poi nted to the l eft si de
of the vehi cl e i s i mpri nted next to the Fuel i con on
the fuel gauge di al face to provi de the dri ver wi th a
remi nder as to the l ocati on of the fuel fi l l er access.
The fuel gauge graphi cs are ei ther whi te, gray and
orange agai nst a bl ack gauge di al face (base cl uster)
or bl ack and gray agai nst a taupe gauge di al face
(premi um cl uster), maki ng them cl earl y vi si bl e
wi thi n the i nstrument cl uster i n dayl i ght. When i l l u-
mi nated from behi nd by the panel l amps di mmer
control l ed cl uster i l l umi nati on l i ghti ng wi th the exte-
ri or l amps turned On, the base cl uster whi te gauge
graphi cs appear bl ue-green and the orange graphi cs
sti l l appear orange, whi l e the premi um cl uster taupe
gauge di al face appears bl ue-green wi th the bl ack
graphi cs si l houetted agai nst the i l l umi nated back-
ground. The gray gauge graphi cs for both versi ons of
the cl uster are not i l l umi nated. The orange gauge
needl e i n the base cl uster gauge i s i nternal l y i l l umi -
nated, whi l e the bl ack gauge needl e i n the premi um
cl uster gauge i s not.
fuel gauge i s servi ced as a uni t wi th the i nstrument
cl uster.
OPERATION
The fuel gauge gi ves an i ndi cati on to the vehi cl e
operator of the l evel of fuel i n the fuel tank. Thi s
gauge i s control l ed by the i nstrument cl uster ci rcui t
board based upon cl uster programmi ng and el ec-
troni c messages recei ved by the cl uster from the
Powertrai n Control Modul e (PCM) over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
fuel gauge i s an ai r core magneti c uni t that recei ves
battery current on the i nstrument cl uster el ectroni c
ci rcui t board through the fused i gni ti on swi tch out-
put (run-start) ci rcui t whenever the i gni ti on swi tch i s
i n the On or Start posi ti ons. The cl uster i s pro-
grammed to move the gauge needl e back to the l ow
end of the scal e after the i gni ti on swi tch i s turned to
the Off posi ti on. The i nstrument cl uster ci rcui try
control s the gauge needl e posi ti on and provi des the
fol l owi ng features:
Percent Tank Full Message - Each ti me the
the percent tank ful l , the cl uster moves the gauge
needl e to the rel ati ve fuel l evel posi ti on on the gauge
scal e. The PCM appl i es an al gori thm to the i nput
from the fuel tank sender to dampen gauge needl e
movement agai nst the negati ve effect that fuel sl osh-
i ng wi thi n the fuel tank can have on accurate i nputs
to the PCM.
Less Than 12.5 Percent Tank Full Message -
Each ti me the cl uster recei ves messages from the
PCM i ndi cati ng the percent tank ful l i s l ess than
12.5 (one-ei ghth), the gauge needl e i s moved to the
proper posi ti on on the gauge scal e and the l ow fuel
i ndi cator i s i l l umi nated. The l ow fuel i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves mes-
sages from the PCM i ndi cati ng that the percent tank
ful l i s greater than 12.5 (one-ei ghth), or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst.
Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
the PCM i ndi cati ng the percent tank ful l i s l ess than
empty, the gauge needl e i s moved to the far l eft (l ow)
end of the gauge scal e and the l ow fuel i ndi cator i s
i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM i s a
short ci rcui t.
More Than Full Percent Tank Full Message
PCM i ndi cati ng the percent tank ful l i s more than
ful l , the gauge needl e i s moved to the far l eft (l ow)
end of the gauge scal e and the l ow fuel i ndi cator i s
i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM i s an
open ci rcui t.
recei ve a percent tank ful l message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on for about twel ve
seconds, unti l a new message i s recei ved, or unti l the
ever occurs fi rst. After twel ve seconds, the cl uster
wi l l return the gauge needl e to the l ow end of the
gauge scal e.
The PCM conti nual l y moni tors the fuel tank
sender to determi ne the fuel l evel . The PCM then
appl i es an al gori thm to the i nput and sends the
proper percent tank ful l messages to the i nstrument
cl uster. For further di agnosi s of the fuel gauge or the
i nstrument cl uster ci rcui try that control s the gauge,
TER - DI AGNOSI S AND TESTI NG). For proper
di agnosi s of the fuel tank sender, the PCM, the PCI
data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the fuel gauge, a
DRBI I I scan tool i s requi red. Refer to the appropri -
ate di agnosti c i nformati on.
HIGH BEAM INDICATOR
DESCRIPTION
A hi gh beam i ndi cator i s standard equi pment on
al l i nstrument cl usters. The hi gh beam i ndi cator i s
l ocated near the upper edge of the i nstrument cl us-
ter, between the tachometer and the speedometer.
The hi gh beam i ndi cator consi sts of an I nternati onal
Control and Di spl ay Symbol i con for Hi gh Beam
i mpri nted on a bl ue l ens. The l ens i s l ocated behi nd a
i l l umi nated. The i con appears si l houetted agai nst a
bl ue fi el d through the transl ucent outer l ayer of the
overl ay when the i ndi cator i s i l l umi nated from
behi nd by a repl aceabl e i ncandescent bul b and bul b
hol der uni t l ocated on the i nstrument cl uster el ec-
troni c ci rcui t board. When the exteri or l i ghti ng i s
turned On, the i l l umi nati on i ntensi ty of the hi gh
beam i ndi cator i s di mmabl e, whi ch i s adjusted usi ng
the panel l amps di mmer control ri ng on the control
stal k of the l eft mul ti -functi on swi tch. The hi gh beam
OPERATION
The hi gh beam i ndi cator gi ves an i ndi cati on to the
vehi cl e operator whenever the headl amp hi gh beams
are i l l umi nated. Thi s i ndi cator i s control l ed by a
Body Control Modul e (BCM) over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. The hi gh
beam i ndi cator bul b i s compl etel y control l ed by the
i nstrument cl uster l ogi c ci rcui t, and that l ogi c wi l l
al l ow thi s i ndi cator to operate whenever the i nstru-
ment cl uster recei ves a battery current i nput on the
fused B(+) ci rcui t. Therefore, the i ndi cator can be
i l l umi nated regardl ess of the i gni ti on swi tch posi ti on.
The LED onl y i l l umi nates when i t i s provi ded a path
i nstrument cl uster wi l l turn on the hi gh beam i ndi -
cator for the fol l owi ng reasons:
High Beam Indicator Lamp-On Message -
Each ti me the cl uster recei ves a hi gh beam i ndi cator
l amp-on message from the BCM i ndi cati ng that the
headl amp hi gh beams are turned On, the hi gh beam
i ndi cator wi l l be i l l umi nated. The i ndi cator remai ns
i l l umi nated unti l the cl uster recei ves a hi gh beam
i ndi cator l amp-off message from the BCM.
through the actuator test, the hi gh beam i ndi cator
trol ci rcui try.
proper outputs to the headl amp l ow beam and hi gh
beam rel ays. The BCM then sends the proper hi gh
beam i ndi cator l amp-on and l amp-off messages to the
i nstrument cl uster. I f the hi gh beam i ndi cator fai l s to
l i ght duri ng the actuator test, repl ace the bul b wi th a
known good uni t. For further di agnosi s of the hi gh
beam i ndi cator or the i nstrument cl uster ci rcui try
TESTI NG). For proper di agnosi s of the headl amp
system, the BCM, the PCI data bus, or the el ectroni c
the hi gh beam i ndi cator, a DRBI I I scan tool i s
mati on.
LOW FUEL INDICATOR
DESCRIPTION
A l ow fuel i ndi cator i s standard equi pment on al l
i nstrument cl usters. The l ow fuel i ndi cator i s l ocated
near the l eft edge of the i nstrument cl uster, to the l eft
of the tachometer. The l ow fuel i ndi cator consi sts of an
I nternati onal Control and Di spl ay Symbol i con for
Fuel i mpri nted on an amber l ens. The l ens i s l ocated
behi nd a cutout i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the overl ay
prevents the i con from bei ng cl earl y vi si bl e when the
i ndi cator i s not i l l umi nated. The i con appears si l hou-
etted agai nst an amber fi el d through the transl ucent
outer l ayer of the overl ay when the i ndi cator i s i l l umi -
nated from behi nd by a repl aceabl e i ncandescent bul b
and bul b hol der uni t l ocated on the i nstrument cl uster
el ectroni c ci rcui t board. When the exteri or l i ghti ng i s
turned On, the i l l umi nati on i ntensi ty of the l ow fuel
i ndi cator i s di mmabl e, whi ch i s adjusted usi ng the
panel l amps di mmer control ri ng on the control stal k
of the l eft mul ti -functi on swi tch. The l ow fuel i ndi ca-
FUEL GAUGE (Continued)
tor l ens i s servi ced as a uni t wi th the i nstrument cl us-
ter l ens, hood and mask uni t.
OPERATION
The l ow fuel i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the l evel of fuel i n the fuel
tank becomes l ow. Thi s i ndi cator i s control l ed by a
l ow fuel i ndi cator bul b i s compl etel y control l ed by the
onl y al l ow thi s i ndi cator to operate when the i nstru-
fused i gni ti on swi tch output (run-start) ci rcui t.
Therefore, the i ndi cator wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The bul b onl y i l l umi nates when i t i s swi tched to
i nstrument cl uster wi l l turn on the l ow fuel i ndi cator
turned to the On posi ti on the l ow fuel i ndi cator i s
i l l umi nated for about three seconds as a bul b test.
Less Than 12.5 Percent Tank Full Message -
Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng that the percent tank ful l i s l ess
than about 12.5 (one-ei ghth), the l ow fuel i ndi cator i s
the cl uster recei ves messages from the PCM i ndi cat-
i ng that the percent tank ful l has i ncreased to
greater than about 12.5 (one-ei ghth). The PCM
appl i es an al gori thm to the i nput from the fuel tank
sender to dampen the i l l umi nati on of the l ow fuel
i ndi cator agai nst the negati ve effect that fuel sl osh-
i ng wi thi n the fuel tank can have on accurate i nputs
to the PCM.
Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
the PCM i ndi cati ng the percent tank ful l i s l ess than
empty, the l ow fuel i ndi cator i s i l l umi nated i mmedi -
atel y. Thi s message woul d i ndi cate that the fuel tank
sender i nput to the PCM i s a short ci rcui t.
More Than Full Percent Tank Full Message
PCM i ndi cati ng the percent tank ful l i s more than
ful l , the l ow fuel i ndi cator i s i l l umi nated i mmedi -
atel y. Thi s message woul d i ndi cate that the fuel tank
sender i nput to the PCM i s an open ci rcui t.
recei ve a percent tank ful l message for more than
about twel ve seconds, the cl uster control ci rcui try
wi l l i l l umi nate the l ow fuel i ndi cator unti l a new per-
cent tank ful l message i s recei ved.
through the actuator test, the l ow fuel i ndi cator wi l l
be turned on for the durati on of the test to confi rm
the functi onal i ty of the bul b and the cl uster control
ci rcui try.
The PCM conti nual l y moni tors the fuel tank
sender i nput to determi ne the fuel l evel . The PCM
then appl i es an al gori thm to the i nput and sends the
proper percent tank ful l messages to the i nstrument
cl uster. I f the l ow fuel i ndi cator fai l s to l i ght duri ng
the bul b test, repl ace the bul b wi th a known good
uni t. For further di agnosi s of the l ow fuel i ndi cator
or the i nstrument cl uster ci rcui try that control s the
i ndi cator, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). For
proper di agnosi s of the fuel tank sender, the PCM,
the PCI data bus, or the el ectroni c message i nputs to
the i nstrument cl uster that control the l ow fuel i ndi -
cator, a DRBI I I scan tool i s requi red. Refer to the
MALFUNCTION INDICATOR
LAMP (MIL)
DESCRIPTION
A Mal functi on I ndi cator Lamp (MI L) i s standard
equi pment on al l i nstrument cl usters. The MI L i s
l ocated near the ri ght edge of the i nstrument cl uster,
to the ri ght of the speedometer. The MI L consi sts of
Engi ne i mpri nted on an amber l ens. The l ens i s
the overl ay prevents the i con from bei ng cl earl y vi s-
i bl e when the i ndi cator i s not i l l umi nated. The i con
appears si l houetted agai nst an amber fi el d through
the transl ucent outer l ayer of the overl ay when the
i ndi cator i s i l l umi nated from behi nd by a repl aceabl e
the i nstrument cl uster el ectroni c ci rcui t board. The
MI L l ens i s servi ced as a uni t wi th the i nstrument
cl uster l ens, hood and mask uni t.
OPERATION
The Mal functi on I ndi cator Lamp (MI L) gi ves an
i ndi cati on to the vehi cl e operator when the Power-
trai n Control Modul e (PCM) has recorded a Di agnos-
ti c Troubl e Code (DTC) for an On-Board Di agnosti cs
I I (OBDI I ) emi ssi ons-rel ated ci rcui t or component
mal functi on. Thi s i ndi cator i s control l ed by a transi s-
tor on the i nstrument cl uster el ectroni c ci rcui t board
sages recei ved by the cl uster from the PCM over the
bus. The MI L bul b i s compl etel y control l ed by the
LOW FUEL INDICATOR (Continued)
onl y al l ow thi s i ndi cator to operate when the i nstru-
fused i gni ti on swi tch output (run-start) ci rcui t.
Therefore, the i ndi cator wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The bul b onl y i l l umi nates when i t i s provi ded a path
i nstrument cl uster wi l l turn on the MI L for the fol -
l owi ng reasons:
turned to the On posi ti on the MI L i s i l l umi nated for
about three seconds as a bul b test.
MIL Lamp-On Message - Each ti me the cl us-
ter recei ves a MI L l amp-on message from the PCM,
the i ndi cator wi l l be i l l umi nated. The i ndi cator can
be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the PCM message. For some DTCs, i f a
probl em does not recur, the PCM wi l l send a MI L
l amp-off message automati cal l y. Other DTCs may
requi re that a faul t be repai red and the PCM be
reset before a MI L l amp-off message wi l l be sent. For
more i nformati on on the PCM and the DTC set and
reset parameters, (Refer to 25 - EMI SSI ONS CON-
TROL - OPERATI ON).
no MI L l amp-on or l amp-off messages from the PCM
for twenty consecuti ve seconds, the MI L i s i l l umi -
nated by the i nstrument cl uster. The i ndi cator
remai ns control l ed and i l l umi nated by the cl uster
unti l a val i d MI L l amp-on or l amp-off message i s
recei ved from the PCM.
through the actuator test, the MI L wi l l be turned on
for the durati on of the test to confi rm the functi onal -
i ty of the bul b and the cl uster control ci rcui try.
The PCM conti nual l y moni tors each of the many
fuel and emi ssi ons system ci rcui ts and sensors to
deci de whether the system i s i n good operati ng con-
di ti on. The PCM then sends the proper MI L l amp-on
or l amp-off messages to the i nstrument cl uster. I f the
MI L fai l s to l i ght duri ng the bul b test, repl ace the
bul b wi th a known good uni t. For further di agnosi s of
the MI L or the i nstrument cl uster ci rcui try that con-
TESTI NG). I f the i nstrument cl uster turns on the
MI L after the bul b test, i t may i ndi cate that a mal -
functi on has occurred and that the fuel and emi s-
si ons system may requi re servi ce. For proper
di agnosi s of the fuel and emi ssi ons systems, the
PCM, the PCI data bus, or the el ectroni c message
MI L, a DRBI I I scan tool i s requi red. Refer to the
ODOMETER
DESCRIPTION
An odometer and tri p odometer are standard
equi pment i n al l i nstrument cl usters. The odometer
and tri p odometer i nformati on are di spl ayed i n a
common el ectroni c, bl ue-green Vacuum-Fl uorescent
Di spl ay (VFD), whi ch i s l ocated i n the l ower edge of
the speedometer di al face i n the i nstrument cl uster
and, when i l l umi nated, i s vi si bl e through a smal l
wi ndow cutout i n the gauge overl ay. However, the
odometer and tri p odometer i nformati on are not di s-
pl ayed si mul taneousl y. The tri p odometer reset
swi tch on the i nstrument cl uster el ectroni c ci rcui t
board toggl es the di spl ay between odometer and tri p
odometer modes by depressi ng the odometer/tri p
odometer swi tch button that extends through the
l ower edge of the cl uster l ens to the ri ght of the
speedometer.
Al l odometer and tri p odometer di stance i nforma-
ti on i s stored i n the i nstrument cl uster memory. Thi s
di stance i nformati on can be i ncreased when the
proper i nputs are provi ded to the i nstrument cl uster,
but the di stance i nformati on cannot be decreased.
The odometer can di spl ay val ues up to 999,999 ki l o-
meters (999,999 mi l es). The odometer wi l l not rol l
over, but wi l l l atch at the maxi mum val ue. The tri p
odometer can di spl ay val ues up to 999.9 ki l ometers
(999.9 mi l es) before i t rol l s over to zero. The odome-
ter di spl ay does not have a deci mal poi nt and wi l l
not show val ues l ess than a ful l uni t (ki l ometer or
mi l e), the tri p odometer di spl ay does have a deci mal
poi nt and wi l l show tenths of a uni t (ki l ometer or
mi l e).
The uni t of measure for the odometer and tri p
odometer di spl ay i s not shown i n the VFD. The uni t
of measure for the odometer/tri p odometer i s sel ected
at the ti me that the i nstrument cl uster i s manufac-
tured, and cannot be changed. I f the i nstrument cl us-
ter has a ki l ometers-per-hour pri mary speedometer
scal e, the odometer/tri p odometer regi sters ki l ome-
ters; and, i f the cl uster features a mi l es-per-hour pri -
mary speedometer scal e, the odometer/tri p odometer
regi sters mi l es.
Duri ng dayl i ght hours (exteri or l amps Off) the
VFD i s i l l umi nated at ful l bri ghtness for cl ear vi si bi l -
i ty. At ni ght (exteri or l amps are On) the i nstrument
cl uster converts an el ectroni c di mmi ng l evel message
recei ved from the Body Control Modul e (BCM) over
data bus to a di gi tal di mmi ng l evel si gnal for control -
l i ng the l i ghti ng l evel of the VFD. However, a
Parade mode posi ti on of the panel l amps di mmer
control ri ng on the control stal k of the l eft (l i ghti ng)
mul ti -functi on swi tch al l ows the VFD to be i l l umi -
MALFUNCTION INDICATOR LAMP (MIL) (Continued)
nated at ful l bri ghtness i f the exteri or l amps are
turned On duri ng dayl i ght hours.
The VFD, the tri p odometer swi tch, and the tri p
odometer swi tch button are servi ced as a uni t wi th
the i nstrument cl uster.
OPERATION
The odometer and tri p odometer gi ve an i ndi cati on
to the vehi cl e operator of the di stance the vehi cl e has
travel ed. Thi s gauge i s control l ed by the i nstrument
cl uster el ectroni c ci rcui try based upon cl uster pro-
grammi ng and el ectroni c messages recei ved by the
cl uster from the Powertrai n Control Modul e (PCM)
(PCI ) data bus. The odometer and tri p odometer
i nformati on i s di spl ayed by the i nstrument cl uster
Vacuum Fl uorescent Di spl ay (VFD). The VFD wi l l
onl y di spl ay odometer or tri p odometer i nformati on
after the i gni ti on swi tch i s turned to the On or Start
posi ti ons, and wi l l di spl ay the i nformati on i n the
odometer or tri p odometer mode based upon the
sel ecti on that was acti ve when the i gni ti on swi tch
was l ast turned to the Off posi ti on. The i nstrument
cl uster ci rcui try control s the VFD and provi des the
fol l owi ng features:
Odometer/Trip Odometer Display Toggling -
Actuati ng the tri p odometer reset swi tch button
momentari l y wi th the i gni ti on swi tch i n the On posi -
ti on wi l l toggl e the di spl ay between the odometer and
tri p odometer i nformati on. Each ti me the i gni ti on
swi tch i s turned to the On or Start posi ti ons, the di s-
pl ay wi l l automati cal l y return to the l ast mode
sel ected (odometer or tri p odometer) before the i gni -
ti on swi tch was turned to the Off posi ti on.
Trip Odometer Reset - When the tri p odome-
ter reset swi tch button i s depressed and hel d for
l onger than about two seconds wi th the i gni ti ons
swi tch i n the On or Start posi ti ons, the tri p odometer
wi l l be reset to 000.0 ki l ometers (mi l es). The VFD
must be di spl ayi ng the current tri p odometer i nfor-
mati on i n order for the tri p odometer i nformati on to
be reset.
recei ve a di stance message duri ng normal operati on,
i t wi l l hol d and di spl ay the l ast data recei ved unti l
the i gni ti on swi tch i s turned to the Off posi ti on. I f
the cl uster does not recei ve a di stance message
wi thi n one second after the i gni ti on swi tch i s turned
to the On posi ti on, i t wi l l di spl ay the l ast di stance
message stored i n the cl uster memory. I f i t i s deter-
mi ned that the di stance i nformati on stored i n the
cl uster memory i s corrupt, i t wi l l di spl ay ------ i n
the VFD. I f the cl uster i s unabl e to di spl ay di stance
i nformati on due to an error i nternal to the cl uster,
the VFD di spl ay wi l l be bl ank.
through the actuator test, the VFD wi l l step sequen-
ti al l y through a di spl ay of 000000 through
999999, then di spl ay the cl uster software versi on
number to confi rm the functi onal i ty of the VFD and
the cl uster control ci rcui try.
The PCM conti nual l y moni tors the vehi cl e speed
pul se i nformati on recei ved from the vehi cl e speed
sensor, then sends the proper di stance messages to
the i nstrument cl uster. For further di agnosi s of the
odometer/tri p odometer or the i nstrument cl uster ci r-
cui try that control s these functi ons, (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER - DI AGNO-
SI S AND TESTI NG). For proper di agnosi s of the
vehi cl e speed sensor, the PCM, the PCI data bus, or
ter that control the odometer/tri p odometer, a
OIL PRESSURE GAUGE
DESCRIPTION
An oi l pressure gauge i s standard equi pment on al l
i nstrument cl usters. The oi l pressure gauge i s l ocated
i n the upper ri ght corner of the i nstrument cl uster, to
the ri ght of the speedometer. The oi l pressure gauge
consi sts of a movabl e gauge needl e or poi nter con-
trol l ed by the i nstrument cl uster ci rcui try and a fi xed
90 degree scal e on the gauge di al face that reads l eft-
to-ri ght from 0 kg/cm to 5.4 kg/cm (metri c cl uster
for gasol i ne engi nes), from 0 kg/cm to 8.3 kg/cm
(metri c cl uster for di esel engi nes), or from 0 psi to 80
psi (U.S. cl uster), dependi ng upon the market for
whi ch the vehi cl e i s manufactured. An I nternati onal
Control and Di spl ay Symbol i con for Engi ne Oi l i s
l ocated on the gauge di al face.
The oi l pressure gauge graphi cs are ei ther whi te,
gray and orange agai nst a bl ack gauge di al face (base
cl uster) or bl ack and gray agai nst a taupe gauge di al
face (premi um cl uster), maki ng them cl earl y vi si bl e
ODOMETER (Continued)
oi l pressure gauge i s servi ced as a uni t wi th the
i nstrument cl uster.
OPERATION
The oi l pressure gauge gi ves an i ndi cati on to the
vehi cl e operator of the engi ne oi l pressure. Thi s
oi l pressure gauge i s an ai r core magneti c uni t that
recei ves battery current on the i nstrument cl uster
el ectroni c ci rcui t board through the fused i gni ti on
swi tch output (run-start) ci rcui t whenever the i gni -
ti on swi tch i s i n the On or Start posi ti ons. The cl us-
ter i s programmed to move the gauge needl e back to
the l ow end of the scal e after the i gni ti on swi tch i s
turned to the Off posi ti on. The i nstrument cl uster
ci rcui try control s the gauge needl e posi ti on and pro-
vi des the fol l owi ng features:
Engine Oil Pressure Normal Message - Each
i ndi cati ng the engi ne oi l pressure i s wi thi n the nor-
mal operati ng range [above 0.28 kg/cm (above 4
psi ), the gauge needl e i s moved to the rel ati ve pres-
sure posi ti on of the gauge scal e.
Engine Oil Pressure Low Message - Each
i ndi cati ng the engi ne oi l pressure i s about 0.28
kg/cm or l ower (about 4 psi or l ower), the gauge
needl e i s moved to the far l eft (l ow) end of the gauge
scal e. The gauge needl e remai ns at the l ow end of
the scal e unti l the cl uster recei ves a message from
the PCM i ndi cati ng that the engi ne oi l pressure i s
about 0.56 kg/cm or hi gher (about 8 psi or hi gher).
recei ve an engi ne oi l pressure message, i t wi l l hol d
the gauge needl e at the l ast i ndi cati on for about
twel ve seconds or unti l a new engi ne oi l pressure
message i s recei ved, whi chever occurs fi rst. After
twel ve seconds, the cl uster wi l l return the gauge nee-
dl e to the l ow end of the gauge scal e.
The PCM conti nual l y moni tors the engi ne oi l pres-
sure sensor to determi ne the engi ne oi l pressure. The
PCM then sends the proper engi ne oi l pressure mes-
sages to the i nstrument cl uster. For further di agnosi s
of the oi l pressure gauge or the i nstrument cl uster
ci rcui try that control s the gauge, (Refer to 8 - ELEC-
AND TESTI NG). I f the i nstrument cl uster turns on
the check gauges i ndi cator due to a l ow oi l pressure
gauge readi ng, i t may i ndi cate that the engi ne or the
engi ne oi l i ng system requi res servi ce. For proper
di agnosi s of the engi ne oi l pressure sensor, the PCM,
the PCI data bus, or the el ectroni c message i nputs to
the i nstrument cl uster that control the oi l pressure
gauge, a DRBI I I scan tool i s requi red. Refer to the
OVERDRIVE OFF INDICATOR
DESCRIPTION
An overdri ve off i ndi cator i s standard equi pment
on al l gasol i ne engi ne i nstrument cl usters. The over-
dri ve off i ndi cator i s l ocated i n the l ower edge of the
tachometer gauge di al face i n the i nstrument cl uster.
The overdri ve off i ndi cator consi sts of the words O/D
OFF i mpri nted on an amber l ens. The l ens i s
tachometer gauge di al face overl ay. The dark outer
l ayer of the gauge di al face overl ay prevents the i ndi -
cator from bei ng cl earl y vi si bl e when i t i s not i l l umi -
nated. The words O/D OFF appear si l houetted
agai nst an amber fi el d through the transl ucent outer
l ayer of the gauge di al face overl ay when the i ndi ca-
tor i s i l l umi nated from behi nd by a repl aceabl e
i ntensi ty of the overdri ve off i ndi cator i s di mmabl e,
ti on swi tch. The overdri ve off i ndi cator l ens i s
servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The overdri ve off i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the Off posi ti on of the
overdri ve off swi tch has been sel ected, di sabl i ng the
el ectroni cal l y control l ed overdri ve feature of the auto-
mati c transmi ssi on. Thi s i ndi cator i s control l ed by a
sages recei ved by the cl uster over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. These
messages are sent by the Powertrai n Control Modul e
(PCM) or by the Transmi ssi on Control Modul e
(TCM), dependi ng on the model of the automati c
transmi ssi on. The overdri ve off i ndi cator bul b i s com-
OIL PRESSURE GAUGE (Continued)
pl etel y control l ed by the i nstrument cl uster l ogi c ci r-
cui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
turn on the overdri ve off i ndi cator for the fol l owi ng
reasons:
turned to the On posi ti on the overdri ve off i ndi cator
Overdrive Off Indicator Lamp-On Message -
Each ti me the cl uster recei ves an overdri ve off i ndi -
cator l amp-on message from the PCM or TCM i ndi -
cati ng that the Off posi ti on of the overdri ve off
swi tch has been sel ected, the overdri ve off i ndi cator
wi l l be i l l umi nated. The i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves an overdri ve off i ndi -
cator l amp-off message from the PCM or TCM, or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
through the actuator test, the overdri ve off i ndi cator
trol ci rcui try.
The PCM or TCM conti nual l y moni tors the over-
dri ve off swi tch to determi ne the proper outputs to
the automati c transmi ssi on. The PCM or TCM then
sends the proper overdri ve off i ndi cator l amp-on or
l amp-off messages to the i nstrument cl uster. I f the
overdri ve off i ndi cator fai l s to l i ght duri ng the bul b
test, repl ace the bul b wi th a known good uni t. For
further di agnosi s of the overdri ve off i ndi cator or the
i nstrument cl uster ci rcui try that control s the i ndi ca-
tor, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
proper di agnosi s of the overdri ve control system, the
PCM, the TCM, the PCI data bus, or the el ectroni c
the overdri ve off i ndi cator, a DRBI I I scan tool i s
mati on.
REAR FOG LAMP INDICATOR
DESCRIPTION
A rear fog l amp i ndi cator i s standard equi pment on
al l i nstrument cl usters, but i s onl y functi onal on
vehi cl es equi pped wi th opti onal rear fog l amps,
whi ch are avai l abl e onl y i n certai n i nternati onal
markets where they are requi red. The rear fog l amp
i ndi cator i s l ocated on the l eft edge of the i nstrument
cl uster, to the l eft of the tachometer. The rear fog
l amp i ndi cator consi sts of an I nternati onal Control
and Di spl ay Symbol i con for Rear Fog Li ght
i mpri nted on an amber l ens. The l ens i s l ocated
behi nd a cutout i n the opaque l ayer of the i nstru-
ment cl uster overl ay. The dark outer l ayer of the
overl ay prevents the i ndi cator from bei ng cl earl y vi s-
i bl e when i t i s not i l l umi nated. The i con appears si l -
houetted agai nst an amber fi el d through the
cator i s i l l umi nated from behi nd by a repl aceabl e
i ntensi ty of the rear fog l amp i ndi cator i s di mmabl e,
ti on swi tch. The rear fog l amp i ndi cator l ens i s
OPERATION
The rear fog l amp i ndi cator gi ves an i ndi cati on to
the vehi cl e operator whenever the rear fog l amps are
i l l umi nated. Thi s i ndi cator i s control l ed by a transi s-
tor on the i nstrument cl uster el ectroni c ci rcui t board
sages recei ved by the cl uster from the Body Control
Modul e (BCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The rear fog l amp
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l al l ow
thi s i ndi cator to operate whenever the i nstrument
B(+) ci rcui t. Therefore, the i ndi cator can be i l l umi -
nated regardl ess of the i gni ti on swi tch posi ti on. The
bul b onl y i l l umi nates when i t i s provi ded a path to
i nstrument cl uster wi l l turn on the rear fog l amp
i ndi cator for the fol l owi ng reasons:
Rear Fog Lamp Indicator Lamp-On Mes-
sage - Each ti me the cl uster recei ves a rear fog l amp
i ndi cator l amp-on message from the BCM i ndi cati ng
that the rear fog l amps are turned On, the rear fog
l amp i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a rear
fog l amp i ndi cator l amp-off message from the BCM.
through the actuator test, the rear fog l amp i ndi cator
trol ci rcui try.
proper outputs to the rear fog l amp rel ay. The BCM
OVERDRIVE OFF INDICATOR (Continued)
then sends the proper rear fog l amp i ndi cator
cl uster. I f the rear fog l amp i ndi cator fai l s to l i ght
duri ng the actuator test, repl ace the bul b wi th a
known good uni t. For further di agnosi s of the rear
fog l amp i ndi cator or the i nstrument cl uster ci rcui try
TESTI NG). For proper di agnosi s of the rear fog l amp
system, the BCM, the PCI data bus, or the el ectroni c
the rear fog l amp i ndi cator, a DRBI I I scan tool i s
mati on.
SEATBELT INDICATOR
DESCRIPTION
A seatbel t i ndi cator i s standard equi pment on al l
i nstrument cl usters. The seatbel t i ndi cator i s l ocated
near the l ower edge of the i nstrument cl uster, to the
l eft of the tachometer. The seatbel t i ndi cator consi sts
of an I nternati onal Control and Di spl ay Symbol i con
for Seat Bel t i mpri nted on a red l ens. The l ens i s
the overl ay prevents the i con from bei ng cl earl y vi s-
i bl e when the i ndi cator i s not i l l umi nated. The i con
appears si l houetted agai nst a red fi el d through the
transl ucent outer l ayer of the overl ay when i t i s i l l u-
mi nated from behi nd by a Li ght Emi tti ng Di ode
(LED), whi ch i s sol dered onto the i nstrument cl uster
el ectroni c ci rcui t board. The seatbel t i ndi cator l ens i s
OPERATION
The seatbel t i ndi cator gi ves an i ndi cati on to the
vehi cl e operator of the status of the dri ver si de front
seatbel t. Thi s i ndi cator i s control l ed by a transi stor
on the i nstrument cl uster el ectroni c ci rcui t board
based upon cl uster programmi ng. On model s
equi pped wi th ai rbags the i ndi cator i s al so control l ed
by el ectroni c messages recei ved by the cl uster from
the Ai rbag Control Modul e (ACM) over the Program-
seatbel t i ndi cator Li ght Emi tti ng Di ode (LED) i s
ti on except On or Start. The LED onl y i l l umi nates
turn on the seatbel t i ndi cator for the fol l owi ng rea-
sons:
Seatbelt Reminder Function - Each ti me the
i gni ti on swi tch output (run-start) ci rcui t, the i ndi ca-
tor wi l l be i l l umi nated as a seatbel t remi nder for
about si x seconds, or unti l the i gni ti on swi tch i s
Thi s remi nder functi on wi l l occur regardl ess of the
status of the el ectroni c seat bel t l amp-on or l amp-off
messages recei ved by the cl uster from the ACM.
Seat Belt Indicator Lamp-On Message - On
model s equi pped wi th ai rbags, fol l owi ng the seatbel t
remi nder functi on, each ti me the cl uster recei ves a
seat bel t i ndi cator l amp-on message from the ACM
i ndi cati ng the dri ver si de front seat bel t i s not fas-
tened wi th the i gni ti on swi tch i n the Start or On
posi ti ons, the seatbel t i ndi cator wi l l be i l l umi nated.
The i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a seat bel t i ndi cator l amp-off message from
the ACM, or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst.
through the actuator test, the seatbel t i ndi cator wi l l
the functi onal i ty of the LED and the cl uster control
ci rcui try.
The i nstrument cl uster conti nual l y moni tors the
status of the i gni ti on swi tch through the hard wi red
fused i gni ti on swi tch output (run-start) ci rcui t to
determi ne when to provi de the seatbel t remi nder
functi on. On model s equi pped wi th ai rbags, the ACM
conti nual l y moni tors the status of both front seat bel t
swi tches to determi ne the proper ai rbag system
response to a frontal i mpact of the vehi cl e. The ACM
then sends the proper seatbel t i ndi cator l amp-on and
l amp-off messages to the i nstrument cl uster based
upon the status of the dri ver si de front seat bel t
swi tch i nput. For further di agnosi s of the seatbel t
TESTI NG). For proper di agnosi s of the seatbel t
swi tches, the ACM, the PCI data bus, or the el ec-
control the seatbel t i ndi cator, a DRBI I I scan tool i s
mati on.
REAR FOG LAMP INDICATOR (Continued)
SHIFT INDICATOR (TRANSFER
CASE)
DESCRIPTION
A part ti me i ndi cator i s standard equi pment on al l
i nstrument cl usters, but i s onl y functi onal on vehi -
cl es equi pped wi th the standard equi pment Sel ec-
Trac four-wheel dri ve system. The part ti me i ndi cator
i s l ocated near the ri ght edge of the i nstrument cl us-
ter, to the ri ght of the speedometer. The part ti me
i ndi cator consi sts of the words PART TI ME
i mpri nted on an amber l ens. The l ens i s l ocated
behi nd a cutout i n the opaque l ayer of the i nstru-
ment cl uster overl ay. The dark outer l ayer of the
overl ay prevents the i ndi cator from bei ng cl earl y vi s-
i bl e when i t i s not i l l umi nated. The words PART
TI ME appear si l houetted agai nst an amber fi el d
repl aceabl e i ncandescent bul b and bul b hol der uni t
board. The part ti me i ndi cator l ens i s servi ced as a
uni t wi th the i nstrument cl uster l ens, hood and mask
uni t.
OPERATION
The part ti me i ndi cator gi ves an i ndi cati on to the
vehi cl e operator that a four-wheel dri ve part ti me
operati ng mode of the transfer case i s sel ected. On
vehi cl es wi th the standard equi pment Sel ec-Trac
four-wheel dri ve system, the part ti me i ndi cator i l l u-
mi nates when the NV-242 transfer case i s engaged i n
ei ther the 4 X 4 Part Ti me or 4 Lo posi ti ons. Thi s
i ndi cator i s control l ed by a transi stor on the i nstru-
ment cl uster el ectroni c ci rcui t board based upon cl us-
I nterface (PCI ) data bus. The part ti me i ndi cator
bul b i s compl etel y control l ed by the i nstrument cl us-
ter l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow thi s
i ndi cator to operate when the i nstrument cl uster
any posi ti on except On or Start. The bul b onl y i l l u-
mi nates when i t i s provi ded a path to ground by the
i nstrument cl uster transi stor. The i nstrument cl uster
wi l l turn on the part ti me i ndi cator for the fol l owi ng
reasons:
Part Time Indicator Lamp-On Message -
Each ti me the cl uster recei ves a part ti me i ndi cator
l amp-on message from the PCM i ndi cati ng that a
four-wheel dri ve part ti me posi ti on of the transfer
case has been sel ected, the part ti me i ndi cator wi l l be
the cl uster recei ves a part ti me i ndi cator l amp-off
message from the PCM.
through the actuator test, the part ti me i ndi cator wi l l
the functi onal i ty of the bul b and the cl uster control
ci rcui try.
The PCM conti nual l y moni tors the transfer case
swi tch to determi ne the dri vel i ne operati ng mode.
The PCM then sends the proper part ti me i ndi cator
cl uster. I f the part ti me i ndi cator fai l s to l i ght duri ng
the actuator test, repl ace the bul b wi th a known good
uni t. For further di agnosi s of the part ti me i ndi cator
or the i nstrument cl uster ci rcui try that control s the
proper di agnosi s of the transfer case swi tch, the
PCM, the PCI data bus, or the el ectroni c message
i nputs to the i nstrument cl uster that control the part
ti me i ndi cator, a DRBI I I scan tool i s requi red. Refer
to the appropri ate di agnosti c i nformati on.
SKIS INDICATOR
DESCRIPTION
A Sentry Key I mmobi l i zer System (SKI S) i ndi cator
i s standard equi pment on al l i nstrument cl usters, but
i s onl y operati onal on vehi cl es equi pped wi th the
opti onal SKI S. The SKI S i ndi cator i s l ocated i n the
upper ri ght corner of the i nstrument cl uster, to the
ri ght of the speedometer. The SKI S i ndi cator consi sts
of a graphi cal representati on or i con of a ci rcl ed and
crossed-out key i mpri nted on an amber l ens. The l ens
l ucent outer l ayer of the overl ay when i t i s i l l umi -
nated from behi nd by an i ncandescent bul b and bul b
troni c ci rcui t board. The SKI S i ndi cator l ens i s ser-
vi ced as a uni t wi th the i nstrument cl uster l ens, hood
and mask uni t.
OPERATION
The Sentry Key I mmobi l i zer System (SKI S) i ndi ca-
tor gi ves an i ndi cati on to the vehi cl e operator of the
status of the SKI S. Thi s i ndi cator i s control l ed by a
troni c messages recei ved by the cl uster from the Sen-
try Key I mmobi l i zer Modul e (SKI M) over the
bus. The SKI S i ndi cator bul b i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l onl y al l ow thi s i ndi cator to operate when the
i nstrument cl uster recei ves a battery current i nput
on the fused i gni ti on swi tch output (run-start) ci r-
cui t. Therefore, the i ndi cator wi l l al ways be off when
the i gni ti on swi tch i s i n any posi ti on except On or
Start. The bul b onl y i l l umi nates when i t i s swi tched
i nstrument cl uster wi l l turn on the SKI S i ndi cator
turned to the On posi ti on, the SKI M tel l s the cl uster
to i l l umi nate the SKI S i ndi cator for about three sec-
onds as a bul b test.
SKIS Indicator Lamp-On Message - Each
ti me the cl uster recei ves a SKI S i ndi cator l amp-on
message from the SKI M, the SKI S i ndi cator wi l l be
i l l umi nated. The i ndi cator can be fl ashed on and off,
or i l l umi nated sol i d, as di ctated by the SKI M mes-
sage. For more i nformati on on the SKI S and the
SKI S i ndi cator control parameters, (Refer to 8 -
ELECTRI CAL/VEHI CLE THEFT SECURI TY -
OPERATI ON). The i ndi cator remai ns i l l umi nated
unti l the cl uster recei ves a SKI S i ndi cator l amp-off
message from the SKI M, or unti l the i gni ti on swi tch
i s turned to the Off posi ti on, whi chever occurs fi rst.
no SKI S i ndi cator l amp-on or l amp-off messages from
the SKI M for twenty consecuti ve seconds, the SKI S
i ndi cator i s i l l umi nated by the i nstrument cl uster.
The i ndi cator remai ns control l ed and i l l umi nated by
the cl uster unti l a val i d SKI S i ndi cator l amp-on or
l amp-off message i s recei ved from the SKI M.
through the actuator test, the SKI S i ndi cator wi l l be
functi onal i ty of the bul b and the cl uster control ci r-
cui try.
The SKI M performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on to deci de
whether the system i s i n good operati ng condi ti on
and whether a val i d key i s present i n the i gni ti on
l ock cyl i nder. The SKI M then sends the proper SKI S
i ndi cator l amp-on or l amp-off messages to the i nstru-
ment cl uster. I f the SKI S i ndi cator fai l s to l i ght dur-
i ng the bul b test, repl ace the bul b wi th a known good
uni t. For further di agnosi s of the SKI S i ndi cator or
the i nstrument cl uster ci rcui try that control s the
CLUSTER - DI AGNOSI S AND TESTI NG). I f the
i nstrument cl uster fl ashes the SKI S i ndi cator upon
i gni ti on On, or turns on the SKI S i ndi cator sol i d
after the bul b test, i t i ndi cates that a SKI S mal func-
ti on has occurred or that the SKI S i s i noperati ve. For
proper di agnosi s of the SKI S, the PCI data bus, or
ter that control the SKI S i ndi cator, a DRBI I I scan
i nformati on.
SPEEDOMETER
DESCRIPTION
A speedometer i s standard equi pment on al l i nstru-
ment cl usters. The speedometer i s l ocated to the
ri ght of the tachometer i n the i nstrument cl uster.
The speedometer consi sts of a movabl e gauge needl e
or poi nter control l ed by the i nstrument cl uster ci r-
cui try, and a fi xed 255 degree pri mary scal e on the
gauge di al face that reads l eft-to-ri ght ei ther from 0
to 120 mph, from 0 to 200 km/h, or from 0 to 220
km/h, dependi ng upon the market for whi ch the vehi -
cl e i s manufactured. Most model s al so have a smal l er
secondary i nner scal e on the gauge di al face that pro-
vi des the equi val ent opposi te measurement uni ts
from the pri mary scal e. Text appeari ng i n the center
of the gauge di al face just beneath the hub of the
speedometer needl e abbrevi ates the uni t of measure
for the pri mary scal e i n al l upper case l etters (i .e.:
MPH or KM/H). On model s wi th a secondary scal e,
the abbrevi ati on for that scal e fol l ows the abbrevi a-
ti on for the pri mary scal e i n al l l ower case l etters
(i .e.: mph or km/h).
The speedometer graphi cs are ei ther whi te, gray
and orange agai nst a bl ack gauge di al face (base
cl uster) or bl ack and gray agai nst a taupe gauge di al
face (premi um cl uster), maki ng them cl earl y vi si bl e
speedometer i s servi ced as a uni t wi th the i nstru-
ment cl uster.
SKIS INDICATOR (Continued)
OPERATION
The speedometer gi ves an i ndi cati on to the vehi cl e
operator of the vehi cl e road speed. Thi s gauge i s con-
trol l ed by the i nstrument cl uster el ectroni c ci rcui t
speedometer i s an ai r core magneti c uni t that
Vehicle Speed Message - Each ti me the cl us-
ter recei ves a vehi cl e speed message from the PCM i t
wi l l cal cul ate the correct vehi cl e speed readi ng and
posi ti on the gauge needl e at that speed posi ti on on
the gauge scal e. The cl uster wi l l recei ve a new vehi -
cl e speed message and reposi ti on the gauge poi nter
accordi ngl y about every 86 mi l l i seconds. The gauge
needl e wi l l conti nue to be posi ti oned at the actual
vehi cl e speed posi ti on on the gauge scal e unti l the
i gni ti on swi tch i s turned to the Off posi ti on.
recei ve a speedometer message, i t wi l l hol d the gauge
needl e at the l ast i ndi cati on for about si x seconds, or
whi chever occurs fi rst. I f a new speed message i s not
recei ved after about si x seconds, the gauge needl e
wi l l return to the far l eft (l ow) end of the scal e.
The PCM conti nual l y moni tors the vehi cl e speed
i nformati on recei ved from the Control l er Anti -l ock
Brake (CAB) to determi ne the vehi cl e road speed,
then sends the proper vehi cl e speed messages to the
i nstrument cl uster. For further di agnosi s of the
speedometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
I NG). For proper di agnosi s of the CAB, the PCM, the
PCI data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the speedometer, a
TACHOMETER
DESCRIPTION
A tachometer i s standard equi pment on al l i nstru-
ment cl usters. The tachometer i s l ocated to the l eft of
the speedometer i n the i nstrument cl uster. The
tachometer consi sts of a movabl e gauge needl e or
poi nter control l ed by the i nstrument cl uster ci rcui try,
and a fi xed 255 degree scal e on the gauge di al face
that reads l eft-to-ri ght from 0 to 7 for gasol i ne
engi nes, or from 0 to 6 for di esel engi nes. The text X
1000 (base cl uster) or RPM X 1000 (premi um cl us-
ter) i mpri nted on the cl uster overl ay di rectl y bel ow
the hub of the tachometer needl e i denti fi es that each
number on the tachometer scal e i s to be mul ti pl i ed
by 1000 rpm. The gasol i ne engi ne tachometer has a
red zone begi nni ng at 5800 RPM, whi l e the red zone
for the di esel engi ne tachometer begi ns at 4200 RPM.
The tachometer i n the premi um versi on cl uster for
certai n engi ne and market appl i cati ons al so i ncl udes
red text l ocated i n the center of the gauge di al face
just above the hub of the tachometer needl e that
speci fi es a speci al fuel requi rement.
The tachometer graphi cs are ei ther whi te, gray
cl uster) or bl ack, gray and red agai nst a taupe gauge
di al face (premi um cl uster), maki ng them cl earl y vi s-
i bl e wi thi n the i nstrument cl uster i n dayl i ght. When
i l l umi nated from behi nd by the panel l amps di mmer
ground and the red graphi cs sti l l appear red. The
gray gauge graphi cs for both versi ons of the cl uster
are not i l l umi nated. The orange gauge needl e i n the
base cl uster gauge i s i nternal l y i l l umi nated, whi l e
the bl ack gauge needl e i n the premi um cl uster gauge
i s not.
tachometer i s servi ced as a uni t wi th the i nstrument
cl uster.
OPERATION
The tachometer gi ves an i ndi cati on to the vehi cl e
operator of the engi ne speed. Thi s gauge i s control l ed
by the i nstrument cl uster el ectroni c ci rcui t board
SPEEDOMETER (Continued)
muni cati ons I nterface (PCI ) data bus. The tachome-
ter i s an ai r core magneti c uni t that recei ves battery
current on the i nstrument cl uster el ectroni c ci rcui t
board through the fused i gni ti on swi tch output (run-
start) ci rcui t whenever the i gni ti on swi tch i s i n the
On or Start posi ti ons. The cl uster i s programmed to
move the gauge needl e back to the l ow end of the
scal e after the i gni ti on swi tch i s turned to the Off
posi ti on. The i nstrument cl uster ci rcui try control s
the gauge needl e posi ti on and provi des the fol l owi ng
features:
Engine Speed Message - Each ti me the cl uster
recei ves an engi ne speed message from the PCM i t
wi l l cal cul ate the correct engi ne speed readi ng and
posi ti on the gauge needl e at that speed posi ti on on
the gauge scal e. The cl uster wi l l recei ve a new
engi ne speed message and reposi ti on the gauge
poi nter accordi ngl y about every 86 mi l l i seconds. The
gauge needl e wi l l conti nue to be posi ti oned at the
actual engi ne speed posi ti on on the gauge scal e unti l
the i gni ti on swi tch i s turned to the Off posi ti on.
recei ve an engi ne speed message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on for about si x sec-
onds, or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst. I f a new engi ne
speed message i s not recei ved after about si x sec-
onds, the gauge needl e wi l l return to the far l eft
(l ow) end of the scal e.
The PCM conti nual l y moni tors the crankshaft posi -
ti on sensor to determi ne the engi ne speed, then
sends the proper engi ne speed messages to the
i nstrument cl uster. For further di agnosi s of the
tachometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
I NG). For proper di agnosi s of the crankshaft posi ti on
sensor, the PCM, the PCI data bus, or the el ectroni c
the tachometer, a DRBI I I scan tool i s requi red.
TRANS TEMP INDICATOR
DESCRIPTION
A transmi ssi on over-temperature i ndi cator i s stan-
dard equi pment on al l gasol i ne engi ne i nstrument
cl usters. The transmi ssi on over-temperature i ndi ca-
tor i s l ocated near the l ower ri ght corner of the
i nstrument cl uster, to the ri ght of the speedometer.
The transmi ssi on over-temperature i ndi cator consi sts
of the words TRANS OVER TEMP i mpri nted on an
amber l ens. The l ens i s l ocated behi nd a cutout i n
the opaque l ayer of the i nstrument cl uster overl ay.
The dark outer l ayer of the overl ay prevents the i ndi -
cator from bei ng cl earl y vi si bl e when i t i s not i l l umi -
nated. The words TRANS OVER TEMP appear
ment cl uster el ectroni c ci rcui t board. The
transmi ssi on over-temperature i ndi cator l ens i s ser-
vi ced as a uni t wi th the i nstrument cl uster l ens, hood
and mask uni t.
OPERATION
The transmi ssi on over-temperature i ndi cator gi ves
an i ndi cati on to the vehi cl e operator when the trans-
mi ssi on fl ui d temperature i s excessi ve, whi ch may
l ead to accel erated transmi ssi on component wear or
fai l ure. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster el ectroni c ci rcui t board based
upon cl uster programmi ng and el ectroni c messages
recei ved by the cl uster over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus. These mes-
sages are sent by the Powertrai n Control Modul e
(PCM) or by the Transmi ssi on Control Modul e
(TCM), dependi ng on the model of the automati c
transmi ssi on. The transmi ssi on over-temperature
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y
al l ow thi s i ndi cator to operate when the i nstrument
i gni ti on swi tch output (run-start) ci rcui t. Therefore,
the i ndi cator wi l l al ways be off when the i gni ti on
swi tch i s i n any posi ti on except On or Start. The bul b
onl y i l l umi nates when i t i s provi ded a path to ground
by the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the transmi ssi on over-tempera-
ture i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the transmi ssi on over-tem-
perature i ndi cator i s i l l umi nated for about three sec-
onds as a bul b test.
Trans Over-Temp Indicator Lamp-On Mes-
sage - Each ti me the cl uster recei ves a trans over-
temp i ndi cator l amp-on message from the PCM or
TCM i ndi cati ng that the transmi ssi on fl ui d tempera-
ture i s 135 C (275 F) or hi gher, the transmi ssi on
over-temperature i ndi cator wi l l be i l l umi nated. The
i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a trans over-temp i ndi cator l amp-off mes-
sage from the PCM or TCM, or unti l the i gni ti on
TACHOMETER (Continued)
swi tch i s turned to the Off posi ti on, whi chever occurs
fi rst.
through the actuator test, the transmi ssi on over-tem-
perature i ndi cator wi l l be turned on for the durati on
of the test to confi rm the functi onal i ty of the bul b
and the cl uster control ci rcui try.
The PCM or TCM conti nual l y moni tors the trans-
mi ssi on temperature sensor to determi ne the trans-
mi ssi on operati ng condi ti on. The PCM or TCM then
sends the proper trans over-temp i ndi cator l amp-on
or l amp-off messages to the i nstrument cl uster. I f the
transmi ssi on over-temperature i ndi cator fai l s to l i ght
duri ng the bul b test, repl ace the bul b wi th a known
good uni t. I f the i nstrument cl uster turns on the
transmi ssi on over-temperature i ndi cator due to a
hi gh transmi ssi on oi l temperature condi ti on, i t may
i ndi cate that the transmi ssi on or the transmi ssi on
cool i ng system are bei ng overl oaded or that they
requi re servi ce. For further di agnosi s of the trans-
mi ssi on over-temperature i ndi cator or the i nstrument
cl uster ci rcui try that control s the i ndi cator, (Refer to
8 - ELECTRI CAL/I NSTRUMENT CLUSTER - DI AG-
NOSI S AND TESTI NG). For proper di agnosi s of the
transmi ssi on temperature sensor, the PCM, the
TCM, the PCI data bus, or the el ectroni c message
transmi ssi on over-temperature i ndi cator, a DRBI I I
scan tool i s requi red. Refer to the appropri ate di ag-
nosti c i nformati on.
TURN SIGNAL INDICATOR
DESCRIPTION
Two turn si gnal i ndi cators, one ri ght and one l eft,
are standard equi pment on al l i nstrument cl usters.
The turn si gnal i ndi cators are l ocated near the upper
edge of the i nstrument cl uster, the l eft one i s l eft of
the tachometer, and the ri ght one i s ri ght of the
speedometer. Each turn si gnal i ndi cator consi sts of
Turn Warni ng i mpri nted on a green l ens. Each l ens
i s l ocated behi nd a dedi cated cutout i n the opaque
l ayer of the i nstrument cl uster overl ay. The dark
outer l ayer of the overl ay prevents these i cons from
bei ng cl earl y vi si bl e when they are not i l l umi nated.
The i cons appear si l houetted agai nst a green fi el d
repl aceabl e i ncandescent bul b and bul b hol der uni t
board. The turn si gnal i ndi cator l enses are servi ced
as a uni t wi th the i nstrument cl uster l ens, hood and
mask uni t.
OPERATION
The turn si gnal i ndi cators gi ve an i ndi cati on to the
vehi cl e operator that the turn si gnal (l eft or ri ght
i ndi cator fl ashi ng) or hazard warni ng (both l eft and
ri ght i ndi cators fl ashi ng) have been sel ected and are
operati ng. These i ndi cators are control l ed by two
i ndi vi dual hard wi red i nputs from the combi nati on
fl asher ci rcui try to the i nstrument cl uster el ectroni c
ci rcui t board. Each turn si gnal i ndi cator bul b i s
grounded on the i nstrument cl uster el ectroni c ci rcui t
board at al l ti mes; therefore, these i ndi cators remai n
functi onal regardl ess of the i gni ti on swi tch posi ti on.
Each i ndi cator bul b wi l l onl y i l l umi nate when i t i s
provi ded wi th battery current by the combi nati on
fl asher i n the Juncti on Bl ock (JB).
The turn si gnal i ndi cators are connected i n paral l el
wi th the other turn si gnal ci rcui ts. Thi s arrangement
al l ows the turn si gnal i ndi cators to remai n func-
ti onal , regardl ess of the condi ti on of the other ci r-
cui ts i n the turn si gnal and hazard warni ng systems.
The combi nati on fl asher outputs to the i nstrument
cl uster turn si gnal i ndi cator i nputs can be di agnosed
usi ng conventi onal di agnosti c tool s and methods. For
more i nformati on on the turn si gnal and hazard
warni ng system, (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR - OPERATI ON - TURN
SI GNAL & HAZARD WARNI NG SYSTEM).
DIAGNOSIS AND TESTING - TURN SIGNAL
INDICATOR
turn si gnal i ndi cator condi ti on. I f the probl em bei ng
di agnosed i s rel ated to i noperati ve turn si gnal or
hazard warni ng l amps, be certai n to repai r the turn
si gnal and hazard warni ng system before attempti ng
to di agnose or repai r the turn si gnal i ndi cators.
(Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR - DI AGNOSI S AND TESTI NG - TURN
SI GNAL & HAZARD WARNI NG SYSTEM). I f no
turn si gnal and hazard warni ng system probl em i s
found, the fol l owi ng procedure wi l l hel p l ocate an
open i n the turn si gnal i ndi cator ci rcui t. Refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, detai l s of wi re harness
TRANS TEMP INDICATOR (Continued)
PERSONAL INJURY.
cabl e. Remove the i nstrument cl uster from the
i nstrument panel and di sconnect the i nstrument
panel wi re harness for the i nstrument cl uster from
the cl uster connector receptacl e.
(2) Reconnect the battery negati ve cabl e. Acti vate
the hazard warni ng system by movi ng the hazard
warni ng swi tch button to the On posi ti on. Check for
battery vol tage at the i noperati ve (ri ght or l eft) turn
si gnal ci rcui t cavi ty of the i nstrument panel wi re
harness connector for the i nstrument cl uster. There
shoul d be a swi tchi ng (on and off) battery vol tage si g-
nal present. I f OK, repl ace the faul ty (ri ght or l eft)
turn si gnal i ndi cator bul b. I f not OK, repai r the open
(ri ght or l eft) turn si gnal ci rcui t between the i nstru-
ment cl uster and the combi nati on fl asher i n the
Juncti on Bl ock (JB) as requi red.
VOLTAGE GAUGE
DESCRIPTION
A vol tage gauge i s standard equi pment on al l
i nstrument cl usters. The vol tage gauge i s l ocated i n
the upper l eft corner of the i nstrument cl uster, to the
l eft of the tachometer. The vol tage gauge consi sts of a
movabl e gauge needl e or poi nter control l ed by the
i nstrument cl uster ci rcui try and a fi xed 90 degree
scal e on the gauge di al face that reads l eft-to-ri ght
from 9 vol ts to 19 vol ts. An I nternati onal Control and
Di spl ay Symbol i con for Battery Chargi ng Condi -
ti on i s l ocated on the gauge di al face.
The vol tage gauge graphi cs are ei ther whi te, gray
cl uster) or bl ack, gray and red agai nst a taupe gauge
di al face (premi um cl uster), maki ng them cl earl y vi s-
i bl e wi thi n the i nstrument cl uster i n dayl i ght. When
i l l umi nated from behi nd by the panel l amps di mmer
ground and the red graphi cs sti l l appear red. The
gray gauge graphi cs for both versi ons of the cl uster
are not i l l umi nated. The orange gauge needl e i n the
base cl uster gauge i s i nternal l y i l l umi nated, whi l e
the bl ack gauge needl e i n the premi um cl uster gauge
i s not.
vol tage gauge i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The vol tage gauge gi ves an i ndi cati on to the vehi -
cl e operator of the el ectri cal system vol tage. Thi s
vol tage gauge i s an ai r core magneti c uni t that
System Voltage Message - Each ti me the cl us-
ter recei ves a message from the PCM i ndi cati ng the
system vol tage, the cl uster moves the gauge needl e to
the rel ati ve vol tage l evel posi ti on on the gauge scal e.
System Voltage Low Message - Each ti me the
the system vol tage i s l ow (system vol tage i s about
el even vol ts or l ower), the gauge needl e i s moved to
the rel ati ve vol tage posi ti on i n the red zone of the
gauge scal e and the check gauges i ndi cator i s i l l umi -
nated. The gauge needl e remai ns i n the red zone and
the check gauges i ndi cator remai ns i l l umi nated unti l
i ng there i s no l ow system vol tage condi ti on (system
vol tage i s above about el even vol ts, but l ower than
about si xteen vol ts).
System Voltage High Message - Each ti me
TURN SIGNAL INDICATOR (Continued)
i ng the system vol tage i s hi gh (system vol tage i s
about si xteen vol ts or hi gher), the gauge needl e i s
moved to the rel ati ve vol tage posi ti on i n the red zone
of the gauge scal e and the check gauges i ndi cator i s
i l l umi nated. The gauge needl e remai ns i n the red
zone and the check gauges i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves a message from the
PCM i ndi cati ng there i s no hi gh system vol tage con-
di ti on (system vol tage i s bel ow about si xteen vol ts,
but hi gher than about el even vol ts).
recei ve a system vol tage message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on for about twel ve
seconds, unti l a new message i s recei ved, or unti l the
ever occurs fi rst. After twel ve seconds, the cl uster
wi l l return the gauge needl e to the l ow end of the
gauge scal e.
swept across the enti re gauge scal e and back to con-
fi rm the functi onal i ty of the gauge and the cl uster
The PCM conti nual l y moni tors the system vol tage
to control the generator output. The PCM then sends
the proper system vol tage messages to the i nstru-
ment cl uster. For further di agnosi s of the vol tage
gauge or the i nstrument cl uster ci rcui try that con-
trol s the gauge, (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG). I f
the i nstrument cl uster turns on the check gauges
i ndi cator due to a system vol tage l ow or hi gh condi -
ti on, i t may i ndi cate that the chargi ng system
requi res servi ce. For proper di agnosi s of the chargi ng
system, the PCI data bus, or the el ectroni c message
i nputs to the i nstrument cl uster that control the vol t-
age gauge, a DRBI I I scan tool i s requi red. Refer to
the appropri ate di agnosti c i nformati on.
WAIT-TO-START INDICATOR
DESCRIPTION
A wai t-to-start i ndi cator i s onl y found i n the
i nstrument cl usters of vehi cl es equi pped wi th an
opti onal di esel engi ne. The wai t-to-start i ndi cator i s
l ocated near the l ower edge of the tachometer gauge
di al face, to the ri ght of center. The wai t-to-start
i ndi cator consi sts of an I nternati onal Control and
Di spl ay Symbol i con for Di esel Preheat i mpri nted
on an amber l ens. The l ens i s l ocated behi nd a cutout
i n the opaque l ayer of the tachometer gauge di al face
overl ay. The dark outer l ayer of the gauge di al face
overl ay prevents the i con from bei ng cl earl y vi si bl e
when the i ndi cator i s not i l l umi nated. The i con
appears si l houetted agai nst an amber fi el d through
the transl ucent outer l ayer of the gauge di al face
behi nd by a repl aceabl e i ncandescent bul b and bul b
troni c ci rcui t board. The wai t-to-start i ndi cator l ens
i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The wai t-to-start i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the di esel engi ne gl ow
pl ugs are energi zed i n thei r preheat operati ng mode.
Thi s i ndi cator i s control l ed by a transi stor on the
i nstrument cl uster ci rcui t board based upon cl uster
programmi ng and el ectroni c messages recei ved by
I nterface (PCI ) data bus. The wai t-to-start i ndi cator
bul b i s compl etel y control l ed by the i nstrument cl us-
ter l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow thi s
i ndi cator to operate when the i nstrument cl uster
any posi ti on except On or Start. The bul b onl y i l l u-
mi nates when i t i s swi tched to ground by the i nstru-
turn on the wai t-to-start i ndi cator for the fol l owi ng
reasons:
Wait-To-Start Indicator Lamp-On Message -
Each ti me the cl uster recei ves a wai t-to-start i ndi ca-
tor l amp-on message from the PCM i ndi cati ng the
gl ow pl ugs are heati ng and the dri ver must wai t to
start the engi ne, the wai t-to-start i ndi cator wi l l be
the cl uster recei ves a wai t-to-start i ndi cator l amp-off
message, or unti l the i gni ti on swi tch i s turned to the
through the actuator test, the wai t-to-start i ndi cator
trol ci rcui try.
The PCM conti nual l y moni tors the ambi ent tem-
perature and the gl ow pl ug pre-heater ci rcui ts to
determi ne how l ong the gl ow pl ugs must be heated i n
the pre-heat operati ng mode. The PCM then sends
the proper wai t-to-start i ndi cator l amp-on and l amp-
off messages to the i nstrument cl uster. I f the wai t-to-
start i ndi cator fai l s to l i ght duri ng the actuator test,
repl ace the bul b wi th a known good uni t. For further
di agnosi s of the wai t-to-start i ndi cator or the i nstru-
ment cl uster ci rcui try that control s the i ndi cator,
TER - DI AGNOSI S AND TESTI NG). For proper
di agnosi s of the gl ow pl ug pre-heater control ci rcui ts,
the PCM, the PCI data bus, or the el ectroni c message
VOLTAGE GAUGE (Continued)
wai t-to-start i ndi cator, a DRBI I I scan tool i s
mati on.
WATER-IN-FUEL INDICATOR
DESCRIPTION
A water-i n-fuel i ndi cator i s onl y found i n the
i nstrument cl usters of vehi cl es equi pped wi th an
opti onal di esel engi ne. The water-i n-fuel i ndi cator i s
l ocated near the l eft edge of the i nstrument cl uster,
to the l eft of the tachometer. The water-i n-fuel i ndi -
cator consi sts of an I nternati onal Control and Di s-
pl ay Symbol i con for Water i n Fuel i mpri nted on a
red l ens. The l ens i s l ocated behi nd a cutout i n the
opaque l ayer of the i nstrument cl uster overl ay. The
dark outer l ayer of the overl ay prevents the i con
from bei ng cl earl y vi si bl e when the i ndi cator i s not
i l l umi nated. The i con appears si l houetted agai nst a
red fi el d through the transl ucent outer l ayer of the
behi nd by a Li ght Emi tti ng Di ode (LED), whi ch i s
sol dered onto the i nstrument cl uster el ectroni c ci rcui t
board. The water-i n-fuel i ndi cator l ens i s servi ced as
a uni t wi th the i nstrument cl uster l ens, hood and
mask uni t.
OPERATION
The water-i n-fuel i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when there i s excessi ve water i n
the fuel system. Thi s i ndi cator i s control l ed by a
muni cati ons I nterface (PCI ) data bus. The water-i n-
fuel i ndi cator Li ght Emi tti ng Di ode (LED) i s
ti on except On or Start. The LED onl y i l l umi nates
turn on the water-i n-fuel i ndi cator for the fol l owi ng
reasons:
turned to the On posi ti on the water-i n-fuel i ndi cator
Water-In-Fuel Indicator Lamp-On Message -
Each ti me the cl uster recei ves a water-i n-fuel i ndi ca-
tor l amp-on message from the PCM i ndi cati ng there
i s excessi ve water i n the di esel fuel system, the
water-i n-fuel i ndi cator wi l l be i l l umi nated. The i ndi -
cator remai ns i l l umi nated unti l the cl uster recei ves a
water-i n-fuel i ndi cator l amp-off message, or unti l the
ever occurs fi rst.
through the actuator test, the water-i n-fuel i ndi cator
fi rm the functi onal i ty of the LED and the cl uster con-
trol ci rcui try.
The PCM conti nual l y moni tors the water-i n-fuel
sensor to determi ne whether there i s excessi ve water
i n the di esel fuel . The PCM then sends the proper
water-i n-fuel i ndi cator l amp-on and l amp-off mes-
sages to the i nstrument cl uster. For further di agnosi s
of the water-i n-fuel i ndi cator or the i nstrument cl us-
ter ci rcui try that control s the i ndi cator, (Refer to 8 -
SI S AND TESTI NG). For proper di agnosi s of the
water-i n-fuel sensor, the PCM, the PCI data bus, or
ter that control the water-i n-fuel i ndi cator, a
WAIT-TO-START INDICATOR (Continued)
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR. . . . . . . . . . . . . . . 28
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
DESCRIPTION - TURN SIGNAL & HAZARD
WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
OPERATION - TURN SIGNAL & HAZARD
WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - TURN SIGNAL &
HAZARD WARNING SYSTEMS . . . . . . . . . . . . 3
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 4
AUTO HEADLAMP SENSOR
DIAGNOSIS AND TESTING - AUTO
HEADLAMP SENSOR (AHL) . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE LAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING BRAKE LAMP
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER HIGH MOUNTED STOP LAMP
REMOVAL
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL - CHMSL . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION
INSTALLATION - BULB . . . . . . . . . . . . . . . . . . 6
INSTALLATION - CHMSL . . . . . . . . . . . . . . . . . 7
COMBINATION FLASHER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DAYTIME RUNNING LAMP MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FOG LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
FOG LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
ADJUSTMENTS
FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . 10
HEADLAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING HEADLAMP
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING HEADLAMP . . 14
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION - BULB . . . . . . . . . . . . . . . . . . . 15
HEADLAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEADLAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 16
LICENSE PLATE LAMP
REMOVAL
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION
INSTALLATION - BULB . . . . . . . . . . . . . . . . . 18
INSTALLATION - LAMP . . . . . . . . . . . . . . . . . 18
WJ LAMPS 8L - 1
LICENSE PLATE LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
LEFT MULTI-FUNCTION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - LEFT MULTI -
FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 20
REMOVAL
REMOVAL - LEFT MULTI-FUNCTION
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL - MULTI-FUNCTION SWITCH
MOUNTING HOUSING. . . . . . . . . . . . . . . . . . 22
INSTALLATION
INSTALLATION - LEFT MULTI-FUNCTION
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION - MULTI-FUNCTION SWITCH
MOUNTING HOUSING. . . . . . . . . . . . . . . . . . 24
PARK/TURN SIGNAL LAMP
REMOVAL - BULBS . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION - BULBS . . . . . . . . . . . . . . . . . . 25
TAIL LAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL
REMOVAL - BULBS . . . . . . . . . . . . . . . . . . . . 25
REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION
INSTALLATION - BULBS . . . . . . . . . . . . . . . . 26
TURN SIGNAL CANCEL CAM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
UNDERHOOD LAMP
REMOVAL
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION
DESCRIPTION - TURN SIGNAL & HAZARD
WARNING SYSTEM
The turn si gnal and hazard warni ng system
i ncl udes the fol l owi ng major components, whi ch are
descri bed i n further detai l el sewhere i n thi s servi ce
i nformati on:
Combi nati on Fl asher
Front Si de Marker Lamps
Hazard Warni ng Swi tch
Turn Si gnal Cancel Cam
Turn Si gnal I ndi cators
Turn Si gnal Lamps
Turn Si gnal Swi tch
The turn si gnal and hazard warni ng systems al so
provi de the fol l owi ng features:
Flash Lights with Lock - Thi s customer pro-
grammabl e feature fl ashes the hazard warni ng l amps
to provi de opti cal veri fi cati on that the Remote Key-
l ess Entry (RKE) System has recei ved a val i d Lock or
Unl ock request from an RKE transmi tter. (Refer to 8
- ELECTRI CAL/POWER LOCKS - DESCRI PTI ON -
REMOTE KEYLESS ENTRY SYSTEM).
Panic Mode Optical Alert - Thi s feature
fl ashes the hazard warni ng l amps to provi de an opti -
cal al ert when the Remote Keyl ess Entry (RKE) Sys-
tem pani c mode i s acti vated by depressi ng the Pani c
button on an RKE transmi tter. (Refer to 8 - ELEC-
TRI CAL/POWER LOCKS - DESCRI PTI ON -
REMOTE KEYLESS ENTRY SYSTEM).
Turn Signal On Warning - Thi s feature pro-
vi des the vehi cl e operator wi th both vi sual and audi -
bl e remi nders when a turn si gnal has been l eft
turned on for an extended peri od. (Refer to 8 - ELEC-
TRI CAL/OVERHEAD CONSOLE/ELECTRONI C
VEHI CLE I NFO CENTER - DESCRI PTI ON).
Vehicle Theft Security System (VTSS) Opti-
cal Alarm - Thi s feature fl ashes the hazard warni ng
l amps to provi de an opti cal al arm when the VTSS i s
armed and acti vated by an unauthori zed entry i nto
the vehi cl e. (Refer to 8 - ELECTRI CAL/VEHI CLE
THEFT SECURI TY - DESCRI PTI ON - VEHI CLE
THEFT SECURI TY SYSTEM).
OPERATION - TURN SIGNAL & HAZARD
WARNING SYSTEM
The turn si gnal system operates on battery current
recei ved on a fused i gni ti on swi tch output (run) ci r-
cui t so that the turn si gnal s wi l l onl y operate wi th
the i gni ti on swi tch i n the On posi ti on. The hazard
warni ng system operates on non-swi tched battery
current recei ved on a fused B(+) ci rcui t so that the
hazard warni ng remai ns operati onal regardl ess of
the i gni ti on swi tch posi ti on. When the turn si gnal
system i s acti vated, the ci rcui try of the turn si gnal
swi tch and the combi nati on fl asher wi l l cause the
sel ected (ri ght or l eft) turn si gnal i ndi cator, front
park/turn si gnal l amp, front si de marker l amp and
rear tai l /stop/turn si gnal l amp to fl ash on and off.
When the hazard warni ng system i s acti vated, the
ci rcui try of the hazard warni ng swi tch and the com-
bi nati on fl asher wi l l cause both the ri ght si de and
the l eft si de turn si gnal i ndi cators, front park/turn
si gnal l amps, front si de marker l amps and rear tai l /
stop/turn si gnal l amps to fl ash on and off.
The Body Control Modul e (BCM) can al so acti vate
the hazard warni ng system l amps by energi zi ng the
combi nati on fl asher through a si ngl e hard wi red con-
necti on to the hazard warni ng swi tch sense ci rcui t.
The BCM grounds the ci rcui t to energi ze and de-en-
8L - 2 LAMPS/LIGHTING - EXTERIOR WJ
ergi ze the combi nati on fl asher i n response to mes-
sage i nputs recei ved over the Programmabl e
Communi cati ons I nterface (PCI ) data bus network.
The BCM can energi ze the combi nati on fl asher when
the VTSS i s requested.
Vehi cl es equi pped wi th the opti onal El ectroni c
Vehi cl e I nformati on Center (EVI C) use turn si gnal
status messages recei ved from the El ectro-Mechani -
cal I nstrument Cl uster (EMI C) and di stance mes-
sages recei ved from the Powertrai n Control Modul e
(PCM) over the PCI data bus to determi ne when the
Turn Si gnal On warni ng shoul d be acti vated. The
EMI C recei ves hard wi red i nputs from the combi na-
ti on fl asher to operate the turn si gnal i ndi cators,
then sends the proper turn si gnal status message to
the EVI C. I f a turn si gnal i s l eft on for more than
about 1.6 ki l ometers (1 mi l e) of dri vi ng di stance, the
EVI C wi l l di spl ay a vi sual Turn Si gnal On message
and wi l l send a request to the BCM over the PCI
data bus to noti fy the vehi cl e operator.
Duri ng both the turn si gnal and the hazard warn-
i ng operati on, i f the exteri or l amps are turned Off,
the front park/turn si gnal l amps and the front si de
marker l amps wi l l fl ash i n uni son. I f the exteri or
l amps are turned On, the front park/turn si gnal
l amps and the front si de marker l amps wi l l fl ash
al ternatel y. Refer to the owners manual .
DIAGNOSIS AND TESTING - TURN SIGNAL &
HAZARD WARNING SYSTEMS
When di agnosi ng the turn si gnal and hazard warn-
i ng ci rcui ts, remember that hi gh generator output
can burn out bul bs rapi dl y and repeatedl y. I f thi s i s a
concern on the vehi cl e bei ng di agnosed, test the
chargi ng system as requi red.
INJURY.
Actuate the turn si gnal swi tch or the hazard warni ng
swi tch. Observe the turn si gnal i ndi cator l amp(s) i n
the i nstrument cl uster. I f the fl ash rate i s very hi gh,
check for a turn si gnal bul b that i s not l i t or i s very
di ml y l i t. Repai r the ci rcui ts to that l amp or repl ace
the faul ty bul b, as requi red. I f the turn si gnal i ndi -
cator(s) fai l to l i ght, go to Step 2.
Check the i gni ti on run fuse and the fl asher fuse i n
the Juncti on Bl ock (JB). I f OK, go to Step 3. I f not
requi red and repl ace the faul ty fuse(s).
(3) Check for battery vol tage at the fl asher fuse i n
the JB. I f OK, go to Step 4. I f not OK, repai r the
open fused B(+) ci rcui t between the JB and the
Power Di stri buti on Center (PDC).
Check for battery vol tage at the i gni ti on run fuse i n
the JB. I f OK, go to Step 5. I f not OK, repai r the
open fused i gni ti on swi tch output (run) ci rcui t
between the JB and the i gni ti on swi tch.
Remove the combi nati on fl asher from the JB and
repl ace i t wi th a known good uni t. Reconnect the bat-
tery negati ve cabl e. Test the operati on of the turn
si gnal and hazard warni ng systems. I f OK, di scard
the faul ty combi nati on fl asher. I f not OK, remove the
test fl asher and go to Step 6.
output (run) ci rcui t cavi ty i n the JB for the combi na-
ti on fl asher. I f OK, go to Step 7. I f not OK, repai r the
open fused i gni ti on swi tch output (run) ci rcui t
between the combi nati on fl asher and the i gni ti on run
fuse i n the JB.
Check for battery vol tage at the B(+) ci rcui t of the JB
for the combi nati on fl asher. I f OK, go to Step 8. I f
not OK, repai r the open B(+) ci rcui t between the
combi nati on fl asher and the fl asher fuse i n the JB.
connector for the turn si gnal and hazard warni ng
swi tches from the mul ti -functi on swi tch connector.
Check for conti nui ty between the ground ci rcui t of
the i nstrument panel wi re harness connector for the
l eft mul ti -functi on swi tch and a good ground. There
shoul d be conti nui ty. I f OK, go to Step 9. I f not OK,
repai r the open ground ci rcui t.
(9) Check for conti nui ty between the hazard swi tch
sense ci rcui t of the i nstrument panel wi re harness
connector for the mul ti -functi on swi tch and a good
Step 10. I f not OK, repai r the shorted hazard swi tch
sense ci rcui t between the mul ti -functi on swi tch and
the combi nati on fl asher.
(10) Check for conti nui ty between the hazard
swi tch sense ci rcui t of the JB for the combi nati on
fl asher and the i nstrument panel wi re harness con-
WJ LAMPS/LIGHTING - EXTERIOR 8L - 3
LAMPS/LIGHTING - EXTERIOR (Continued)
nector for the mul ti -functi on swi tch. There shoul d be
open hazard swi tch sense ci rcui t between the mul ti -
functi on swi tch and the combi nati on fl asher.
(11) Check for conti nui ty between the turn swi tch
sense ci rcui t of the i nstrument panel wi re harness
Step 12. I f not OK, repai r the shorted l eft turn
swi tch sense ci rcui t between the mul ti -functi on
swi tch and the combi nati on fl asher.
(12) Check for conti nui ty between the l eft turn
open l eft turn swi tch sense ci rcui t between the mul ti -
functi on swi tch and the combi nati on fl asher.
(13) Check for conti nui ty between the ri ght turn
swi tch sense ci rcui t of the i nstrument panel wi re
harness connector for the l eft mul ti -functi on swi tch
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 14. I f not OK, repai r the shorted ri ght
turn swi tch sense ci rcui t between the l eft mul ti -func-
ti on swi tch and the combi nati on fl asher.
(14) Check for conti nui ty between the ri ght turn
conti nui ty. I f OK, test the l eft mul ti -functi on swi tch.
EXTERI OR/LEFT MULTI -FUNCTI ON SWI TCH -
DI AGNOSI S AND TESTI NG). I f not OK, repai r the
open ri ght turn swi tch sense ci rcui t between the
mul ti -functi on swi tch and the combi nati on fl asher as
requi red.
SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs other than the bulbs
listed in the Bulb Application Table. Damage to
lamp can result. Do not touch halogen bulbs with
fingers or other oily surfaces. Bulb life will be
reduced.
LAMP BULB TYPE
BACK-UP 3157
CENTER HIGH
MOUNTED STOP LAMP
921
FOG LAMP 9005
FRONT SIDE MARKER 194/194NA
LAMP BULB TYPE
FRONT TURN SIGNAL 3157/3157NA
HIGH BEAM 9005XS
LOW BEAM 9006XS
LICENSE PLATE 168
TAIL/BRAKE 3157
REAR TURN SIGNAL 3157
UNDERHOOD LAMP 561
AUTO HEADLAMP SENSOR
DIAGNOSIS AND TESTING - AUTO HEADLAMP
SENSOR (AHL)
The auto headl amp sensor needs real sunl i ght to
properl y regi ster the l i ght l evel . When auto head-
l amps are enabl ed i ndoors, the headl amps may be
turned on. The sensor i s l ocated i n the center of the
defroster gri l l e at the base of the wi ndshi el d. There
are no faul ts set i n the Body Control Modul e (BCM)
for a i noperati ve or mi ssi ng AHL Sensor. Symptom of
a mi ssi ng sensor or unconnected sensor woul d be
that the Headl amps and Parkl amps turn on when
the vehi cl e i s started and there i s a hi gh l evel of
ambi ent l i ght present (i e. dayti me). Auto headl amps
shoul d not functi on i n the presence of dayl i ght.
REMOVAL
(1) Remove the i nstrument panel top cover. (Refer
to 23 - BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL TOP COVER - REMOVAL) for servi ce proce-
dures.
(2) Remove the screw attachi ng auto headl amp
sensor to i nstrument panel (Fi g. 1).
(3) Di sengage the harness connector from auto
headl amp sensor.
(4) Separate the auto headl amp sensor from
i nstrument panel .
INSTALLATION
(1) Posi ti on the auto headl amp sensor on i nstru-
ment panel .
(2) Engage the harness connector to auto head-
l amp sensor.
(3) I nstal l the screw attachi ng auto headl amp sen-
sor to i nstrument panel .
(4) I nstal l the i nstrument panel top cover. (Refer
to 23 - BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL TOP COVER - I NSTALLATI ON) for servi ce
procedures.
LAMPS/LIGHTING - EXTERIOR (Continued)
BRAKE LAMP SWITCH
DESCRIPTION
The brake l amp swi tch i s mounted on a bracket
attached to the brake pedal support. The swi tch i s
adjustabl e.
OPERATION
The brake l amp swi tch i s used for the brake l amp,
speed control and brake sensor ci rcui ts.
DIAGNOSIS AND TESTING BRAKE LAMP
SWITCH
Brake l amp swi tch operati on can be tested wi th an
ohmmeter. The ohmmeter i s used to check conti nui ty
between the pi n termi nal s at di fferent pl unger posi -
ti ons (Fi g. 2).
SWITCH CIRCUIT IDENTIFICATION
Termi nal s 1 and 2: brake sensor ci rcui t
Termi nal s 3 and 4: speed control ci rcui t
Termi nal s 5 and 6: brake l amp ci rcui t
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
continuity.
Wi th the swi tch pl unger retracted, attach the test
l eads to termi nal pi ns 1 and 2. Repl ace swi tch i f
meter i ndi cates no conti nui ty.
Wi th the swi tch pl unger retracted, attach the test
Wi th the swi tch pl unger extended, attach the test
REMOVAL
(1) Remove the steeri ng col umn cover and l ower
tri m panel .
(2) Press the brake pedal downward to ful l y
appl i ed posi ti on.
(3) Rotate the swi tch approxi matel y 30 i n coun-
tercl ockwi se di recti on to unl ock the swi tch retai ner.
Pul l swi tch rearward and out of bracket.
(4) Di sconnect swi tch harness and remove swi tch
from vehi cl e (Fi g. 3).
INSTALLATION
(1) Pul l the swi tch pl unger al l the way out to ful l y
extended posi ti on.
(2) Connect the harness wi res to swi tch.
(3) Press and hol d brake pedal i n appl i ed posi ti on.
(4) I nstal l the swi tch as fol l ows: Al i gn the tab on
the swi tch wi th the notch i n the swi tch bracket.
I nsert the swi tch i n the bracket and turn i t cl ockwi se
about 30 to l ock i t i n pl ace.
(5) Rel ease the brake pedal . Then pul l the pedal
l i ghtl y rearward. The pedal wi l l set the pl unger to
the correct posi ti on as the pedal pushes the pl unger
i nto swi tch body. The swi tch wi l l make ratcheti ng
sound as i t sel f adjusts.
CAUTION: Booster damage may occur if the pedal
pull exceeds 20 lbs.
Fig. 1 Auto Headlamp Sensor
1 - AUTO HEADLAMP SENSOR
2 - I/P ASSEMBLY
3 - CONNECTOR
Fig. 2 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
AUTO HEADLAMP SENSOR (Continued)
ADJ USTMENTS
ADJUSTMENT
(1) Press and hol d brake pedal i n appl i ed posi ti on.
(2) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(3) Rel ease brake pedal . Then pul l pedal l i ghtl y
rearward. Pedal wi l l set pl unger to correct posi ti on
as pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make ratcheti ng sound as i t sel f adjusts.
CAUTION: Booster damage may occur if the pedal
pull exceeds 20 lbs.
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
REMOVAL - BULB
(1) Remove the screws attachi ng the l amp housi ng
to the l i ftgate.
(2) Rotate the bul b socket 1/4 turn and remove i t
from the housi ng (Fi g. 4).
(3) Remove the bul b from the socket.
REMOVAL - CHMSL
(1) Remove the screws attachi ng CHMSL to the
l i ftgate (Fi g. 5).
(2) Di sconnect the wi re harness connector.
(3) Separate the CHMSL from the vehi cl e.
INSTALLATION
INSTALLATION - BULB
(1) Push the bul b i nto the socket.
(2) Posi ti on the socket i n l amp and rotate 1/4 turn.
(3) I nstal l the screws attachi ng the l amp housi ng
to l i ftgate.
Fig. 3 Brake Lamp
1 - SWITCH
2 - HARNESS CONNECTOR
Fig. 4 CHMSL Bulb
1 - CHMSL
2 - CHMSL BULB
Fig. 5 Center High Mounted Stop lamp
1 - PUSH-IN NUT
2 - CONNECTOR
3 - LIFTGATE
4 - CHSML
BRAKE LAMP SWITCH (Continued)
INSTALLATION - CHMSL
(1) Connect the wi re harness connector.
(2) Posi ti on the CHMSL on l i ftgate.
(3) I nstal l the screws attachi ng the CHMSL to the
l i ftgate.
COMBINATION FLASHER
DESCRIPTION
The combi nati on fl asher i s l ocated i n the Juncti on
Bl ock (JB) (Fi g. 6). The JB i s l ocated underneath the
dri ver si de of the i nstrument panel outboard of the
steeri ng col umn. The combi nati on fl asher i s a smart
rel ay that functi ons as both the turn si gnal system
and the hazard warni ng system fl asher. The combi -
nati on fl asher contai ns acti ve el ectroni c I ntegrated
Ci rcui try (I C) el ements. Thi s fl asher i s desi gned to
handl e the current fl ow requi rements of the factory-
i nstal l ed l i ghti ng. I f suppl emental l i ghti ng i s added
to the turn si gnal l amp ci rcui ts, such as when towi ng
a trai l er wi th l i ghts, the combi nati on fl asher wi l l
automati cal l y try to compensate to keep the fl ash
rate the same.
The combi nati on fl asher has ni ne bl ade-type termi -
nal s that connect i t to the vehi cl e el ectri cal system.
Refer to the appropri ate wi ri ng i nformati on.
Because of the acti ve el ectroni c el ements wi thi n
the combi nati on fl asher, i t cannot be tested wi th con-
venti onal automoti ve el ectri cal test equi pment. I f the
combi nati on fl asher i s bel i eved to be faul ty, test the
turn si gnal system and hazard warni ng system ci r-
cui ts.(Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG
- EXTERI OR - DI AGNOSI S AND TESTI NG - TURN
SI GNAL & HAZARD WARNI NG SYSTEM). The com-
bi nati on fl asher cannot be repai red or adjusted and,
OPERATION
The combi nati on fl asher control s the fol l owi ng
i nputs and outputs: B(+), fused i gni ti on swi tch out-
put, l eft turn swi tch sense, ri ght turn swi tch sense,
hazard swi tch sense, l eft front turn si gnal ci rcui t,
ri ght front turn si gnal ci rcui t, l eft rear turn si gnal
ci rcui t and ri ght rear turn si gnal ci rcui t. Constant
battery vol tage i s suppl i ed to the fl asher so that i t
can perform the hazard warni ng functi on, and i gni -
ti on swi tched battery vol tage i s suppl i ed for the turn
si gnal functi on. However, when the fl asher i s i dl e no
current i s drawn through the modul e. The uni t does
not become acti ve unti l i t i s provi ded a si gnal ground
from the turn si gnal swi tch, hazard warni ng swi tch
or the Body Control Modul e (BCM).
The I C wi thi n the combi nati on fl asher (Fi g. 7) con-
tai ns the l ogi c that control s the fl asher operati on and
the fl ash rate. When a bul b i s burnt out, or when a
ci rcui t for a l amp i s open, the turn si gnal fl ash rate
wi l l i ncrease. However, an open l amp ci rcui t or burnt
out bul b does not change the hazard warni ng fl ash
rate.
Fig. 6 Combination Flasher
2 - JUNCTION BLOCK
CENTER HIGH MOUNTED STOP LAMP (Continued)
COMBINATION FLASHER CIRCUITS
CAVITY CIRCUIT FUNCTION
1 L25 Fused B(+)
2 L61 Left Front Turn Signal
3 L60 Right Front Turn Signal
4 L63 Left Rear Turn Signal
5 L62 Right Rear Turn Signal
6 F22 Fused Ignition Switch Output
7 L305 Left Turn Switch Sense
8 L302 Right Turn Switch Sense
9 L91 Hazard Switch Sense
COMBINATION FLASHER (Continued)
Turn si gnal i nputs that actuate the combi nati on
fl asher are l ow current grounds, each drawi ng a
maxi mum of 300 mi l l i amperes.The hazard warni ng
si gnal i nput i s a l ow current ground drawi ng a max-
i mum of 600 mi l l i amperes.
REMOVAL
INJURY.
cabl e.
(2) Remove the steeri ng col umn cover. (Refer to 23
- BODY/I NSTRUMENT PANEL/STEERI NG COL-
UMN OPENI NG COVER - REMOVAL).
(3) Remove the combi nati on fl asher from the Junc-
ti on Bl ock (JB) (Fi g. 8).
INSTALLATION
INJURY.
(1) Al i gn the termi nal s of the combi nati on fl asher
wi th the termi nal cavi ti es i n the JB. (Fi g. 8)
(2) Push i n fi rml y and evenl y on the combi nati on
fl asher unti l the termi nal s are ful l y seated.
(3) Rei nstal l the steeri ng col umn openi ng cover.
TI ON).
DAYTIME RUNNING LAMP
MODULE
DESCRIPTION
The Dayti me Runni ng Li ghts (Headl amps) System
i s i nstal l ed on vehi cl es manufactured for sal e i n Can-
ada onl y. A separate modul e, mounted i n the juncti on
bl ock under the dash, control s the DRL.
OPERATION
The headl amps are i l l umi nated at a reduced i nten-
si ty when the engi ne i s runni ng, headl amp swi tch
off, and the parki ng brake rel eased.
REMOVAL
(1) Lower the juncti on bl ock. (Refer to 8 - ELEC-
TRI CAL/POWER DI STRI BUTI ON/JUNCTI ON
BLOCK - REMOVAL) for servi ce procedures.
(2) Remove the modul e from the juncti on bl ock.
INSTALLATION
(1) Posi ti on the modul e i n the juncti on bl ock and
press to secure.
(2) I nstal l the juncti on bl ock. (Refer to 8 - ELEC-
TRI CAL/POWER DI STRI BUTI ON/JUNCTI ON
BLOCK - I NSTALLATI ON) for servi ce procedures.
2 - JUNCTION BLOCK
COMBINATION FLASHER (Continued)
FOG LAMP
REMOVAL
(1) Di sconnect the fog l amp harness connector.
(2) Rotate the bul b socket 1/4 turn counter cl ock-
wi se.
(3) Remove the bul b socket from l amp (Fi g. 9).
INSTALLATION
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) Posi ti on the bul b socket i n fog l amp.
(2) Rotate the bul b socket 1/4 turn cl ockwi se.
(3) Connect the fog l amp harness connector.
FOG LAMP UNIT
REMOVAL
(1) Di sengage the fog l amp el ectri cal connector.
(2) Remove the nuts attachi ng fog l amp to fasci a
(Fi g. 10).
(3) Separate the fog l amp from vehi cl e.
INSTALLATION
(1) Posi ti on the fog l amp i n fasci a.
(2) I nstal l the nuts attachi ng fog l amp to fasci a.
(3) Engage the fog l amp el ectri cal connector.
(4) Al i gn the fog l amp, i f necessary.
ADJ USTMENTS
FOG LAMP ADJUSTMENT
Prepare an al i gnment screen. A properl y al i gned
fog l amp wi l l project a pattern on the al i gnment
screen 100 mm (4 i n.) bel ow the fog l amp centerl i ne
and strai ght ahead (Fi g. 11).
Rotate the adjustment screw to adjust beam hei ght
(Fi g. 12).
Fig. 10 Fog Lamp
1 - FOG LAMP
2 - FASCIA
Fig. 9 Fog Lamp Bulb
1 - FOG LAMP
2 - FASCIA
3 - BULB
4 - BULB SOCKET
HEADLAMP
DESCRIPTION
The headl amps are modul ar i n desi gn.The head-
l amp modul e contai ns fi ve bul bs; a dual fi l ament
headl amp l ow beam bul b, a si ngl e fi l ament hi gh
beam bul b, two turnsi gnal /park bul bs, and a si de
marker bul b.
OPERATION
Al l headl amp, turnsi gnal , park l amp, and hi gh
beam operati ons are control l ed by the l eft mul ti func-
ti on swi tch. Exteri or l amps and bul bs are servi ceabl e
separatel y.
Fig. 11 Fog Lamp AlignmentTypical
1 - VEHICLE CENTERLINE
2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS
3 - HIGH-INTENSITY AREA
4 - FLOOR TO CENTER OF FOG LAMP LENS
5 - 100 mm (4 in.)
6 - 7.62 METERS (25 FEET)
7 - FRONT OF FOG LAMP
Fig. 12 Fog Lamp Adjustment
1 - ADJUSTMENT SCREW
2 - FOG LAMP
FOG LAMP UNIT (Continued)
SYSTEM
HEADLAMPS
HEADLAMPS ARE DIM
WITH ENGINE IDLING
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
OR IGNITION TURNED
OFF
2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer
to Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of -charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to
Electrical,Battery System.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Electrical, Wiring Digram
Information.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS BURN
OUT
1. Charging system output too high. 1. Test and repair charging system, refer
to Electrical, Charging.
FREQUENTLY 2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices, refer to Electrical, Wiring
Information.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
1. Charging system output too low. 1. Test and repair charging system, refer
to Electrical, Wiring Information.
ABOVE IDLE* 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp
circuit.
HEADLAMPS FLASH
RANDOMLY
locations, refer to Electrical, Wiring
Information.
2. High resistance in headlamp
circuit.
2. Test amperage draw of headlamp
circuit. Should not exceed 30 amps.
3. Loose or corroded terminals or
splices in circuit.
splices, refer to Electrical, Wiring
Information.
HEADLAMPS DO NOT
ILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Electrical, Wiring Information.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Electrical,
Wiring Information.
HEADLAMP (Continued)
3. Faulty headlamp switch. 3. Refer to BCM diagnostics.
4. Blown fuse for headlamps. 4. Replace fuse refer to Electrical, Wiring
Information.
5. Broken connector terminal or wire
splice in headlamp circuit.
5. Repair connector terminal or wire splice.
*Canada vehicles must have lamps ON.
FOG LAMP
FOG LAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Electrical, Charging,
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical,
Battery System.
locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. Refer to
Electrical, Charging.
splices in circuit.
splices. Refer to Electrical, Wiring
Information.
FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system. Refer to
Electrical, Charging.
Information.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY
Information.
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty multifunction switch. 3. Refer to Electrical, Electronic Control
Modules.
splices in circuit.
splices. Refer to Electrical, Wiring
Information.
FOG LAMPS DO NOT
ILLUMINATE
1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring
Information.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to Electrical,
Wiring Information.
3. Faulty multifunction switch. 3. Refer to Electrical, Wiring Information.
4. Broken connector terminal or wire
splice in fog lamp circuit.
4. Repair connector terminal or wire splice.
5. Defective or burned out bulb. 5. Replace bulb.
DAYTIME RUNNING LAMP
DAYTIME RUNNING LAMPS DO
NOT WORK
1. Poor connection at DRL module. 1. Secure connector on DRL
module.
2. Parking brake engaged. 2. Disengage parking brake.
3. Parking brake circuit shorted to
ground.
3. Check cluster telltale, refer to
Group 8W.
4. Headlamp circuit shorted to
ground.
4. Refer to Group 8W.
5. Defective DRL relay. 5. Replace DRL relay.
6. Body controller not programed
with Canadian country code.
6. Check country code.
7. DRL relay is missing. 7. Install DRL relay.
8. Blown fuse for DRL. 8. Replace fuse refer to Electrical,
Wiring Information.
Clicking or chattering when DRL is
on.
1. Mechanical relay is installed in
the junction block.
1. Ensure that the DRL relay is
installed in the proper socket in
junction block, and that no
mechanical relay exists in the low
beam socket.
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL 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 other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
Each vehi cl e i s equi pped wi th vari ous l amp assem-
bl i es. A good power feed and ground are necessary for
proper l i ghti ng operati on. Groundi ng i s provi ded by
the l amp socket when i t comes i n contact wi th the
metal body, or through a separate ground wi re.
When changi ng l amp bul bs check the socket for
corrosi on. I f corrosi on i s present, cl ean i t wi th a wi re
brush and coat the i nsi de of the socket l i ghtl y wi th
Mopar Mul ti -Purpose Grease or equi val ent.
REMOVAL - BULB
(1) Remove the headl amp.
(2) Turn the bul b socket one quarter turn counter
cl ockwi se.
(3) Remove the socket from l amp (Fi g. 13).
(4) Remove the bul b from socket.
INSTALLATION - BULB
(1) Posi ti on the bul b i nto socket and push i nto
pl ace.
(2) Posi ti on the bul b socket i n headl amp and turn
the bul b socket one quarter turn cl ockwi se.
(3) I nstal l the headl amp.
HEADLAMP SWITCH
DESCRIPTION
The headl amp swi tch i s part of the l eft mul ti -func-
ti on swi tch. A knob on the end of the mul ti -functi on
swi tch control stal k control s al l of the exteri or l i ght-
i ng swi tch functi ons. The exteri or l i ghti ng swi tch i s
hard wi red to the Body Control Modul e (BCM).
The exteri or l i ghti ng swi tch cannot be adjusted or
repai red and, i f faul ty or damaged, the enti re l eft
mul ti -functi on swi tch uni t must be repl aced. (Refer
to 8 - ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI -
OR/TURN SI GNAL/HAZARD SWI TCH - REMOVAL)
for the servi ce procedures. (Refer to 8 - ELECTRI -
CAL/ELECTRONI C CONTROL MODULES/BODY
CONTROL/CENTRAL TI MER MODUL - DESCRI P-
TI ON) for more i nformati on on thi s component.
OPERATION
The exteri or l i ghti ng swi tch uses a hard wi red fi ve
vol t reference ci rcui t from the BCM, resi stor mul ti -
pl exi ng and a hard wi red swi tch output ci rcui t to
provi de the BCM wi th a zero to fi ve vol t si gnal that
i ndi cates the status of al l of the exteri or l i ghti ng
swi tch setti ngs. The BCM then uses control outputs
to energi ze the headl amp and park l amp rel ays that
acti vate the exteri or l i ghti ng ci rcui ts.
The BCM moni tors the exteri or l i ghti ng swi tch sta-
tus, then sends the proper swi tch status messages to
other modul es over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus network. The exteri or
l i ghti ng swi tch status i s al so used by the BCM as an
i nput for chi me warni ng system operati on.
SWITCH
Before testi ng the headl amp swi tch, turn on the
exteri or l i ghti ng and open the dri ver si de front door.
I f the exteri or l amps of the vehi cl e operate, but there
i s no chi me warni ng i ssued wi th the dri ver si de front
door open, (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - I NTERI OR/DOOR AJAR SWI TCH -
DI AGNOSI S AND TESTI NG). I f the exteri or l amps
of the vehi cl e are i noperati ve, but the chi me warni ng
i s i ssued, (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR - DI AGNOSI S AND TESTI NG).
I f the exteri or l amps and the chi me warni ng are
both i noperati ve, test the l eft mul ti -functi on swi tch.
EXTERI OR - DI AGNOSI S AND TESTI NG). I f the
mul ti -functi on swi tch tests OK, proceed as fol l ows.
The fol l owi ng tests wi l l hel p to l ocate a short or open
i n the hard wi red ci rcui ts between the mul ti -functi on
swi tch and the Body Control Modul e (BCM). For
compl ete ci rcui t di agrams, refer to the appropri ate
wi ri ng i nformati on.
connector from the l eft mul ti -functi on swi tch connec-
tor. Di sconnect the i nstrument panel wi re harness
connector from the Body Control Modul e (BCM).
Check for conti nui ty between the headl amp swi tch
mux ci rcui t of the i nstrument panel wi re harness
Step 2. I f not OK, repai r the shorted headl amp
swi tch mux ci rcui t.
(2) Check for conti nui ty between the headl amp
swi tch mux ci rcui t of the i nstrument panel wi re har-
Fig. 13 Headlamp Bulb
1 - HIGH BEAM BULB
2 - LOW BEAM BULB
3 - MARKER BULB
4 - PARK/TURN SIGNAL BULB
ness connector for the mul ti -functi on swi tch and the
I f not OK, repai r the open headl amp swi tch mux ci r-
cui t.
swi tch return ci rcui t of the i nstrument panel wi re
harness connector for the mul ti -functi on swi tch and a
to Step 4. I f not OK, repai r the shorted headl amp
swi tch return ci rcui t.
swi tch return ci rcui t of the i nstrument panel wi re
harness connector for the mul ti -functi on swi tch and
the i nstrument panel wi re harness connector for the
BCM. There shoul d be conti nui ty. I f OK, use a
DRBI I I scan tool and the proper Di agnosti c Proce-
dures manual to test the BCM. I f not OK, repai r the
open headl amp swi tch return ci rcui t.
HEADLAMP UNIT
REMOVAL
(1) Remove the jack screw attachi ng the top of
headl amp to the headl amp mounti ng modul e (Fi g.
14).
(2) Grasp upper i nboard and l ower outboard cor-
ners of headl amp (Fi g. 15) and pul l headl amp out-
ward.
(3) Remove al l of the bul b sockets from headl amp
modul e.
(4) Separate the headl amp from vehi cl e.
INSTALLATION
(1) I nstal l al l of the bul b sockets i n headl amp mod-
ul e.
(2) Posi ti on the headl amp on the vehi cl e and al i gn
the bal l studs wi th the sockets.
(3) Push the headl amp i nward to secure the bal l
studs wi th the sockets.
(4) I nstal l the jack screw attachi ng the top of
headl amp to the headl amp mounti ng modul e.
ADJUSTMENTS
VEHICLE PREPARATION FOR LAMP ALIGNMENT
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) Correct defecti ve components that coul d hi nder
proper l amp al i gnment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean l amp l enses.
(5) Veri fy that l uggage area i s not heavi l y l oaded.
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
LAMP ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 7.62 meters (25 ft) away from front
of headl amp l ens (Fi g. 16).
(2) I f necessary, tape a l i ne on the fl oor 7.62
meters (25 ft) away from and paral l el to the wal l .
(3) Measure from the fl oor up 1.27 meters (5 ft)
and tape a l i ne on the wal l at the centerl i ne of the
vehi cl e. Si ght al ong the centerl i ne of the vehi cl e
Fig. 14 Headlamp Jackscrew
1 - JACKSCREW
2 - HEADLAMP
Fig. 15 Headlamp Removal
1 - HEADLAMP
HEADLAMP SWITCH (Continued)
(from rear of vehi cl e forward) to veri fy accuracy of
the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for
up/down adjustment reference.
(7) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
HEADLAMP ADJUSTMENT
A properl y ai med l ow beam wi l l project the top
edge of the beam i ntensi ty pattern on the screen
from 25 mm (1 i n.) above to 75 mm (3 i n.) bel ow
headl amp centerl i ne. The si de-to-si de l eft edge of the
beam i ntensi ty pattern shoul d be from 50 mm (2 i n.)
l eft to 50 mm (2 i n.) ri ght of headl amp centerl i ne
(Fi g. 17).
(1) Cl ean front of the headl amps.
(2) Pl ace headl amps on LOW beam.
(3) Cover front of the headl amp that i s not bei ng
adjusted.
(4) Turn adjustment screw (Fi g. 18) and (Fi g. 19)
unti l the top edge of the beam i ntensi ty pattern i s
posi ti oned wi thi n 25 mm (1 i n.) above or 75 mm (3
i n.) bel ow the headl amp hori zontal centerl i ne.
(5) Cover front of the headl amp and adjust the
other headl amp beam as i nstructed bel ow.
(6) Rotate the adjustment screw unti l the top edge
of the beam i ntensi ty pattern i s posi ti oned wi thi n 25
mm (1 i n.) above or 75 mm (3 i n.) bel ow the head-
l amp hori zontal centerl i ne.
LICENSE PLATE LAMP
REMOVAL
REMOVAL - BULB
(1) Remove l amp assembl y from l i ftgate l amp mod-
ul e.
(2) Rotate bul b socket countercl ockwi se to di scon-
nect bul b socket from l amp.
(3) Remove bul b from socket.
Fig. 16 Headlamp Alignment ScreenTypical
1 - CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS
2 - FLOOR TO CENTER OF HEADLAMP LENS
3 - 7.62 METERS (25 FEET)
4 - FRONT OF HEADLAMP
5 - VEHICLE CENTERLINE
HEADLAMP UNIT (Continued)
REMOVAL - LAMP
(1) Remove the screws attachi ng l amp assembl y to
l i ftgate. (Fi g. 20).
(2) Pul l the l amp assembl y away from the sheet-
metal at extreme outboard edges to di sengage the
push pi ns.
(3) Separate l amp assembl y harness wi ri ng con-
nector.
(4) Remove l amp.
INSTALLATION
INSTALLATION - BULB
(1) I nstal l bul b i n socket.
(2) I nstal l socket and bul b assembl y i n l amp hous-
i ng.
(3) I nstal l l amp assembl y i n l i ftgate l amp modul e.
INSTALLATION - LAMP
(1) Connect bul b harness to l amp assembl y.
(2) Posi ti on l amp assembl y on l i ftgate and press
outboard fasteners i n pl ace.
(3) I nstal l screws i n l amp assembl y.
LICENSE PLATE LAMP UNIT
REMOVAL
(1) Remove the screws retai ni ng the l amp housi ng/
tri m panel to the l i ftgate (Fi g. 21).
(2) Di sconnect the wi re harness for the l i cense
pl ate l amps and the fl i p up gl ass swi tch, i f equi pped.
(3) Remove the l i cense pl ate l amps and the fl i p up
gl ass swi tch, i f equi pped.
(4) Remove the l i cense pl ate l amp housi ng.
Fig. 17 Low Beam Pattern
1 - LOW BEAM INTENSITY PATTERN (ISO-CANDELA CURVE)
Fig. 18 Headlamp Beam Adjustment Screw
1 - ADJUSTMENT SCREW LOCATION
Fig. 19 Headlamp Beam Adjustment
Fig. 20 License Plate Lamp Housing
1 - LICENSE PLATE LAMP
2 - CONNECTOR
3 - LIFTGATE
LICENSE PLATE LAMP (Continued)
INSTALLATION
(1) I nstal l the l i cense pl ate l amps, and the fl i p up
gl ass swi tch, i f equi pped.
(2) Connect the wi re harnesses for the l i cense
pl ate l amps and the fl i p up gl ass swi tch.
(3) I nstal l the l amp housi ng/tri m panel on the l i ft-
gate.
LEFT MULTI-FUNCTION
SWITCH
DESCRIPTION
The l eft mul ti -functi on swi tch, i ts mounti ng provi -
si ons, and i ts el ectri cal connecti ons are al l conceal ed
beneath the steeri ng col umn shrouds, just bel ow the
steeri ng wheel (Fi g. 22).
A si ngl e connector wi th el even termi nal pi ns i s
l ocated on the back of the swi tch housi ng and con-
nects the swi tch to the vehi cl e el ectri cal system. The
l eft mul ti -functi on swi tch supports the fol l owi ng exte-
ri or l i ghti ng functi ons:
Auto Headl amps
Front Fog Lamps
Hazard Warni ng Control
Headl amps
Headl amp Beam Sel ecti on
Headl amp Opti cal Horn
Park Lamps
Rear Fog Lamps
Turn Si gnal Control
The l eft mul ti -functi on swi tch al so supports the fol -
l owi ng i nteri or l i ghti ng functi ons:
Panel Lamps Di mmi ng
I nteri or Lamps Defeat
I nteri or Lamps On
Parade Mode
The l eft mul ti -functi on swi tch cannot be adjusted
or repai red. I f any functi on of the swi tch i s faul ty, or
i f the swi tch i s damaged, the enti re swi tch uni t must
be repl aced.
OPERATION
The l eft mul ti -functi on swi tch uses a combi nati on
of resi stor mul ti pl exed and conventi onal l y swi tched
outputs to control the many functi ons and features i t
provi des usi ng a mi ni mal number of hard wi red ci r-
cui ts. The swi tch i s grounded to the chassi s beneath
the center fl oor consol e, just forward of the Ai rbag
Control Modul e (ACM). Fol l owi ng are descri pti ons of
the how the l eft mul ti -functi on swi tch operates to
control the many exteri or l i ghti ng functi ons and fea-
tures i t provi des:
Auto Headlamps - The automati c headl amps
feature i s provi ded by the Body Control Modul e
(BCM), whi ch moni tors an i nput from a photodi ode
sensor l ocated on the top of the i nstrument panel to
detect ambi ent l i ght l evel s whenever the i gni ti on
swi tch i s i n the On posi ti on. Based upon the mul ti -
pl exed i nput from the l eft mul ti -functi on swi tch and
the i nput of the photodi ode sensor, the BCM control s
outputs to the park l amp and headl amp rel ays to
i l l umi nate or exti ngui sh al l exteri or l i ghti ng.
Front Fog Lamps - The Body Control Modul e
(BCM) moni tors the l eft mul ti -functi on swi tch then,
based upon that swi tched ground i nput, control s an
output to the front fog l amp rel ay to i l l umi nate or
exti ngui sh the front fog l amps.
Fig. 21 License Plate Lamp Housing
1 - LICENSE PLATE LAMP
2 - CONNECTOR
3 - LIFTGATE
Fig. 22 Left (Lighting) Multi-Function Switch
1 - EXTERIOR LIGHTING CONTROL
2 - INTERIOR LIGHTING CONTROL
3 - CONTROL STALK
4 - HAZARD WARNING BUTTON
5 - CANCEL ACTUATOR
6 - LEFT (LIGHTING) MULTI-FUNCTION SWITCH
LICENSE PLATE LAMP UNIT (Continued)
Hazard Warning Control - The hazard warn-
i ng push button i s pressed down to acti vate the haz-
ard warni ng system, and pressed down agai n to turn
the system off. The l eft mul ti -functi on swi tch pro-
vi des a ground to the hazard warni ng sense i nput of
the combi nati on fl asher to control acti vati on of the
hazard warni ng l amps.
Headlamps - The Body Control Modul e (BCM)
moni tors the l eft mul ti -functi on swi tch then, based
upon that mul ti pl exed i nput, control s an output to
the headl amp l ow or hi gh beam rel ays to i l l umi nate
or exti ngui sh the headl amps.
Headlamp BeamSelection - The Body Control
Modul e (BCM) moni tors the l eft mul ti -functi on
swi tch then, based upon that swi tched ground i nput,
control s an output to the headl amp l ow or hi gh beam
rel ays to acti vate the sel ected headl amp beam.
Headlamp Optical Horn - The Body Control
swi tch then, based upon that swi tched ground i nput,
control s an output to the headl amp hi gh beam rel ay
to acti vate the headl amp hi gh beams.
Park Lamps - The Body Control Modul e (BCM)
moni tors the l eft mul ti -functi on swi tch then, based
upon that mul ti pl exed i nput, control s an output to
the park l amp rel ay to i l l umi nate or exti ngui sh the
parki ng l amps.
Rear Fog Lamps - The Body Control Modul e
based upon that mul ti pl exed i nput, control s an out-
put to the rear fog l amp rel ay to i l l umi nate or exti n-
gui sh the rear fog l amps.
Turn Signal Control - The l eft mul ti -functi on
swi tch control stal k actuates the turn si gnal swi tch.
The Body Control Modul e (BCM) moni tors the l eft
mul ti -functi on swi tch then, based upon that mul ti -
pl exed i nput, provi des a vari abl e vol tage output to
control the l i ghti ng of the turn si gnal s.
Fol l owi ng are descri pti ons of the how the l eft
mul ti -functi on swi tch operates to control the many
i nteri or l i ghti ng functi ons and features i t provi des:
Panel Lamps Dimming - The Body Control
swi tch then, based upon that mul ti pl exed i nput, pro-
vi des a vari abl e vol tage output through several panel
l amps dri ver ci rcui ts to control the l i ghti ng of many
i ncandescent panel l amps. The BCM al so sends panel
l amps di mmi ng messages over the Programmabl e
Communi cati ons I nterface (PCI ) data bus to other
modul es to control Di spl ay l i ghti ng l evel s i n those
modul es.
Interior Lamps Defeat - The Body Control
swi tch then, based upon that mul ti pl exed i nput,
i nternal l y di sabl es the functi on the BCM normal l y
provi des to control the i l l umi nati on of the i nteri or
l amps.
Interior Lamps On - The Body Control Modul e
based upon that mul ti pl exed i nput, provi des a control
output to acti vate al l of the i nteri or l amp ci rcui ts.
Parade Mode - The Body Control Modul e
based upon that mul ti pl exed i nput, provi des a vol t-
age output through several panel l amps dri ver ci r-
cui ts to control the l i ghti ng of many i ncandescent
panel l amps. The BCM al so sends panel l amps di m-
mi ng messages over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus to other modul es on
the bus to control l i ghti ng l evel s i n those modul es.
DIAGNOSIS AND TESTING - LEFT MULTI -
FUNCTION SWITCH
INJURY.
connector from the mul ti -functi on swi tch connector.
(2) Usi ng an ohmmeter, perform the conti nui ty
and resi stance tests at the termi nal s i n the mul ti -
functi on swi tch connector as shown i n the Left Mul ti -
Functi on Swi tch Test chart (Fi g. 23).
LEFT MULTI-FUNCTION SWITCH (Continued)
LEFT (LIGHTING) MULTI-FUNCTION SWITCH
TURN SIGNAL AND HAZARD WARNING SWITCH TESTS
SWITCH POSITION CONTINUITY
BETWEEN
TURN HAZARD
Neutral Off No Related Continuity
Left Off Pins 2 & 8
Right Off Pins 2 & 7
Neutral On Pins 2 & 9
EXTERIOR LIGHTING SWITCH TESTS
SWITCH POSITION CONTINUITY
BETWEEN
RESISTANCE
BETWEEN
RESISTANCE RANGE (OHMS)
Off - Pins 4 & 11 3743 - 3824
Park Lamps On - Pins 4 & 11 901 - 926
Head Lamps On - Pins 4 & 11 345 - 358
Auto Headlamps On - Pins 4 & 11 74 - 81
Fog Lamps Pins 1 & 2 - -
Optical Horn Pins 2 & 5 - -
High Beam Pins 2 & 6 - -
INTERIOR LIGHTING SWITCH TESTS
Dome Lamp Disable
On
- Pins 4 & 9 63 - 70
Panel Lamps
Dimming Position 1
- Pins 4 & 9 198 - 208
Dimming Position 2 - Pins 4 & 9 551 - 569
Parade Mode On - Pins 4 & 9 3534 - 3611
Dome Lamp Enable
On
- Pins 4 & 9 7811 - 7974
Fig. 23 Left Multi -Function Switch Test
(3) I f the mul ti -functi on swi tch fai l s any of the
conti nui ty or resi stance tests, repl ace the swi tch.
REMOVAL
REMOVAL - LEFT MULTI-FUNCTION SWITCH
INJURY.
cabl e.
(2) Remove the l ower ti l ti ng steeri ng col umn
shroud (Fi g. 24).
(3) Unsnap the two hal ves of the steeri ng col umn
shroud, and remove.
connector from the swi tch connector.
(5) Remove the screws that secure the l eft mul ti -
functi on swi tch to the housi ng (Fi g. 25).
(6) Remove the l eft mul ti -functi on swi tch.
REMOVAL - MULTI-FUNCTION SWITCH
MOUNTING HOUSING
INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
cabl e.
Fig. 24 Steering Column Shrouds Remove/Install
1 - UPPER TILTING COLUMN SHROUD
2 - FIXED COLUMN SHROUD
3 - LOWER TILTING COLUMN SHROUD
4 - SCREW
Fig. 25 Left Multi-Function Switch Remove/Install
1 - SCREW (2)
2 - STEERING COLUMN
3 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
4 - LEFT MULTI-FUNCTION SWITCH
(2) Remove the cl ockspri ng from the mul ti -functi on
swi tch mounti ng housi ng. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/CLOCKSPRI NG - REMOVAL).
(3) Remove the l eft mul ti -functi on swi tch from the
mul ti -functi on swi tch mounti ng housi ng. (Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI OR/
LEFT MULTI -FUNCTI ON SWI TCH - REMOVAL -
LEFT MULTI -FUNCTI ON SWI TCH).
(4) Remove the ri ght mul ti -functi on swi tch from
the mul ti -functi on swi tch mounti ng housi ng. (Refer
to 8 - ELECTRI CAL/WI PERS/WASHERS/RI GHT
MULTI -FUNCTI ON SWI TCH - REMOVAL).
(5) Remove the screw that secures the mul ti -func-
ti on swi tch mounti ng housi ng to the steeri ng col umn
housi ng (Fi g. 26).
(6) Remove the mul ti -functi on swi tch mounti ng
INSTALLATION
INSTALLATION - LEFT MULTI-FUNCTION
SWITCH
INJURY.
(1) Posi ti on the l eft mul ti -functi on swi tch onto the
(2) I nstal l and ti ghten the screws that secure the
l eft mul ti -functi on swi tch housi ng. Ti ghten the
connector to the swi tch connector.
Fig. 26 Multi-Function Switch Mounting Housing
Screw Remove/Install
1 - CLOCK SPRING
2 - SCREW
Remove/install
1 - MULTI-FUNCTION SWITCH ASSEMBLY
2 - CLOCKSPRING
Fig. 28 Left Multi-Function Switch Remove/Install
1 - SCREW (2)
2 - STEERING COLUMN
(4) Posi ti on the l ower ti l ti ng steeri ng col umn
shroud to the undersi de of the steeri ng col umn (Fi g.
29).
l ower steeri ng col umn shroud housi ng. Ti ghten the
screw to 1.9 Nm (17 i n. l bs.).
(6) Al i gn the upper ti l ti ng steeri ng col umn shroud
to the l ower shroud and snap the two shroud hal ves
together.
INSTALLATION - MULTI-FUNCTION SWITCH
MOUNTING HOUSING
INJURY.
NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
position.
(1) Rotate the turn si gnal cancel cam i n the mul ti -
functi on swi tch housi ng unti l the al i gnment hol e i n
the one cam l obe i s al i gned wi th the al i gnment hol e
i n the back of the housi ng. The obl ong hol e i n the
hub of the cam shoul d now be at the top, and the
l ocati ng tab i n the hub of the cam shoul d be at the
bottom (Fi g. 30).
(2) Posi ti on the mul ti -functi on swi tch housi ng onto
the top of the steeri ng col umn. The l ocati ng tab i n
the hub of the turn si gnal cancel cam must be
engaged wi th the al i gnment groove i n the bottom of
the upper steeri ng col umn shaft.
mul ti -functi on swi tch housi ng to the top of the col -
umn housi ng (Fi g. 31). Ti ghten the screw to 1.9 Nm
(17 i n. l bs.).
(4) Rei nstal l the ri ght mul ti -functi on swi tch onto
the mul ti -functi on swi tch housi ng. (Refer to 8 -
ELECTRI CAL/WI PERS/WASHERS/RI GHT MULTI -
FUNCTI ON SWI TCH - I NSTALLATI ON).
(5) Rei nstal l the l eft mul ti -functi on swi tch onto the
mul ti -functi on swi tch housi ng. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/LEFT
4 - SCREW
Fig. 30 Turn Signal Cancel Cam Alignment
1 - ALIGNMENT HOLE
3 - ALIGNMENT HOLE
4 - TURN SIGNAL CANCEL CAM
5 - LOCATING TAB
6 - WASHER
7 - TURN SIGNAL SWITCH CANCEL ACTUATOR
MULTI -FUNCTI ON SWI TCH - I NSTALLATI ON -
LEFT MULTI -FUNCTI ON SWI TCH).
(6) Rei nstal l the cl ockspri ng onto the mul ti -func-
ti on swi tch housi ng. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - I NSTALLATI ON).
PARK/TURN SIGNAL LAMP
REMOVAL - BULBS
(1) Remove the headl amp modul e.
(2) Rotate the turn si gnal bul b socket 1/4 turn
counter cl ockwi se.
(3) Remove the bul b socket from modul e.
(4) Remove the bul b from socket.
INSTALLATION - BULBS
(1) Press the bul b i nto socket.
(2) Posi ti on the bul b socket i n modul e.
(3) Rotate the turn si gnal bul b socket 1/4 turn
cl ockwi se.
(4) I nstal l the headl amp modul e.
TAIL LAMP
DESCRIPTION
The tai l l amp modul e contai ns a housi ng, l ens, and
three bul bs. A dual fi l ament bul b i s used for tai l and
stop functi ons. A si ngl e fi l ament bul b i s used for turn
si gnal operati ons. A separate bul b i s used for back-up
i l l umi nati on.
OPERATION
Al l exteri or l i ghti ng functi on are control l ed by the
mul ti functi on swi tch. Stop l amp functi ons are con-
trol l ed by the stopl amp swi tch. The back-up l amps
are control l ed by the back-up l amp swi tch.
REMOVAL
REMOVAL - BULBS
The brake, turn si gnal , back-up, and si de marker
l amp bul bs are i ncorporated i nto the tai l l amp.
(1) Remove the tai l l amp.
(2) Rotate the bul b socket countercl ockwi se.
(3) Separate the socket from the l amp
(4) Remove the bul b from the socket (Fi g. 32).
REMOVAL - LAMP
l amps are i ncorporated i n the tai l l amp.
(1) Remove the screws attachi ng the l amp to body
(Fi g. 33).
(2) Di sengage the l amp from the al i gnment pi n.
(3) Di sconnect l amp wi re harness connector.
(4) Separate l amp from vehi cl e.
Screw Remove/Install
1 - CLOCK SPRING
2 - SCREW
Fig. 32 Tail Lamp Bulbs
1 - TAIL/STOP BULB
2 - TAIL LAMP
3 - BACK-UP BULB
4 - TURN SIGNAL BULB
INSTALLATION
INSTALLATION - BULBS
(1) Posi ti on the bul b i n socket and push i nto pl ace.
(2) Posi ti on the bul b socket i n the l amp and rotate
cl ockwi se.
(3) I nstal l the l amp.
INSTALLATION - LAMP
l amps are i ncorporated i n the tai l l amp.
(1) Posi ti on the l amp.
(2) Connect the l amp wi re harness connector.
(3) Al i gn the pi n wi th the retai ner and press the
l amp i nward to engage.
(4) I nstal l the screws attachi ng the l amp to body.
TURN SIGNAL CANCEL CAM
DESCRIPTION
The turn si gnal cancel cam i s conceal ed wi thi n the
mul ti -functi on swi tch housi ng bel ow the steeri ng
wheel and the cl ockspri ng mechani sm. The turn si g-
nal cancel cam consi sts of a di sc uni t wi th two i nte-
gral l obes. The upper l obe of the cam has an
al i gnment hol e that i s used to al i gn i t wi th another
hol e i n the back of the mul ti -functi on swi tch mount-
i ng housi ng. The upper surface of the turn si gnal
cancel cam features three hol es, two round and one
obl ong. These hol es engage and key the cancel cam to
three matchi ng pi ns i n the hub of the cl ockspri ng
mechani sm. The hub of the cl ockspri ng and the turn
si gnal cancel cam rotate wi th the steeri ng wheel . The
centered cl ockspri ng housi ng i s then secured to the
mul ti -functi on swi tch mounti ng housi ng over the top
of the turn si gnal cancel cam.
The turn si gnal cancel cam i s servi ced as a assem-
bl y wi th the mul ti -functi on swi tch housi ng. The turn
si gnal cancel cam cannot be repai red and, i f faul ty or
damaged, the mul ti -functi on swi tch mounti ng hous-
i ng uni t must be repl aced. (Refer to 8 - ELECTRI -
CAL/LAMPS/LI GHTI NG - EXTERI OR/LEFT MULTI -
FUNCTI ON SWI TCH - REMOVAL - MULTI -
FUNCTI ON SWI TCH MOUNTI NG HOUSI NG).
OPERATION
The turn si gnal cancel cam has two l obes. When
the turn si gnal s are acti vated by movi ng the l eft
mul ti -functi on swi tch control stal k to a detent posi -
ti on, a turn si gnal cancel actuator i s extended from
the i nsi de surface of the mul ti -functi on swi tch hous-
i ng toward the center of the steeri ng col umn and the
turn si gnal cancel cam. When the steeri ng wheel i s
rotated duri ng a turni ng maneuver, one of the two
turn si gnal cancel cam l obes wi l l contact the turn si g-
nal cancel actuator. The cancel actuator l atches
agai nst the cancel cam rotati on i n the di recti on oppo-
si te that whi ch i s si gnal ed.
Fig. 33 Tail Lamp
1 - CONNECTOR
2 - RETAINER
3 - TAILLAMP (STOP, TURN, BACK-UP, SIDE MARKER)
4 - PIN
TAIL LAMP (Continued)
UNDERHOOD LAMP
REMOVAL
REMOVAL - BULB
(1) I nsert a smal l fl at bl ade i n access sl ot between
the l amp base and l amp l ens.
(2) Li ft the l amp l ens upward and remove the
l amp l ens (Fi g. 34).
(3) Depress bul b termi nal i nward (Fi g. 35) to
rel ease bul b.
REMOVAL - LAMP
(1) Di sconnect the wi re harness connector from
l amp.
(2) Remove the screw attachi ng underhood l amp to
i nner hood panel (Fi g. 36).
(3) Remove the underhood l amp from the vehi cl e.
INSTALLATION
INSTALLATION - BULB
(1) Engage the repl acement bul b wi re l oop to ter-
mi nal cl osest to l amp base wi re connector.
(2) Depress the opposi te termi nal i nward and
engage the remai ni ng bul b wi re l oop.
(3) Posi ti on the l amp l ens on the l amp base and
press i nto pl ace.
INSTALLATION - LAMP
(1) Posi ti on the underhood l amp on the hood i nner
panel .
(2) I nstal l the screw attachi ng the l amp base to
the i nner hood panel .
(3) I nstal l the l amp housi ng and press i nto pl ace.
(4) Connect the wi re harness connector.
Fig. 34 Underhood Lamp Lens
1 - LAMP
2 - LAMP LENS
Fig. 35 Underhood Lamp Bulb
1 - BULB
2 - DEPRESS TERMINAL INWARD
3 - BULB WIRE LOOP
4 - LAMP BASE
Fig. 36 Underhood Lamp
1 - CONNECTOR
2 - UNDERHOOD LAMP
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
COURTESY LAMP
REMOVAL
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION
DOME LAMP
REMOVAL
REMOVAL - BULB . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION
DOOR AJAR SWITCH
DESCRIPTION
DESCRIPTION - DOOR AJAR SWITCH . . . . . 29
DESCRIPTION - FLIP UP GLASS AJAR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION - LIFTGATE AJAR SWITCH . . 30
OPERATION
OPERATION - DOOR AJAR SWITCH . . . . . . . 30
OPERATION - FLIP UP GLASS AJAR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION - LIFTGATE AJAR SWITCH . . . . 30
DIAGNOSIS AND TESTING - DOOR AJAR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
GLOVE BOX LAMP/SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
READING LAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
TRANS RANGE INDICATOR ILLUMINATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
VANITY LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
SPECIFICATIONS
CAUTION: Do not use bulbs other than the bulbs
listed in the Bulb Application Table. Damage to
lamp can result.
Servi ce procedures for most of the l amps i n the
i nstrument panel , are l ocated i n El ectri cal , I nstru-
ment Panel . Some components have l amps that can
onl y be servi ced by an Authori zed Servi ce Center
(ASC) after the component i s removed from the vehi -
cl e.
LAMP BULB TYPE
A/C HEATER NOT SERVICED
ASH RECEIVER 161
CLIMATE CONTROL 74
PASSENGER ASSIST
HANDLE
2142
FRONT READING 192
GLOVE COMPARTMENT 194
TELLTALE/HAZARD LAMP 74
HEATER NOT SERVICED
OVERHEAD CONSOLE 192
RADIO ASC
REAR CARGO 2142
UNDER PANEL COURTESY 906
CLUSTER ILLUMINATION 103
SUNVISOR VANITY CHRYSLER P/N
6501966
8L - 28 LAMPS/LIGHTING - INTERIOR WJ
COURTESY LAMP
REMOVAL
REMOVAL - BULB
(1) Remove the door tri m panel . (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - REMOVAL)
for the servi ce procedures.
(2) Remove the bul b socket from the l amp.
(3) Remove the bul b from the socket.
REMOVAL - LAMP
(1) Remove door tri m panel . (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - REMOVAL) for the
procedures.
(2) Di sengage the el ectri cal connectors.
(3) Depress the l ocki ng tabs and remove the l amp
modul e.
(4) Remove the bul b socket.
INSTALLATION
INSTALLATION - BULB
(1) I nstal l the bul b i n the socket.
(2) I nstal l the bul b socket i n the l amp.
(3) I nstal l the door tri m panel .
INSTALLATION - LAMP
(1) I nstal l the bul b socket i nto the l amp modul e.
(2) Al i gn the l amp modul e wi th the door tri m
panel .
(3) Snap the l amp modul e i nto pl ace.
(4) I nstal l the door panel .
DOME LAMP
REMOVAL
REMOVAL - BULB
(1) Rotate the the grab handl e down.
(2) Remove the screws retai ni ng the grab handl e/
dome l ens.
(3) Remove the grab handl e/l ens from the modul e.
(4) Remove the bul b from the l amp termi nal s.
REMOVAL - LAMP
I t wi l l be necessary to parti al l y remove the head-
l i ner to remove the bul b socket.
(1) Remove the screws hol di ng the grab handl e/
l ens assembl y to the headl i ner and roof panel .
(2) Lower the headl i ner as needed. (Refer to 23 -
BODY/I NTERI OR/HEADLI NER - REMOVAL) for the
servi ce procedure.
(3) Separate the l amp socket from the headl i ner
and roof panel .
(4) Di sconnect the wi re connector.
INSTALLATION
INSTALLATION - BULB
(1) I nsert the bul b i nto the l amp termi nal s.
(2) Posi ti on the grab handl e/l ens on the l amp mod-
ul e.
(3) I nstal l the screws retai ni ng the grab handl e/
l ens to the l amp modul e.
INSTALLATION - LAMP
(1) Posi ti on the l amp socket on the headl i ner and
roof panel .
(2) Connect the wi re harness.
(3) I nstal l the headl i ner.
(4) Posi ti on the grab handl e/l ens on the l amp mod-
ul e.
(5) I nstal l the screws retai ni ng the grab handl e/
l ens i nto the l amp socket.
DOOR AJ AR SWITCH
DESCRIPTION
DESCRIPTION - DOOR AJAR SWITCH
The door ajar swi tches are i ntegral to the door
l atch mechni ci sm. The front door ajar swi tches are
actuated by the front door l atch mechani sms, and are
hard wi red between a body ground and the Dri ver
Door Modul e (DDM) or the Passenger Door Modul e
(PDM). The rear door ajar swi tches are actuated by
the rear door l atch mechani sms, and are hard wi red
between a body ground and the Body Control Modul e
(BCM) through the rear door and body wi re har-
nesses.
The door ajar swi tches cannot be adjusted or
repai red and, i f faul ty or damaged, the door l atch
uni t must be repl aced. (Refer to 23 - BODY/DOOR -
FRONT/LATCH - REMOVAL) or (Refer to 23 -
BODY/DOORS - REAR/LATCH - REMOVAL) for the
servi ce procedures. For compl ete ci rcui t di agrams,
refer to the appropri ate wi ri ng i nformati on.
DESCRIPTION - FLIP UP GLASS AJAR SWITCH
The l i ftgate fl i p-up gl ass ajar swi tch i s i ntegral to
the l i ftgate fl i p-up gl ass l atch mechni ci sm. The l i ft-
gate fl i p-up gl ass ajar swi tch i s actuated by the l i ft-
gate fl i p-up gl ass l atch mechani sm, and i s hard
WJ LAMPS/LIGHTING - INTERIOR 8L - 29
wi red between a body ground, the Body Control Mod-
ul e (BCM) and the rear wi per motor modul e through
the l i ftgate and body wi re harnesses.
The l i ftgate fl i p-up gl ass ajar swi tch cannot be
adjusted or repai red and, i f faul ty or damaged, the
l i ftgate fl i p-up gl ass l atch uni t must be repl aced.
(Refer to 23 - BODY/DECKLI D/HATCH/LI FTGATE/
TAI LGATE/FLI P-UP GLASS LATCH - REMOVAL)
for the servi ce procedures. For compl ete ci rcui t di a-
grams, refer to the appropri ate wi ri ng i nformati on.
DESCRIPTION - LIFTGATE AJAR SWITCH
The two l i ftgate ajar swi tches are i ntegral to the
two l i ftgate l atch mechani sms. The two l i ftgate ajar
swi tches are actuated by the l i ftgate l atch mecha-
ni sms, and are hard wi red wi th each other between a
body ground and the Body Control Modul e (BCM)
through the l i ftgate and body wi re harnesses.
The l i ftgate ajar swi tches cannot be adjusted or
repai red and, i f faul ty or damaged, the l i ftgate l atch
uni t must be repl aced. (Refer to 23 - BODY/DECK-
LI D/HATCH/LI FTGATE/TAI LGATE/LATCH -
REMOVAL) for the servi ce procedures. For compl ete
ci rcui t di agrams, refer to the appropri ate wi ri ng
i nformati on.
OPERATION
OPERATION - DOOR AJAR SWITCH
The front door ajar swi tches cl ose a path to ground
for the DDM or the PDM when a front door i s
opened, and opens the ground path when a front door
i s cl osed. The rear door ajar swi tches cl ose a path to
ground for the BCM when a rear door i s opened, and
opens the ground path when a rear door i s cl osed.
The DDM, PDM, or BCM read the swi tch status then
send the proper swi tch status messages to other
modul es over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. The door ajar
swi tch status message i s used by the BCM as an
i nput for Vehi cl e Theft Securi ty System (VTSS) oper-
ati on.
OPERATION - FLIP UP GLASS AJAR SWITCH
The l i ftgate fl i p-up gl ass ajar swi tch can cl ose a
path to ground for the BCM and the rear wi per
motor modul e when the l i ftgate fl i p-up gl ass i s
opened, and opens the ground path when the l i ftgate
fl i p-up gl ass i s cl osed. The rear wi per motor modul e
uses the l i ftgate fl i p-up gl ass ajar swi tch i nput to
control the rear wi per operati on, and wi l l park the
rear wi per bl ade i f thi s i nput i ndi cates that the l i ft-
gate fl i p-up gl ass i s ajar. The BCM reads the swi tch
status then sends the proper swi tch status message
to other modul es over the Programmabl e Communi -
cati ons I nterface (PCI ) data bus network. The l i ftgate
fl i p-up gl ass ajar swi tch status message i s used by
the BCM as an i nput for Vehi cl e Theft Securi ty Sys-
tem (VTSS) operati on.
OPERATION - LIFTGATE AJAR SWITCH
Each of the l i ftgate ajar swi tches can cl ose a path
to ground for the BCM when the l i ftgate i s opened,
and opens the ground path when the l i ftgate i s
cl osed. The BCM reads the swi tch status then sends
the proper swi tch status message to other modul es
(PCI ) data bus network. The l i ftgate ajar swi tch sta-
tus message i s used by the BCM as an i nput for
Vehi cl e Theft Securi ty System (VTSS) operati on.
DIAGNOSIS AND TESTING - DOOR AJAR
SWITCH
The following diagnosis and testing is only
for the chime functions. For interior lamp diag-
nosis, refer to the appropriate wiring informa-
tion. The dri ver door ajar swi tch i s hard wi red to the
Dri ver Door Modul e (DDM). The DDM communi cates
the swi tch status to the other modul es i n the vehi cl e
on the Programmabl e Communi cati ons I nterface
(PCI ) data bus network. The fol l owi ng test wi l l di ag-
nose a faul ty dri ver door ajar swi tch and ci rcui ts. For
compl ete ci rcui t di agrams, refer to the appropri ate
wi ri ng i nformati on.
(1) Check that the i nteri or l i ghti ng swi tch on the
control stal k of the l eft mul ti -functi on swi tch i s not
i n the dome l amp di sabl e posi ti on. Open the dri ver
si de front door and note whether the i nteri or l amps
l i ght. They shoul d l i ght. I f OK, refer to Key-I n I gni -
ti on Swi tch i n the Di agnosi s and Testi ng secti on of
thi s group for further di agnosi s of the chi me warni ng
system. I f not OK, go to Step 2.
cabl e. Remove the tri m panel from the dri ver front
door and di sconnect the 4-way door wi re harness con-
nector from the front door l atch connector. Check for
conti nui ty between the ground ci rcui t of the 4-way
door wi re harness connector and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 3. I f not
OK, repai r the ground ci rcui t.
DOOR AJ AR SWITCH (Continued)
from the Dri ver Door Modul e (DDM) connector.
Check for conti nui ty between the dri ver door ajar
swi tch sense ci rcui t of the door wi re harness connec-
tor for the DDM and a good ground. There shoul d be
no conti nui ty. I f OK, go to Step 4. I f not OK, repai r
the shorted dri ver door ajar swi tch sense ci rcui t.
(4) Check for conti nui ty between the dri ver door
ajar swi tch sense ci rcui t of the door wi re harness
connector for the DDM and the 4-way door wi re har-
ness connector for the front door l atch. There shoul d
be conti nui ty. I f OK, go to Step 5. I f not OK, repai r
the open dri ver door ajar swi tch sense ci rcui t.
cui t termi nal and the dri ver door ajar swi tch sense
ci rcui t termi nal of the front door l atch connector.
There shoul d be conti nui ty wi th the dri ver si de front
door open, and no conti nui ty wi th the door cl osed. I f
OK, use a DRBI I I scan tool and the proper Di agnos-
ti c Procedures manual to test the operati on of the
PCI data bus and the DDM. I f not OK, repl ace the
faul ty dri ver si de front door l atch uni t.
GLOVE BOX LAMP/SWITCH
REMOVAL
cabl e.
(2) Rol l down the gl ove box from the i nstrument
panel .(Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL) for the procedures.
(3) Remove the l ower ri ght center bezel from the
i nstrument panel .(Refer to 23 - BODY/I NSTRU-
MENT PANEL - REMOVAL) for the procedures.
(4) Reach through the gl ove box openi ng and
depress the retai ni ng l atches on the top and bottom
of the gl ove box l amp and swi tch housi ng.
(5) Whi l e hol di ng the retai ni ng l atches depressed,
push the gl ove box l amp and swi tch out through the
mounti ng hol e (Fi g. 1).
connector from the gl ove box l amp and swi tch con-
nector.
(7) Remove the gl ove box l amp and swi tch.
INSTALLATION
(1) Posi ti on the gl ove box l amp and swi tch to the
i nstrument panel .
connector to the gl ove box l amp and swi tch connector.
(3) Al i gn the gl ove box l amp and swi tch housi ng
wi th the mounti ng hol e i n the i nstrument panel
gl ove box openi ng upper rei nforcement.
(4) Push the gl ove box l amp and swi tch i nto the
mounti ng hol e unti l the retai ni ng l atches are ful l y
engaged.
(5) I nstal l the l ower ri ght center bezel onto the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL - I NSTALLATI ON) for the proce-
dures.
(6) Rol l the gl ove box back up i nto the i nstrument
panel .(Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - I NSTALLATI ON) for the procedures.
Fig. 1 Glove Box Lamp and Switch Remove/Install
1 - GLOVE BOX OPENING UPPER REINFORCEMENT
2 - WIRE HARNESS CONNECTOR
3 - GLOVE BOX LAMP & SWITCH
4 - LATCH
5 - MOUNTING HOLE
WJ LAMPS/LIGHTING - INTERIOR 8L - 31
DOOR AJ AR SWITCH (Continued)
READING LAMP
DESCRIPTION
The overhead consol e i n thi s vehi cl e i s equi pped
wi th two i ndi vi dual readi ng and courtesy l amps.Each
l amp has i ts own swi tch, bul b, refl ector and l ens; but
both l amps share a common l amp housi ng wi thi n the
overhead consol e.
The overhead consol e readi ng and courtesy l amps
operate on battery current that i s provi ded at al l
ti mes, regardl ess of the i gni ti on swi tch posi ti on. The
ground feed for the l amps i s swi tched through the
i ntegral readi ng and courtesy l amp swi tches or
through the door jamb swi tches.
The readi ng and courtesy l amp l enses and the
l amp housi ng and refl ector uni t are servi ced onl y as
a uni t wi th the overhead consol e housi ng.The readi ng
and courtesy l amp swi tches, bul b hol ders and wi ri ng
are onl y avai l abl e as part of the overhead consol e
wi re harness.
For servi ce of the readi ng and courtesy l amp bul bs,
I NTERI OR/READI NG LAMP - REMOVAL). For di ag-
nosi s of the readi ng and courtesy l amps, refer to the
appropri ate wi ri ng i nformati on.
OPERATION
Al l readi ng and courtesy l amps l ocated i n the over-
head consol e are acti vated by the door jamb swi tches.
When al l of the doors are cl osed, these l amps can be
i ndi vi dual l y acti vated by depressi ng the correspond-
i ng l ens. When any door i s open, depressi ng the l amp
l enses to acti vate the l amp swi tches wi l l not turn the
l amps off.
REMOVAL
(1) Remove the overhead consol e.
(2) Rotate the consol e unti l the bul b i s vi si bl e (Fi g.
2).
(3) Grasp the bul b and remove from the socket.
INSTALLATION
(1) Push the bul b i nto the bul b socket.
(2) I nstal l the consol e on the headl i ner and roof
panel .
(3) Al i gn the screw hol e and i nstal l the screw.
TRANS RANGE INDICATOR
ILLUMINATION
DESCRIPTION
The Transmi ssi on Range I ndi cator Lamp, mounted
on the fl oor consol e, uses el ectrol umi nescent technol -
ogy as the l i ght source. Thi s l amp requi res a 120 vol t
AC si gnal that i s provi ded by a power converter
i ncl uded as part of the assembl y. The modul e i s not
servi ceabl e separatel y. Because of a potenti al shock
hazard, di agnosti c testi ng of the l amp assembl y
shoul d be avoi ded. Refer to TRANSMI SSI ON, Range
Sel ector Assembl y Removal and I nstal l ati on.
VANITY LAMP
REMOVAL
(1) Fol d down the vi sor.
(2) Usi ng a smal l fl at bl ade, and stari ng at the
base of the l amp assembl y, careful l y pry the base of
the l amp from the vi sor.
(3) Di sconnect the vani ty l amp vi sor and remove
the l amp from the vehi cl e.
INSTALLATION
(1) Posi ti on the l amp at the vi sor and connect the
wi re connector.
(2) Press the l amp i n pl ace.
Fig. 2 Overhead Console Reading Lamp Bulb
1 - BULB
MESSAGE SYSTEMS
TABLE OF CONTENTS
page page
OVERHEAD CONSOLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE
STANDARD PROCEDURE - MODULE LAMP
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE - COURTESY
LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE - MODULE LENS
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - ELECTRONIC
VEHICLE INFORMATION CENTER
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - COMPASS
DEMAGNETIZING . . . . . . . . . . . . . . . . . . . . . . 4
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . 5
VARIATION ADJUSTMENT. . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS
OVERHEAD CONSOLE SYSTEMS . . . . . . . . . 6
ELECTRONIC VEHICLE INFO CENTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - ELECTRONIC
VEHICLE INFORMATION CENTER . . . . . . . . . 9
STANDARD PROCEDURE - TIRE PRESSURE
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
UNIVERSAL TRANSMITTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 11
AMBIENT TEMP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR . . . . . . . . . . . . . . . 12
TEMPERATURE SENSOR CIRCUIT . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OVERHEAD CONSOLE
DESCRIPTION
An overhead consol e i s standard factory-i nstal l ed
equi pment on thi s model . The overhead consol e
i ncl udes the El ectroni c Vehi cl e I nformati on Center
(EVI C) and two readi ng and courtesy l amps (Fi g. 1).
On vehi cl es equi pped wi th a power sunroof opti on,
the overhead consol e al so houses the power sunroof
swi tch between the two readi ng and courtesy l amps.
The overhead consol e i s mounted wi th one screw and
two snap-cl i ps to a mol ded pl asti c retai ner bracket
l ocated above the headl i ner. The retai ner bracket i s
secured wi th adhesi ve to the i nsi de surface of the
roof panel .
Fol l owi ng are general descri pti ons of the major
components used i n the overhead consol e. Refer to
Overhead Console i n Wi ri ng Di agrams for compl ete
ci rcui t di agrams.
OPERATION
more i nformati on on the use and operati on of the
vari ous overhead consol e features.
STANDARD PROCEDURE
STANDARD PROCEDURE - MODULE LAMP
REPLACEMENT
(1) Remove the overhead consol e (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - REMOV-
AL).
(2) Usi ng a fl at bl ade screwdri ver twi st out socket/
l amp (Fi g. 2).
(3) Repl ace l amp(s) as necessary.
STANDARD PROCEDURE - COURTESY LAMP
REPLACEMENT
(1) Open hood, di sconnect and i sol ate the negati ve
battery cabl e.
WJ MESSAGE SYSTEMS 8M - 1
(2) Remove the overhead consol e from the head-
l i ner (Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - REMOVAL).
(3) Remove the l amp and socket assembl y from the
overhead consol e.
(4) Remove the l amp bul b by pul l i ng i t strai ght
out of i ts socket.
STANDARD PROCEDURE - MODULE LENS
REPLACEMENT
(1) Remove the overhead consol e (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - REMOV-
AL).
(2) Remove the el ectroni cs modul e from the over-
head consol e. Refer to the procedure i n thi s secti on.
(3) Unsnap the l ens from the modul e and repl ace
l ens as necessary.
STANDARD PROCEDURE - ELECTRONIC
PROGRAMMING
EVIC PROGRAMMING MODE
The El ectroni c Vehi cl e I nformati on Center (EVI C)
provi des the vehi cl e operator wi th a user i nterface,
whi ch al l ows the sel ecti on of several opti onal cus-
tomer programmabl e el ectroni c features to sui t i ndi -
vi dual preferences. The EVI C must be pl aced i nto i ts
programmi ng mode i n order to vi ew or change the
programmabl e features. To enter the EVI C program-
mi ng mode and to vi ew or change the sel ected pro-
grammabl e features opti ons, proceed as fol l ows:
(2) Depress and rel ease the Menu push button.
The fi rst i tem i n the programmabl e features menu
l i st wi l l appear i n the EVI C di spl ay.
(3) Momentari l y depress and rel ease the Menu
push button to step through the programmabl e fea-
tures l i st. Each programmabl e feature and i ts cur-
rentl y sel ected opti on wi l l appear on the EVI C
di spl ay i n the sequence shown i n the Programmabl e
Features l i st that fol l ows.
(4) Momentari l y depress and rel ease the Step push
button to step through the avai l abl e opti ons for the
programmabl e feature bei ng di spl ayed.
(5) The opti on that l ast appears i n the di spl ay
wi th a programmabl e feature before exi ti ng the pro-
grammi ng mode, becomes the newl y sel ected pro-
grammabl e feature opti on.
(6) The EVI C exi ts the programmi ng mode and
returns to i ts normal operati ng mode when the C/T
push button i s depressed or when the end of the pro-
grammabl e features menu l i st i s reached, whi chever
occurs fi rst.
Fig. 1 Overhead Console
1 - POWER SUNROOF SWITCH (IF EQUIPPED)
2 - READING AND COURTESY LAMPS
3 - UNIVERSAL GARAGE DOOR OPENER PUSH BUTTONS (IF
EQUIPPED)
4 - SCREW
5 - ELECTRONIC VEHICLE INFORMATION CENTER PUSH
BUTTONS
Fig. 2 Top of Overhead Console
1 - OVERHEAD CONSOLE HOUSING
2 - EVIC MODULE
4 - SCREWS (4)
8M - 2 MESSAGE SYSTEMS WJ
OVERHEAD CONSOLE (Continued)
PROGRAMMABLE FEATURES
LANGUAGE? - The opti ons i ncl ude Engl i sh,
Francai se, Deutsch, I tal i ana, or Espanol . The defaul t i s
Engl i sh. Al l EVI C di spl ay nomencl ature, i ncl udi ng the
tri p computer functi ons, warni ng messages and the pro-
grammabl e features appear i n the sel ected l anguage.
DISPLAY U.S. OR METRIC? - The opti ons
i ncl ude U.S. and M. The defaul t i s U.S. Thi s feature
toggl es the tri p computer temperature, fuel economy
and odometer di spl ay readi ngs between U.S. and
metri c uni ts of measure. I t al so changes the odome-
ter di spl ay i n the i nstrument cl uster.
AUTO DOOR LOCKS? - The opti ons i ncl ude
Yes and No. The defaul t i s Yes. When Yes i s sel ected,
al l doors and the l i ftgate l ock automati cal l y when
vehi cl e speed reaches 25 ki l ometers-per-hour (15
mi l es-per-hour). I f YES i s sel ected, a second program-
mabl e feature appears, AUTO UNLOCK ON EXIT?
- The opti ons agai n i ncl ude Yes and No. The defaul t
i s No. When Yes i s sel ected, fol l owi ng each Auto Door
Lock event al l doors and the l i ftgate wi l l automati -
cal l y unl ock when the dri ver door i s opened, i f the
vehi cl e i s stopped and the transmi ssi on gear sel ector
i s i n Park or Neutral . The Auto Door Unl ock event
wi l l onl y occur once fol l owi ng each Auto Door Lock
event.
REMOTE UNLOCK - The opti ons i ncl ude
Dri ver Door 1st and Al l Doors. The defaul t i s Dri ver
Door 1st. When Di ver Door 1st i s sel ected, onl y the
dri ver door unl ocks when the Unl ock button of the
Remote Keyl ess Entry (RKE) transmi tter i s
depressed once. The Unl ock button of the RKE trans-
mi tter must be depressed twi ce to unl ock al l doors
and the l i ftgate. When Al l Doors i s sel ected, al l doors
and the l i ftgate unl ock when the Unl ock button of
the RKE transmi tter i s depressed once.
REMOTE LINKED TO MEMORY? - Thi s pro-
grammabl e feature onl y appl i es to vehi cl es equi pped
wi th the opti onal memory system. The opti ons
i ncl ude Yes and No. The defaul t i s No. When Yes i s
sel ected, the memory system wi l l recal l the Dri ver 1
or Dri ver 2 memory setti ngs assi gned to the RKE
transmi tter bei ng used to unl ock the vehi cl e. When
No i s sel ected, the memory system wi l l onl y recal l
memory setti ngs when the Dri ver 1 or Dri ver 2 push
buttons of the memory swi tch on the dri ver si de front
door tri m panel are depressed.
SOUND HORN ON LOCK? - The opti ons
sel ected, a short horn chi rp wi l l provi de an audi bl e
confi rmati on when the RKE recei ver recogni zes a
val i d Lock si gnal from an RKE transmi tter. When No
i s sel ected, no horn chi rp wi l l occur wi th the RKE
Lock event. Thi s feature may be sel ected i ndepen-
dent of the FLASH LIGHTS WITH LOCKS? pro-
grammabl e feature.
FLASH LIGHTS WITH LOCKS? - The opti ons
i ncl ude Yes and No. The defaul t i s Yes. When Yes i s
sel ected, a si ngl e fl ash of the hazard warni ng l amps
wi l l provi de an opti cal confi rmati on when the RKE
recei ver recogni zes a val i d Lock si gnal from an RKE
transmi tter, and two fl ashes of the same l amps wi l l
occur when the RKE recei ver recogni zes a val i d
Unl ock si gnal from an RKE transmi tter. When No i s
sel ected, no l amp fl ash wi l l occur wi th the RKE Lock
or Unl ock event. Thi s feature may be sel ected i nde-
pendent of the SOUND HORN ON LOCK? pro-
grammabl e feature.
HEADLAMP DELAY = - The opti ons i ncl ude
Off, 30 Sec, 60 Sec, and 90 Sec. The defaul t i s 90 Sec.
When a ti me i nterval i s sel ected, the headl amps wi l l
remai n on for that l ength of ti me when the head-
l amps are turned off after the i gni ti on i s turned off,
or i f the Auto mode i s sel ected on vehi cl es wi th the
Auto Headl amps opti on. When Off i s sel ected, the
headl amp del ay feature i s di sabl ed.
HEADLAMPS ON WITH WIPERS? - Thi s pro-
grammabl e feature onl y appl i es to vehi cl es equi pped
wi th the opti onal Auto Headl amps. The opti ons
sel ected, the headl amps wi l l turn on automati cal l y
when the wi ndshi el d wi pers are turned on. The head-
l amps wi l l turn off when the wi pers are turned off,
as l ong as the headl amp swi tch i s i n the Auto or Off
posi ti ons. When No i s sel ected, the headl amps wi l l
onl y turn on i f manual l y sel ected or i f the Auto mode
i s sel ected and the outsi de ambi ent l i ght l evel s di c-
tate that they shoul d be on.
SERVICE INTV. = - The opti ons i ncl ude from
1000 to 12000 ki l ometers i n 1000 ki l ometer i ncre-
ments (2000 to 7500 mi l es i n 500 mi l e i ncrements).
The defaul t i s 12000 ki l ometers (7500 mi l es). The
sel ected di stance becomes the i nterval at whi ch the
Perform Servi ce warni ng message wi l l be di spl ayed
by the EVI C. I f a new di stance i s sel ected, a second
programmabl e feature appears, RESET SERVICE
DISTANCE? - The opti ons i ncl ude No and Yes. The
defaul t i s Yes. When Yes i s sel ected, the accumul ated
di stance si nce the l ast previ ous Perform Servi ce
warni ng message wi l l be reset to zero because the
servi ce i nterval has been changed. When No i s
sel ected, the di stance unti l the next Perform Servi ce
warni ng message i s reduced by the accumul ated di s-
tance si nce the l ast previ ous message.
LOWFUEL CHIME? - The opti ons i ncl ude Yes
and No. The defaul t i s Yes. When Yes i s sel ected, a
si ngl e chi me wi l l sound as an audi bl e al ert whenever
the i nstrument cl uster l ow fuel warni ng l amp l i ghts.
The chi me wi l l sound onl y once per i gni ti on cycl e.
When No i s sel ected, onl y the l ow fuel warni ng l amp
i n the i nstrument cl uster wi l l l i ght and no chi me wi l l
sound.
RETRAIN TIRE SENSORS? - Thi s program-
mabl e feature onl y appl i es to vehi cl es equi pped wi th
the opti onal ti re pressure moni tori ng system. The
opti ons i ncl ude Yes and No. The defaul t i s No. When
Yes i s sel ected and the menu button i s depressed, the
EVI C wi l l enter the trai ni ng mode starti ng wi th the
l eft front ti re.
EASY EXIT SEAT? - Thi s programmabl e fea-
ture onl y appl i es to vehi cl es equi pped wi th the
opti onal memory system. The opti ons i ncl ude Yes and
No. The defaul t i s No. When Yes i s sel ected, the
dri ver seat moves rearward about 55 mi l l i meters
(two i nches) or to the farthest rearward posi ti on,
whi chever comes fi rst, when the key i s removed from
the i gni ti on swi tch l ock cyl i nder. Thi s provi des addi -
ti onal ease for exi ti ng from the vehi cl e. The seat wi l l
automati cal l y return to the memory system setti ng
posi ti on when the Dri ver 1 or Dri ver 2 button of the
memory swi tch on the door panel i s depressed or, i f
the REMOTE LINKED TO MEMORY programma-
bl e feature i s enabl ed, when the RKE Unl ock button
i s depressed. Whi l e not automati c, an easy entry fea-
ture can be obtai ned by enabl i ng the EASY EXIT
SEAT feature and di sabl i ng the REMOTE LINKED
TO MEMORY feature. Then the EASY EXIT SEAT
feature wi l l move the seat back, but the RKE unl ock
event wi l l not reposi ti on the seat. Thus, the seat
remai ns posi ti oned for easy entry, and the memory
swi tch on the door panel can be depressed after
enteri ng the vehi cl e to return the seat to the desi red
memory posi ti on.
DEMAGNETIZING
A degaussi ng tool (Speci al Tool 6029) i s used to
demagneti ze, or degauss, the overhead consol e for-
ward mounti ng screw and the roof panel above the
overhead consol e. Equi val ent uni ts must be rated as
conti nuous duty for 110/115 vol ts and 60 Hz. They
must al so have a fi el d strength of over 350 gauss at 7
mi l l i meters (0.25 i nch) beyond the ti p of the probe.
To demagneti ze the roof panel and the overhead
consol e forward mounti ng screw, proceed as fol l ows:
(1) Be certai n that the i gni ti on swi tch i s i n the Off
posi ti on, before you begi n the demagneti zi ng proce-
dure.
(2) Connect the degaussi ng tool to an el ectri cal
outl et, whi l e keepi ng the tool at l east 61 centi meters
(2 feet) away from the compass uni t.
(3) Sl owl y approach the head of the overhead con-
sol e forward mounti ng screw wi th the degaussi ng
tool connected.
(4) Contact the head of the screw wi th the pl asti c
coated ti p of the degaussi ng tool for about two sec-
onds.
(5) Wi th the degaussi ng tool sti l l energi zed, sl owl y
back i t away from the screw. When the ti p of the tool
i s at l east 61 centi meters (2 feet) from the screw
head, di sconnect the tool .
(6) Pl ace a pi ece of paper approxi matel y 22 by 28
centi meters (8.5 by 11 i nches), ori ented on the vehi cl e
l engthwi se from front to rear, on the center l i ne of
the roof at the wi ndshi el d header (Fi g. 3). The pur-
pose of the paper i s to protect the roof panel from
scratches, and to defi ne the area to be demagneti zed.
(7) Connect the degaussi ng tool to an el ectri cal
outl et, whi l e keepi ng the tool at l east 61 centi meters
(2 feet) away from the compass uni t.
(8) Sl owl y approach the center l i ne of the roof
panel at the wi ndshi el d header, wi th the degaussi ng
tool connected.
(9) Contact the roof panel wi th the pl asti c coated
ti p of the degaussi ng tool . Be sure that the templ ate
i s i n pl ace to avoi d scratchi ng the roof panel . Usi ng a
sl ow, back-and-forth sweepi ng moti on, and al l owi ng
13 mi l l i meters (0.50 i nch) between passes, move the
tool at l east 11 centi meters (4 i nches) to each si de of
the roof center l i ne, and 28 centi meters (11 i nches)
back from the wi ndshi el d header.
(10) Wi th the degaussi ng tool sti l l energi zed,
sl owl y back i t away from the roof panel . When the
Fig. 3 Roof Demagnetizing Pattern
ti p of the tool i s at l east 61 centi meters (2 feet) from
the roof panel , di sconnect the tool .
(11) Cal i brate the compass and adjust the compass
vari ance (Refer to 8 - ELECTRI CAL/OVERHEAD
CONSOLE - STANDARD PROCEDURE).
CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
The el ectroni c compass uni t features a sel f-cal i -
brati ng desi gn, whi ch si mpl i fi es the cal i brati on pro-
cedure. Thi s feature automati cal l y updates the
compass cal i brati on whi l e the vehi cl e i s bei ng dri ven.
Thi s al l ows the compass uni t to compensate for smal l
changes i n the resi dual magneti sm that the vehi cl e
may acqui re duri ng normal use. I f the compass read-
i ngs appear to be errati c or out of cal i brati on, per-
form the fol l owi ng cal i brati on procedure. Al so, new
servi ce repl acement El ectroni c Vehi cl e I nformati on
Center (EVI C) modul es must have thei r compass cal -
i brated usi ng thi s procedure. Do not attempt to cal i -
brate the compass near l arge metal objects such as
other vehi cl es, l arge bui l di ngs, or bri dges; or, near
overhead or underground power l i nes.
NOTE: Whenever an EVIC module is replaced, the
variance number must also be reset. Refer to Com-
pass Variation Adjustment in this group.
Cal i brate the compass manual l y as fol l ows:
(1) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/temperature data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the C/T
push button to reach the compass/temperature di s-
pl ay.
(2) Depress the Reset push button and hol d the
button down unti l CAL appears i n the di spl ay. Thi s
takes about ten seconds, and appears about fi ve sec-
onds after VARI ANCE = XX i s di spl ayed.
(3) Rel ease the Reset push button.
(4) Dri ve the vehi cl e on a l evel surface, away from
l arge metal objects and power l i nes, through one
compl ete ci rcl e at between fi ve and ei ght ki l ometers-
per-hour (three and fi ve mi l es-per-hour) i n not l ess
than 20 seconds. The CAL message wi l l di sappear
from the di spl ay to i ndi cate that the compass i s now
cal i brated.
NOTE: If the CAL message remains in the display,
either there is excessive magnetism near the com-
pass, or the unit is faulty. Repeat the calibration
procedure one more time.
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
VARIATION ADJUSTMENT
Compass vari ance, al so known as magneti c decl i -
nati on, i s the di fference i n angl e between magneti c
north and true geographi c north. I n some geographi c
l ocati ons, the di fference between magneti c and geo-
graphi c north i s great enough to cause the compass
to gi ve fal se readi ngs. I f thi s probl em occurs, the
compass vari ance setti ng may need to be changed.
To set the compass vari ance:
(1) Usi ng the Vari ance Setti ngs map, fi nd your
geographi c l ocati on and note the zone number (Fi g.
4).
(2) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/temperature data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the C/T
push button to reach the compass/temperature di s-
pl ay.
(3) Depress the Reset push button and hol d the
button down unti l VARI ANCE = XX appears i n the
di spl ay. Thi s takes about fi ve seconds.
(4) Rel ease the Reset push button. VARI ANCE
=XX wi l l remai n i n the di spl ay. XX equal s the cur-
rent vari ance zone setti ng.
(5) Momentari l y depress and rel ease the Step push
button to step through the zone numbers, unti l the
zone number for your geographi c l ocati on appears i n
the di spl ay.
(6) Momentari l y depress and rel ease the Reset
push button to enter the di spl ayed zone number i nto
the EVI C modul e memory.
(7) Confi rm that the correct di recti ons are now
i ndi cated by the compass.
REMOVAL
cabl e.
(2) Remove the screw that secures the front of the
overhead consol e to the front of the overhead consol e
retai ner bracket.
(3) I nsert the fi ngerti ps of both hands between the
headl i ner and the si des of the overhead consol e hous-
i ng i n the area near the readi ng and courtesy l amps.
(4) Pul l downward on the si des of the overhead
consol e housi ng fi rml y and evenl y to di sengage the
two snap cl i ps that secure the rear of the uni t from
thei r receptacl es i n the overhead consol e retai ner
bracket.
(5) Lower the overhead consol e from the headl i ner
far enough to access the wi re harness connectors.
(6) Di sconnect the roof wi re harness connectors
from the El ectroni c Vehi cl e I nformati on Center con-
nector receptacl e, the readi ng and courtesy l amp wi re
harness connector and, i f the vehi cl e i s so equi pped,
from the back of the power sunroof swi tch.
l i ner.
INSTALLATION
(1) Posi ti on the overhead consol e near the mount-
i ng l ocati on on the headl i ner.
(2) Reconnect the roof wi re harness connectors to
the El ectroni c Vehi cl e I nformati on Center connector
receptacl e, the readi ng and courtesy l amp wi re har-
ness connector and, i f the vehi cl e i s so equi pped, to
the back of the power sunroof swi tch.
(3) Al i gn the two snap cl i ps on the rear of the
overhead consol e housi ng wi th thei r receptacl es i n
the overhead consol e retai ner bracket.
(4) Push upward fi rml y and evenl y on the si des of
the overhead consol e housi ng over both of the snap
cl i p l ocati ons unti l each of the two snap cl i ps i s ful l y
engaged wi th i ts receptacl e i n the overhead consol e
retai ner bracket.
front of the overhead consol e housi ng to the overhead
consol e retai ner bracket. Ti ghten the screw to 1.2
Nm (10 i n. l bs.).
SPECIAL TOOLS
OVERHEAD CONSOLE SYSTEMS
ELECTRONIC VEHICLE INFO
CENTER
DESCRIPTION
i s l ocated i n the overhead consol e on model s
equi pped wi th thi s opti on. Three versi ons of the
EVI C modul e are avai l abl e on the Grand Cherokee.
These three versi ons are i denti cal except that some
model s i ncl ude an i ntegral three-push button Uni ver-
sal Transmi tter transcei ver and/or Ti re Pressure
Moni tori ng System (TPM). Al l three EVI C modul es
feature a l arge Vacuum Fl uorescent Di spl ay (VFD)
screen for di spl ayi ng i nformati on, and back-l i t push
buttons functi on swi tches l abel ed C/T (compass/tem-
perature), RESET, STEP, and MENU. The VFD
screen can al so di spl ay a vehi cl e graphi c that i s used
Fig. 4 Variance Settings
Degaussing Tool 6029
for door and l i ftgate open i ndi cati ons and to show i f a
turn si gnal has been l eft on. The EVI C messages and
di spl ays are coordi nated wi th warni ng i ndi cators i n
the i nstrument cl uster to avoi d dupl i cati on.
The EVI C modul e contai ns a central processi ng
uni t and i nterfaces wi th other el ectroni c modul es i n
the vehi cl e over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. The PCI data bus
network al l ows the shari ng of sensor i nformati on.
Thi s hel ps to reduce wi re harness compl exi ty, reduce
i nternal control l er hardware, and reduce component
i ti es.
The EVI C modul e i ncl udes the fol l owi ng di spl ay
opti ons:
Compass and Temperature - provi des the out-
si de temperature and one of ei ght compass readi ngs
to i ndi cate the di recti on the vehi cl e i s faci ng.
Average fuel economy - shows the average
fuel economy si nce the l ast tri p computer reset.
Distance to empty - shows the esti mated di s-
tance that can be travel l ed wi th the fuel remai ni ng
i n the fuel tank. Thi s esti mated di stance i s computed
usi ng the average mi l es-per-gal l on from the l ast 30
gal l ons of fuel used.
Instant fuel economy - shows the present fuel
economy based upon the current vehi cl e di stance and
fuel used i nformati on.
Trip distance - shows the di stance travel l ed
si nce the l ast tri p computer reset.
Elapsed time - shows the accumul ated i gni -
ti on-on ti me si nce the l ast tri p computer reset.
Distance to service - shows the di stance
remai ni ng unti l the next schedul ed servi ce i nterval .
Tire Pressure - shows the ti re pressure i n each
ti re.
Blank screen - the EVI C compass/temperature/
tri p computer VFD i s turned off.
The EVI C i s capabl e of di spl ayi ng the fol l owi ng
al ert messages, whi ch are accompani ed by an audi bl e
announcement consi sti ng of a seri es of beeps:
TURN SIGNALS ON (with vehicle graphic) -
I ndi cates that a turn si gnal has remai ned on for
about 1.6 ki l ometers (one mi l e).
PERFORM SERVICE - I ndi cates that a cus-
tomer programmabl e servi ce i nterval di stance has
been reached.
DOOR OPEN (one or more, with vehicle
graphic) - I ndi cates that a door i s open or not ful l y
cl osed.
LIFTGATE OPEN (with vehicle graphic) -
I ndi cates that the l i ftgate i s open or not ful l y cl osed.
LIFTGLASS OPEN (with vehicle graphic) -
I ndi cates that the l i ftgl ass i s open or not ful l y cl osed.
COOLANT LEVEL LOW (with vehicle
graphic) - I ndi cates that the cool ant l evel i n the
engi ne cool ant reservoi r i s l ow.
XX LOW PRESSURE (with vehicle graphic)
- I ndi cates that the ai r pressure i n the sel ected ti re
i s l ow.
WASHER FLUID LOW (with vehicle
graphic) - I ndi cates that the fl ui d l evel i n the
washer fl ui d reservoi r i s l ow.
The EVI C Menu push button provi des the vehi cl e
operator wi th a user i nterface, whi ch al l ows the
sel ecti on of several opti onal customer programmabl e
el ectroni c features to sui t i ndi vi dual preferences.
Refer to ELECTRONIC VEHICLE INFORMA-
TION CENTER PROGRAMMING i n the Servi ce
Procedures secti on of thi s group for more i nformati on
on the customer programmabl e feature opti ons.
I f the vehi cl e i s equi pped wi th the opti onal mem-
ory system, the EVI C wi l l di spl ay the fol l owi ng mem-
ory system messages:
MEMORY #X POSITION SET (X =Driver 1
or Driver 2) - Thi s message appears i n the EVI C
di spl ay each ti me the memory system i s successful l y
programmed. I t i s accompani ed by an audi bl e
announcement chi me tone.
MEMORY SYSTEM DISABLED - The memory
system i s automati cal l y di sabl ed whi l e the dri ver
si de seat bel t i s fastened and/or whi l e the automati c
transmi ssi on gear sel ector i s i n any posi ti on except
Park or Neutral . Thi s message appears i n the EVI C
di spl ay as a remi nder when a memory swi tch push
button i s depressed whi l e the memory system i s di s-
abl ed. I f the REMOTE LI NKED TO MEMORY cus-
tomer programmabl e feature has been sel ected, thi s
message wi l l al so appear when the Unl ock button of
the Remote Keyl ess Entry (RKE) transmi tter i s
depressed whi l e the memory system i s di sabl ed.
I f the vehi cl e i s equi pped wi th the opti onal Uni ver-
sal Transmi tter transcei ver, the EVI C wi l l al so di s-
pl ay messages and an i con i ndi cati ng when the
Uni versal Transmi tter i s bei ng trai ned, whi ch of the
three transmi tter buttons i s transmi tti ng, and when
the transcei ver i s cl eared.
I f the vehi cl e i s equi pped wi th the opti onal Tire
Pressure Monitoring System, the EVI C wi l l al so
di spl ay messages and an i con i ndi cati ng when the
ti re ai r pressure fal l s bel ow a gi ven set-poi nt, and
whi ch of the fi ve ti res i s transmi tti ng the l ow pres-
sure warni ng, and when the condi ti on i s cl eared.
Refer to the Ti res/Wheel s secti on of thi s manual for
compl ete Ti re Pressure Moni tori ng System descri p-
ti on. Refer to thi s secti on of the servi ce manual for
EVI C modul es functi on descri pti on for the Ti re Pres-
sure Moni tori ng.
Data i nput for al l EVI C functi ons, i ncl udi ng VFD
di mmi ng l evel , i s recei ved through PCI data bus
ELECTRONIC VEHICLE INFO CENTER (Continued)
messages. The EVI C modul e uses i ts i nternal pro-
grammi ng and al l of i ts data i nputs to cal cul ate and
di spl ay the requested data. I f the data di spl ayed i s
i ncorrect, perform the sel f-di agnosti c tests as
descri bed i n thi s group. I f these tests prove i nconcl u-
si ve, the use of a DRBI I I scan tool and the proper
Di agnosti c Procedures manual are recommended for
further testi ng of the EVI C modul e and the PCI data
bus.
The EVI C modul e cannot be repai red, and i s avai l -
abl e for servi ce onl y as a uni t. Thi s uni t i ncl udes the
push button swi tches and the pl asti c housed modul e.
I f any of these components are faul ty or damaged,
the compl ete EVI C modul e must be repl aced. The
i ncandescent bul bs used for EVI C push button back-
l i ghti ng and the di spl ay l ens are avai l abl e for servi ce
repl acement.
ELECTRONIC VEHICLE INFORMATION CENTER
CHIME
uses the chi me warni ng system for two di fferent
ki nds of support. I n addi ti on to requesti ng chi me
tones from the Body Control Modul e (BCM) as tacti l e
beep support, the EVI C i s programmed to send chi me
request messages over the Programmabl e Communi -
cati ons I nterface (PCI ) data bus when i t detects the
fol l owi ng condi ti ons:
Door Open Warning - A door i s open above a
cri ti cal speed [about 16 ki l ometers-per-hour (10
mi l es-per-hour) for the dri ver si de front door, or
about 5 ki l ometers-per-hour (3 mi l es-per-hour) for
any other door].
Liftgate Open Warning - The l i ftgate i s open
above a cri ti cal speed [about 5 ki l ometers-per-hour (3
mi l es-per-hour)].
Liftglass Open Warning - The l i ftgate fl i p-up
gl ass i s open above a cri ti cal speed [about 5 ki l ome-
ters-per-hour (3 mi l es-per-hour)].
Low Coolant Level Warning - The cool ant
l evel i n the engi ne cool ant reservoi r i s l ow.
Perform Service Alert - An audi bl e al ert that
a Perform Servi ce remi nder message i s bei ng di s-
pl ayed by the EVI C.
Turn Signal On Warning - A turn si gnal
remai ns on for about 1.6 ki l ometers (one mi l e).
Washer Fluid Low Warning - The fl ui d l evel
i n the washer reservoi r i s l ow.
of the EVI C. (Refer to 8 - ELECTRI CAL/OVERHEAD
- DESCRI PTI ON) for more i nformati on on the EVI C.
COMPASS
Whi l e i n the compass/temperature mode, the com-
pass wi l l di spl ay the di recti on i n whi ch the vehi cl e i s
poi nted usi ng the ei ght major compass headi ngs
(Exampl es: north i s N, northeast i s NE). The sel f-cal -
i brati ng compass uni t requi res no adjusti ng i n nor-
mal use. The onl y cal i brati on that may prove
necessary i s to dri ve the vehi cl e i n one ci rcl e at 5 to
8 ki l ometers-per-hour (3 to 5 mi l es-per-hour), on l evel
ground, i n not l ess than 20 seconds. Thi s wi l l reori -
ent the compass uni t to i ts vehi cl e.
The compass uni t al so wi l l compensate for magne-
ti sm the body of the vehi cl e may acqui re duri ng nor-
mal use. However, avoi d pl aci ng anythi ng magneti c
di rectl y on the roof of the vehi cl e. Magneti c mounts
for an antenna, a repai r order hat, or a funeral pro-
cessi on fl ag can exceed the compensati ng abi l i ty of
the compass uni t i f pl aced on the roof panel . Mag-
neti c bi t dri vers used on the fasteners that hol d the
overhead consol e assembl y to the roof header can
al so affect compass operati on. I f the vehi cl e roof
shoul d become magneti zed, the demagneti zi ng and
cal i brati on procedures found i n thi s group may be
requi red to restore proper compass operati on.
TEMPERATURE
The outsi de ambi ent temperature i s di spl ayed i n
whol e degrees. The temperature di spl ay can be tog-
gl ed from Fahrenhei t to Cel si us by sel ecti ng the
desi red U.S./Metri c opti on from the customer pro-
grammabl e features as descri bed i n ELECTRONIC
VEHICLE INFORMATION CENTER PROGRAM-
MING i n the Standard Procedures secti on of thi s
group. The di spl ayed temperature i s not an i nstant
readi ng of condi ti ons, but an average temperature. I t
may take the temperature di spl ay several mi nutes to
respond to a major temperature change, such as dri v-
i ng out of a heated garage i nto wi nter temperatures.
When the i gni ti on swi tch i s turned to the Off posi -
ti on, the l ast di spl ayed temperature readi ng stays i n
the Body Control Modul e (BCM) uni t memory. When
the i gni ti on swi tch i s turned to the On posi ti on
agai n, the EVI C wi l l di spl ay the memory tempera-
ture for one mi nute; then update the di spl ay to the
current average temperature readi ng wi thi n fi ve
mi nutes.
The temperature functi on i s supported by an ambi -
ent temperature sensor. The sensor i s mounted out-
si de the passenger compartment near the front and
center of the vehi cl e, and i s hard wi red to the Body
Control Modul e (BCM). The BCM sends temperature
status messages to the EVI C modul e over the PCI
data bus network. The ambi ent temperature sensor
i s avai l abl e as a separate servi ce i tem.
OPERATION
The EVI C has access to both non-swi tched and
i gni ti on swi tched sources of battery current so that
some of i ts features remai n operati onal at any ti me,
whi l e others may onl y operate wi th the i gni ti on
swi tch i n the On posi ti on. When the i gni ti on swi tch
i s turned to the On posi ti on, the EVI C modul e VFD
wi l l return to the l ast functi on bei ng di spl ayed before
the i gni ti on was turned to the Off posi ti on.
The compass/temperature di spl ay i s the normal
EVI C di spl ay. Wi th the i gni ti on swi tch i n the On
posi ti on, momentari l y depressi ng and rel easi ng the
C/T (compass/temperature) push button swi tch wi l l
cause the EVI C to return to the compass/tempera-
ture/tri p computer di spl ay mode from any other
mode. Whi l e i n the compass/temperature/tri p com-
puter di spl ay mode, momentari l y depressi ng and
rel easi ng the Step push button wi l l step through the
avai l abl e tri p computer di spl ay opti ons.
The EVI C tri p computer features several functi ons
that can be reset. The functi ons that can be reset
are: average fuel economy, tri p odometer and el apsed
ti me. Wi th the i gni ti on swi tch i n the On posi ti on and
wi th one of the functi ons of the tri p computer that
can be reset currentl y di spl ayed, depressi ng the
Reset push button twi ce wi thi n three seconds wi l l
perform a gl obal reset, and al l of the tri p computer
i nformati on that can be reset wi l l be reset to zero.
Wi th the i gni ti on swi tch i n the On posi ti on and the
functi on that i s to be reset currentl y di spl ayed,
momentari l y depressi ng and rel easi ng the Reset
push button once wi l l perform a l ocal reset, and onl y
the val ue of the di spl ayed functi on wi l l be reset to
zero. A gl obal or l ocal reset wi l l onl y occur i f the
functi on currentl y di spl ayed i s a functi on that can be
reset. The di stance to servi ce functi on can al so be
reset usi ng the l ocal reset method, but i t wi l l reset
back to the Servi ce I nterval di stance that i s set i n
the EVI C programmabl e features mode. Refer to
ELECTRONIC VEHICLE INFORMATION CEN-
TER PROGRAMMING i n the Servi ce Procedures
secti on of thi s group for more i nformati on on setti ng
the Servi ce I nterval .
For more i nformati on on the features, control func-
ti ons and setti ng procedures for the EVI C modul e,
see the owners manual i n the vehi cl e gl ove box.
DIAGNOSIS AND TESTING - ELECTRONIC
I f the probl em wi th the El ectroni c Vehi cl e I nforma-
ti on Center (EVI C) i s a temperature readi ng of 130
F or -40F shown i n the compass/temperature di s-
pl ay, refer to Ambient Temperature Sensor Diag-
nosis and Testing i n thi s group. I f the probl em wi th
the EVI C i s an i naccurate or scrambl ed di spl ay, refer
to Self-Diagnostic Test i n thi s group. I f the prob-
l em wi th the EVI C i s i ncorrect Vacuum Fl uorescent
Di spl ay (VFD) di mmi ng l evel s, use a DRB scan tool
and the proper Di agnosti c Procedures manual to test
for the correct di mmi ng message i nputs bei ng
recei ved from the Body Control Modul e (BCM) over
data bus. I f the probl em i s a no-di spl ay condi ti on,
use the fol l owi ng procedures. For compl ete ci rcui t
di agrams, refer to Overhead Console i n Wi ri ng
Di agrams.
fuse.
repai r the open fused B(+) ci rcui t to the fused B(+)
fuse i n the PDC as requi red.
(3) Check the fused i gni ti on swi tch output (run/
start) fuse i n the juncti on bl ock. I f OK, go to Step 4.
I f not OK, repai r the shorted ci rcui t or component as
output (run/start) fuse i n the juncti on bl ock. I f OK,
go to Step 5. I f not OK, repai r the open fused i gni ti on
swi tch output (run/start) ci rcui t to the i gni ti on swi tch
as requi red.
Remove the overhead consol e. Check for conti nui ty
between the ground ci rcui t cavi ty of the roof wi re
harness connector for the EVI C modul e and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
as requi red.
(6) Connect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
roof wi re harness connector for the EVI C modul e. I f
B(+) ci rcui t to the fused B(+) fuse i n the juncti on
bl ock as requi red.
output (run/start) ci rcui t cavi ty of the roof wi re har-
ness connector for the EVI C modul e. I f OK, refer to
Self-Diagnostic Test bel ow for further di agnosi s of
the EVI C modul e and the PCI data bus. I f not OK,
repai r the open fused i gni ti on swi tch output (run/
start) ci rcui t to the fuse i n the juncti on bl ock as
requi red.
SELF-DIAGNOSTIC TEST
A sel f-di agnosti c test i s used to determi ne that the
EVI C modul e i s operati ng properl y, and that al l PCI
data bus messages are bei ng recei ved for i ni ti al oper-
ati on. I ni ti ate the sel f-di agnosti c test as fol l ows:
(1) Wi th the i gni ti on swi tch i n the Off posi ti on,
si mul taneousl y depress and hol d the C/T button and
the Reset button.
(3) Conti nue to hol d both buttons depressed unti l
the EVI C software versi on i nformati on i s di spl ayed,
then rel ease both buttons.
(4) Fol l owi ng compl eti on of these tests, the EVI C
modul e wi l l di spl ay one of the fol l owi ng messages:
a. Pass Self Test - Momentari l y depress and
rel ease the Reset button to return to the compass/
temperature/tri p computer di spl ay mode. The EVI C
modul e i s worki ng properl y.
b. Failed Self Test - The EVI C modul e has an
i nternal fai l ure. The EVI C modul e i s faul ty and must
be repl aced.
c. Not Receiving J 1850 Message - The EVI C
modul e i s not recei vi ng proper message i nput
through the PCI data bus. Thi s can resul t from one
or more faul ty el ectroni c modul es i n the vehi cl e, or
from a faul ty PCI data bus. The use of a DRB scan
are requi red for further di agnosi s.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earths mag-
netic field strength, based on geographic location.
Refer to Compass Variation Adjustment in the Stan-
dard Procedures section of this group.
NOTE: If the compass reading displays a blank, and
only CAL appears in the display, demagnetizing
may be necessary to remove excessive residual
magnetic fields from the vehicle. Refer to Compass
Demagnetizing in the Standard Procedures section
of this group.
STANDARD PROCEDURE - TIRE PRESSURE
SYSTEM TEST
The fol l owi ng test can be used to veri fy two func-
ti ons. One, that the ti re pressure sensors are trans-
mi tti ng properl y and two, the EVI C modul e i s
recei vi ng these transmi ssi ons accordi ngl y.
(1) Retrai n the ti re sensors (Refer to 22 - TI RES/
WHEELS/TI RE PRESSURE MONI TORI NG/SEN-
SOR - STANDARD PROCEDURE). The ti re sensors
must be retrai ned i n order to set the proper trans-
mi tti ng ti me cycl e (twi ce a mi nute), fai l ure to retrai n
the sensors wi l l cause a much sl ower transmi tti ng
ti me cycl e (once a hour).
(2) Usi ng the STEP button on the overhead con-
sol e, scrol l to the bl ank di spl ay, then press the
RESET button for fi ve seconds, a beep wi l l sound
i ndi cati ng the start of thi s test. The vehi cl e i con and
transmi ssi on counters wi l l now be di spl ayed, (same
di spl ay as i ndi vi dual ti re pressure except counters
repl ace ti re pressure val ues).
(3) Upon enteri ng the test mode, the EVI C wi l l
cl ear the sensor counter and each ti me a sensor si g-
nal for a road ti re i s recei ved, the EVI C wi l l update
the counter val ue (vehi cl e must be dri ven at 25 mph
to transmi t). The counter val ues shoul d al l read the
same val ue. I f any of the road ti res i ndi cate a di ffer-
ent val ue than another ti re sensor, thi s i s a si gn of a
probl em. Repl ace the appropri ate ti re sensor and
retest the system. Thi s test wi l l conti nue unti l any of
the overhead consol e buttons are pressed or the i gni -
ti on i s turned off.
NOTE: Pressing the RESET button during the test
will sound a beep and reset all the counter values
back to zero.
REMOVAL
cabl e.
l i ner (Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - REMOVAL).
(3) Remove the four screws that secure the El ec-
troni c Vehi cl e I nformati on Center (EVI C) modul e to
the overhead consol e housi ng (Fi g. 5).
(4) Remove the EVI C modul e from the overhead
consol e housi ng.
INSTALLATION
(1) Posi ti on the EVI C modul e onto the overhead
consol e housi ng.
the EVI C modul e to the overhead consol e housi ng.
(3) I nstal l the overhead consol e onto the headl i ner
(Refer to 8 - ELECTRI CAL/OVERHEAD CONSOLE -
I NSTALLATI ON).
NOTE: If a new EVIC module has been installed, the
compass will have to be calibrated and the variance
set. Refer to Compass Variation Adjustment and
Compass Calibration in the Service Procedures sec-
tion of this group for the procedures.
NOTE: If the vehicle is equipped with the Tire Pres-
sure Monitoring (TPM) System, and the overhead
console electronics module is removed or replaced,
the TPM system will need to be retrained. Refer to
the Tires/Wheels section of this manual for the pro-
cedure.
UNIVERSAL TRANSMITTER
DESCRIPTION
The Grand Cherokee Li mi ted model has a Uni ver-
sal Garage Door Opener (UGDO) transcei ver as stan-
dard factory-i nstal l ed equi pment. The UGDO i s
opti onal on Laredo model s. The UGDO transcei ver i s
i ntegral to the El ectroni c Vehi cl e I nformati on Center
(EVI C), whi ch i s l ocated i n the overhead consol e. The
onl y vi si bl e component of the UGDO are the three
transmi tter push buttons centered between the four
EVI C push buttons l ocated just rearward of the
EVI C di spl ay screen i n the overhead consol e. The
three UGDO transmi tter push buttons are i denti fi ed
wi th one, two or three dots so that they be easi l y
i denti fi ed by si ght.
Each of the three UGDO transmi tter push buttons
control s an i ndependent radi o transmi tter channel .
Each of these three channel s can be trai ned to trans-
mi t a di fferent radi o frequency si gnal for the remote
operati on of garage door openers, motori zed gate
openers, home or offi ce l i ghti ng, securi ty systems or
just about any other devi ce that can be equi pped
wi th a radi o recei ver i n the 288 to 410 MegaHertz
(MHz) frequency range for remote operati on. The
UGDO i s capabl e of operati ng systems usi ng ei ther
rol l i ng code or non-rol l i ng code technol ogy.
The EVI C modul e di spl ays messages and a smal l
house-shaped i con wi th one, two or three dots corre-
spondi ng to the three transmi tter buttons to i ndi cate
the status of the UGDO. The EVI C messages are:
Cleared Channels - I ndi cates that al l of the
transmi tter codes stored i n the UGDO have been suc-
cessful l y cl eared.
Training - I ndi cates that the UGDO i s i n i ts
transmi tter l earni ng mode.
Trained - I ndi cates that the UGDO has success-
ful l y acqui red a new transmi tter code.
Transmit - I ndi cates that a trai ned UGDO
transmi tter button has been depressed and that the
UGDO i s transmi tti ng.
The UGDO cannot be repai red, and i s avai l abl e for
servi ce onl y as a uni t wi th the EVI C modul e. Thi s
uni t i ncl udes the push button swi tches and the pl as-
ti c modul e. I f any of these components are faul ty or
damaged, the compl ete EVI C modul e must be
repl aced.
OPERATION
The uni versal transmi tter operates on a non-
swi tched source of battery current so the uni t wi l l
remai n functi onal , regardl ess of the i gni ti on swi tch
posi ti on. For more i nformati on on the features, pro-
grammi ng procedures and operati on of the uni versal
transmi tter, see the owners manual i n the vehi cl e
gl ove box.
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER
I f the Uni versal Transmi tter i s i noperati ve, but the
El ectroni c Vehi cl e I nformati on Center (EVI C) i s oper-
ati ng normal l y, see the owners manual i n the vehi cl e
gl ove box for i nstructi ons on trai ni ng the Transmi t-
ter. Retrai n the Transmi tter wi th a known good
transmi tter as i nstructed i n the owners manual and
test the Transmi tter operati on agai n. I f the uni t i s
sti l l i noperati ve, repl ace the faul ty Transmi tter and
EVI C modul e as a uni t. I f both the Transmi tter and
the EVI C modul e are i noperati ve, refer to Elec-
tronic Vehicle Information Center Diagnosis
and Testing i n thi s group for further di agnosi s. For
compl ete ci rcui t di agrams, refer to Wiring Dia-
grams.
Fig. 5 Top of Overhead Console
1 - OVERHEAD CONSOLE HOUSING
2 - EVIC MODULE
4 - SCREWS (4)
AMBIENT TEMP SENSOR
DESCRIPTION
Ambi ent ai r temperature i s moni tored by the El ec-
troni c Vehi cl e I nformati on Center (EVI C) through
ambi ent temperature messages recei ved from the
Body Control Modul e (BCM) over the Programmabl e
The BCM recei ves a hard wi red i nput from the ambi -
ent temperature sensor. The ambi ent temperature
sensor i s a vari abl e resi stor mounted to a bracket
that i s secured wi th a screw to the ri ght si de of the
headl amp mounti ng modul e gri l l e openi ng, behi nd
the radi ator gri l l e and i n front of the engi ne compart-
ment.
Refer to Body Control Module i n El ectroni c Con-
trol Modul es. For compl ete ci rcui t di agrams, refer to
the appropri ate wi ri ng i nformati on. The ambi ent
temperature sensor cannot be adjusted or repai red
OPERATION
The ambi ent temperature sensor i s a vari abl e
resi stor that operates on a fi ve-vol t reference si gnal
sent to i t by the BCM. The resi stance i n the sensor
changes as temperature changes, changi ng the tem-
perature sensor si gnal ci rcui t vol tage to the BCM.
Based upon the resi stance i n the sensor, the BCM
senses a speci fi c vol tage on the temperature sensor
si gnal ci rcui t, whi ch i t i s programmed to correspond
to a speci fi c temperature. The BCM then sends the
proper ambi ent temperature messages to the EVI C
over the PCI data bus.
The temperature functi on i s supported by the
ambi ent temperature sensor, a wi ri ng ci rcui t, the
Body Control Modul e (BCM), the Programmabl e
Communi cati ons I nterface (PCI ) data bus, and a por-
ti on of the El ectroni c Vehi cl e I nformati on Center
(EVI C) modul e. I f any porti on of the ambi ent temper-
ature sensor ci rcui t fai l s, the BCM wi l l sel f-di agnose
the ci rcui t. A temperature readi ng of 130 F wi l l
appear i n the EVI C di spl ay i n pl ace of the tempera-
ture when the sensor ci rcui t i s shorted. A tempera-
ture readi ng of 40 F wi l l appear i n the EVI C
di spl ay i n pl ace of the temperature when the sensor
ci rcui t i s open.
The ambi ent temperature sensor ci rcui t can al so be
di agnosed by referri ng to Diagnosis and Testing -
Ambient Temperature Sensor, and Diagnosis
and Testing - Ambient Temperature Sensor Cir-
cuit. I f the temperature sensor and ci rcui t are con-
fi rmed to be OK, but the temperature di spl ay i s
i noperati ve or i ncorrect, refer to Diagnosis and
Testing - Electronic Vehicle Information Center
i n thi s group. For compl ete ci rcui t di agrams, refer to
the appropri ate wi ri ng i nformati on.
TEMPERATURE SENSOR
Di sconnect the ambi ent temperature sensor wi re har-
ness connector.
(2) Measure the resi stance of the ambi ent temper-
ature sensor. At 40 C (40 F), the sensor resi s-
tance i s 336.6 ki l ohms. At 60 C (140 F), the sensor
resi stance i s 2.49 ki l ohms. The sensor resi stance
shoul d read between these two val ues. I f OK, refer to
Diagnosis and Testing - Ambient Temperature
Sensor Circuit i n thi s group. I f not OK, repl ace the
faul ty ambi ent temperature sensor.
TEMPERATURE SENSOR CIRCUIT
Di sconnect the 2-way ambi ent temperature sensor
wi re harness connector and the 22-way Body Control
Modul e (BCM) wi re harness connector.
(2) Connect a jumper wi re between the two termi -
nal s i n the body hal f of the 2-way ambi ent tempera-
ture sensor wi re harness connector.
(3) Check for conti nui ty between the sensor return
ci rcui t and the ambi ent temperature sensor si gnal
ci rcui t cavi ti es of the 22-way BCM wi re harness con-
nector. There shoul d be conti nui ty. I f OK, go to Step
4. I f not OK, repai r the open sensor return ci rcui t or
ambi ent temperature sensor si gnal ci rcui t to the
ambi ent temperature sensor as requi red.
(4) Remove the jumper wi re from the body hal f of
the 2-way ambi ent temperature sensor wi re harness
connector. Check for conti nui ty between the sensor
return ci rcui t cavi ty of the 22-way BCM wi re harness
connector and a good ground. There shoul d be no
shorted sensor return ci rcui t as requi red.
(5) Check for conti nui ty between the ambi ent tem-
perature sensor si gnal ci rcui t cavi ty of the 22-way
BCM wi re harness connector and a good ground.
There shoul d be no conti nui ty. I f OK, refer to Diag-
nosis and Testing - Electronic Vehicle Informa-
tion Center i n thi s group. I f not OK, repai r the
shorted ambi ent temperature sensor si gnal ci rcui t as
requi red.
REMOVAL
cabl e.
(2) Locate the ambi ent temperature sensor, on the
ri ght si de of the radi ator openi ng i n the headl amp
mounti ng modul e, behi nd the gri l l e (Fi g. 6).
(3) Remove the radi ator gri l l e fasci a and i nsert
from the headl amp mounti ng modul e. Refer to Body
for the procedures.
(4) Di sconnect the wi re harness connector from the
ambi ent temperature sensor connector receptacl e.
(5) Remove the one screw that secures the ambi ent
temperature sensor bracket to the headl amp mount-
i ng modul e.
(6) Remove the ambi ent temperature sensor from
the headl amp mounti ng modul e.
INSTALLATION
(1) Posi ti on the ambi ent temperature sensor onto
the headl amp mounti ng modul e.
the ambi ent temperature sensor bracket to the head-
l amp mounti ng modul e. Ti ghten the screw to 2.2 Nm
(20 i n. l bs.).
(3) Reconnect the wi re harness connector to the
ambi ent temperature sensor connector receptacl e.
(4) I nstal l the radi ator gri l l e fasci a and i nsert onto
the headl amp mounti ng modul e. Refer to the Body
secti on of thi s manual for the procedures.
Fig. 6 AMBIENT TEMPERATURE SENSOR
1 - AMBIENT TEMPERATURE SENSOR
3 - HEADLAMP MOUNTING MODULE
AMBIENT TEMP SENSOR (Continued)
POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . 11
POWER SEAT SYSTEM. . . . . . . . . . . . . . . . . . . . . 18
POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . 33
POWER LOCKS
TABLE OF CONTENTS
page page
POWER LOCKS
DESCRIPTION
DESCRIPTION - POWER LOCK SYSTEM . . . . 1
DESCRIPTION - REMOTE KEYLESS ENTRY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - LIFTGATE FLIP-UP GLASS
POWER RELEASE SYSTEM . . . . . . . . . . . . . . 4
OPERATION
OPERATION - POWER LOCK SYSTEM . . . . . . 4
OPERATION - REMOTE KEYLESS ENTRY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION - LIFTGATE FLIP-UP GLASS
POWER RELEASE SYSTEM . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - POWER LOCK
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - LIFTGATE
FLIP-UP GLASS POWER RELEASE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DOOR CYLINDER LOCK SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER LOCK MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
POWER LOCK SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOTE KEYLESS ENTRY MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOTE KEYLESS ENTRY TRANSMITTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
KEYLESS ENTRY TRANSMITTER . . . . . . . . . . 9
STANDARD PROCEDURE
STANDARD PROCEDURE - RKE
TRANSMITTER PROGRAMMING. . . . . . . . . . 10
STANDARD PROCEDURE - RKE
TRANSMITTER BATTERIES. . . . . . . . . . . . . . 10
POWER LOCKS
DESCRIPTION
DESCRIPTION - POWER LOCK SYSTEM
A power operated door and l i ftgate l ock system i s
The power l ock system al l ows al l of the doors and the
l i ftgate to be l ocked or unl ocked el ectri cal l y by oper-
ati ng a swi tch on ei ther front door tri m panel . The
power l ock system recei ves non-swi tched battery feed
through a fuse i n the Power Di stri buti on Center
(PDC), so that the power l ocks remai n operati onal ,
regardl ess of the i gni ti on swi tch posi ti on.
The power l ock system for thi s vehi cl e al so has a
door l ock i nhi bi t feature, whi ch prevents the power
l ock system from bei ng energi zed wi th a power door
l ock swi tch i f a front door i s open wi th the key i n the
i gni ti on. However, the l ocks can sti l l be operated
manual l y, wi th a key, energi zed wi th the RKE trans-
mi tter or by sl i di ng the door l ock l ever to the appro-
pri ate posi ti on.
WJ POWER SYSTEMS 8N - 1
ences. (Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE/ELECTRONI C VEHI CLE I NFO CENTER -
DESCRI PTI ON). Customer programmabl e feature
opti ons affecti ng the power door l ock system i ncl ude:
Auto Door Locks - Automati cal l y l ocks al l of
the vehi cl e doors and the l i ftgate when the vehi cl e
reaches a speed of about 24 ki l ometers-per-hour (15
mi l es-per-hour) wi th 10% throttl e ti p-i n.
Auto Unlock on Exit - Automati cal l y unl ocks
al l of the vehi cl e doors and the l i ftgate when the
dri ver si de front door i s opened, i f the vehi cl e i s
stopped and the transmi ssi on gear sel ector i s i n the
Park or Neutral posi ti ons. Thi s feature i s l i nked to
the Auto Door Locks feature, and wi l l onl y occur one
ti me fol l owi ng each Auto Door Lock event.
The power l ock system for thi s vehi cl e can al so be
operated remotel y usi ng the standard equi pment
Remote Keyl ess Entry (RKE) system radi o frequency
transmi tters. (Refer to 8 - ELECTRI CAL/POWER
LOCKS - DESCRI PTI ON - REMOTE KEYLESS
ENTRY SYSTEM).
The components of the power l ock system i ncl ude:
Driver Door Module (DDM)
Passenger Door Module (PDM)
PCI Bus Messages
Power Lock Motors
Certai n functi ons and features of the power l ock
system rel y upon resources shared wi th other el ec-
troni c modul es i n the vehi cl e over the Programmabl e
The PCI data bus network al l ows the shari ng of sen-
sor i nformati on. Thi s hel ps to reduce wi re harness
compl exi ty, i nternal control l er hardware, and compo-
nent sensor current l oads. At the same ti me, thi s sys-
tem provi des i ncreased rel i abi l i ty, enhanced
ture capabi l i ti es. For proper di agnosi s of these el ec-
troni c modul es or of the PCI data bus network, the
use of a DRBI I I scan tool and the appropri ate di ag-
nosti c i nformati on are requi red.
The other el ectroni c modul es that may affect power
l ock system operati on are as fol l ows:
ULES/BODY CONTROL/CENTRAL TI MER MOD-
ULE - DESCRI PTI ON).
(EVIC) - (Refer to 8 - ELECTRI CAL/OVERHEAD
- DESCRI PTI ON).
Powertrain Control Module (PCM) - (Refer
to 8 - ELECTRI CAL/ELECTRONI C CONTROL
MODULES/POWERTRAI N CONTROL MODULE -
DESCRI PTI ON).
Hard wi red ci rcui try connects the power l ock sys-
tem components to the el ectri cal system of the vehi -
cl e. These hard wi red ci rcui ts are i ntegral to several
wi re harnesses, whi ch are routed throughout the
vehi cl e and retai ned by many di fferent methods.
These ci rcui ts may be connected to each other, to the
vehi cl e el ectri cal system and to the power l ock sys-
tem components through the use of a combi nati on of
sol dered spl i ces, spl i ce bl ock connectors, and many
di fferent types of wi re harness termi nal connectors
and i nsul ators. Refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
DESCRIPTION - REMOTE KEYLESS ENTRY
SYSTEM
A Radi o Frequency (RF) type Remote Keyl ess
Entry (RKE) system i s standard factory-i nstal l ed
equi pment on thi s model . The RKE system al l ows
the use of a remote battery-powered radi o transmi t-
ter to control the power l ock system. The RKE
recei ver operates on non-swi tched battery current
(PDC), so that the system remai ns operati onal ,
regardl ess of the i gni ti on swi tch posi ti on.
I n addi ti on to Lock and Unl ock buttons, the RKE
transmi tters are al so equi pped wi th a Pani c button.
I f the Pani c button on the RKE transmi tter i s
depressed, the horn wi l l sound and the exteri or l i ghts
wi l l fl ash on the vehi cl e for about three mi nutes, or
unti l the Pani c button i s depressed a second ti me, i f
i gni ti on i s i n the Off posi ti on. A vehi cl e speed of
about 24 ki l ometers-per-hour (15 mi l es-per-hour) wi l l
al so cancel the pani c event.
The RKE system can al so perform other functi ons
on thi s vehi cl e. I f the vehi cl e i s equi pped wi th the
opti onal Vehi cl e Theft Securi ty System (VTSS), the
RKE transmi tter wi l l arm the VTSS when the Lock
button i s depressed, and di sarm the VTSS when the
Unl ock button i s depressed. (Refer to 8 - ELECTRI -
CAL/VEHI CLE THEFT SECURI TY - DESCRI PTI ON
- VEHI CLE THEFT SECURI TY SYSTEM). I f the
vehi cl e i s equi pped wi th the opti onal Memory Sys-
tem, each of the two numbered and col or-coded RKE
transmi tters can be used to recal l the stored dri ver
si de front seat posi ti on, both outsi de power rear vi ew
mi rror posi ti ons, and the radi o stati on presets for the
two assi gned dri vers. (Refer to 8 - ELECTRI CAL/
POWER SEATS - DESCRI PTI ON - MEMORY SYS-
TEM).
8N - 2 POWER LOCKS WJ
POWER LOCKS (Continued)
The RKE system i ncl udes two transmi tters when
the vehi cl e i s shi pped from the factory, but the sys-
tem can retai n the vehi cl e access codes of up to four
transmi tters. The transmi tter codes are retai ned i n
the RKE recei ver memory, even i f the battery i s di s-
connected. I f an RKE transmi tter i s faul ty or l ost,
new transmi tter vehi cl e access codes can be pro-
grammed i nto the system usi ng a DRBI I I scan tool
and the appropri ate di agnosti c i nformati on.
ences. (Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE/ELECTRONI C VEHI CLE I NFO CENTER -
DESCRI PTI ON). Customer programmabl e feature
opti ons affecti ng the RKE system i ncl ude:
Remote Unlock - Al l ows the opti on of havi ng
onl y the dri ver si de front door unl ock when the RKE
transmi tter Unl ock button i s depressed the fi rst ti me
and the remai ni ng doors and the l i ftgate unl ock
when the button i s depressed a second ti me, or hav-
i ng al l doors and the l i ftgate unl ock upon the fi rst
depressi on of the RKE transmi tter Unl ock button.
Remote Linked to Memory - I f the vehi cl e i s
equi pped wi th the Memory System, thi s feature
al l ows the opti on of havi ng the RKE transmi tter
Unl ock button acti vate the recal l of the stored set-
ti ngs, or havi ng the recal l functi on assi gned sol el y to
the memory swi tch on the dri ver si de front door tri m
panel .
Sound Horn on Lock - Al l ows the opti on of
havi ng the horn sound a short chi rp as an audi bl e
veri fi cati on that the doors have l ocked, or havi ng no
audi bl e veri fi cati on.
Flash Lights with Lock - Al l ows the opti on of
havi ng the l i ghts fl ash as an opti cal veri fi cati on that
the doors have l ocked, or havi ng no opti cal veri fi ca-
ti on.
RKE system:
RKE Receiver
RKE Transmitter
Certai n functi ons and features of the RKE system
the PCI data bus network, the use of a DRBI I I scan
tool and the appropri ate di agnosti c i nformati on are
requi red.
The other el ectroni c modul es that may affect RKE
ULES/BODY CONTROL/CENTRAL TI MER MOD-
Driver Door Module (DDM) - (Refer to 8 -
ULES/DOOR MODULE - DESCRI PTI ON).
(EVIC) - (Refer to 8 - ELECTRI CAL/OVERHEAD
- DESCRI PTI ON).
Passenger Door Module (PDM) - (Refer to 8 -
Powertrain Control Module (PCM) - (Refer
MODULES/POWERTRAI N CONTROL MODULE -
DESCRI PTI ON).
Hard wi red ci rcui try connects the RKE system
components vi a the PDM to the el ectri cal system of
the vehi cl e. These hard wi red ci rcui ts are i ntegral to
several wi re harnesses, whi ch are routed throughout
the vehi cl e and retai ned by many di fferent methods.
vehi cl e el ectri cal system and to the RKE system com-
ponents through the use of a combi nati on of sol dered
spl i ces, spl i ce bl ock connectors, and many di fferent
types of wi re harness termi nal connectors and i nsu-
l ators. Refer to the appropri ate wi ri ng i nformati on.
proper wi re and connector repai r procedures, further
detai l s on wi re harness routi ng and retenti on, as wel l
as pi n-out and l ocati on vi ews for the vari ous wi re
COMBINATION FLASHER
The combi nati on fl asher i s a smart rel ay that func-
ti ons as both the turn si gnal system and the hazard
warni ng system fl asher. The combi nati on fl asher con-
tai ns acti ve el ectroni c I ntegrated Ci rcui try (I C) el e-
ments. Thi s fl asher can be energi zed by the BCM to
fl ash al l of the park/turn si gnal /front si de marker
l amps as an opti cal al ert for the RKE pani c functi on
and, i f the Fl ash Li ghts wi th Lock programmabl e fea-
ture i s enabl ed, as an opti cal veri fi cati on for the RKE
l ock event. (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/COMBI NATI ON FLASHER
- DESCRI PTI ON).
HORN RELAY
The horn rel ay i s a el ectromechani cal devi ce that
swi tches battery current to the horn when the horn
swi tch grounds the rel ay coi l . The horn rel ay i s
l ocated i n the Power Di stri buti on Center (PDC) i n
WJ POWER LOCKS 8N - 3
the engi ne compartment. Thi s rel ay can be energi zed
by the BCM to sound the horns as an audi bl e al ert
for the RKE pani c functi on and, i f the Sound Horn
on Lock programmabl e feature i s enabl ed, as an
audi bl e veri fi cati on for the RKE l ock event. (Refer to
8 - ELECTRI CAL/HORN/HORN RELAY - DESCRI P-
TI ON).
LOW BEAM HEADLAMP RELAY
The l ow beam headl amp rel ay i s a el ectromechan-
i cal devi ce that swi tches battery current to the head-
l amp l ow beams when the BCM grounds the rel ay
coi l . The l ow beam headl amp rel ay i s l ocated i n the
juncti on bl ock i n the passenger compartment. Thi s
rel ay can be energi zed by the BCM to fl ash the head-
l amp l ow beams as an opti cal al ert for the RKE pani c
functi on. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/HEADLAMP - DESCRI PTI ON).
DESCRIPTION - LIFTGATE FLIP-UP GLASS
POWER RELEASE SYSTEM
A power operated l i ftgate fl i p-up gl ass rel ease sys-
tem i s standard factory i nstal l ed equi pment on thi s
model . The l i ftgate fl i p-up gl ass power rel ease system
al l ows the fl i p-up gl ass l atch to be rel eased el ectri -
cal l y by depressi ng a swi tch l ocated on the bottom of
the l i ftgate l i cense pl ate l amp housi ng uni t, above
the l i cense pl ate on the outsi de of the l i ftgate.
The l i ftgate fl i p-up gl ass rel ease system operates
on non-swi tched battery current suppl i ed through a
fuse i n the juncti on bl ock so that the system remai ns
functi onal , regardl ess of the i gni ti on swi tch posi ti on.
However, a l i mi t swi tch that i s i ntegral to the l i ftgate
l atch actuator uni t opens to prevent the fl i p-up gl ass
l atch from bei ng actuated when the l i ftgate l atch i s
l ocked.
The l i ftgate fl i p-up gl ass power rel ease system
i ncl udes the fol l owi ng components:
Liftgate Flip-Up Glass Limit Switch - The
l i ftgate fl i p-up gl ass l i mi t swi tch i s i ntegral to the
l i ftgate l atch uni t. (Refer to 23 - BODY/DECKLI D/
HATCH/LI FTGATE/TAI LGATE/LATCH - REMOVAL)
and (Refer to 23 - BODY/DECKLI D/HATCH/LI FT-
GATE/TAI LGATE/LATCH - I NSTALLATI ON).
Liftgate Flip-Up Glass Release Motor - The
l i ftgate fl i p-up gl ass rel ease motor i s i ntegral to the
l i ftgate fl i p-up gl ass l atch uni t. (Refer to 23 - BODY/
DECKLI D/HATCH/LI FTGATE/TAI LGATE/FLI P-UP
GLASS LATCH - REMOVAL) and (Refer to 23 -
BODY/DECKLI D/HATCH/LI FTGATE/TAI LGATE/
FLI P-UP GLASS LATCH - I NSTALLATI ON).
Liftgate Flip-Up Glass Release Switch - The
l i ftgate fl i p-up gl ass rel ease swi tch i s i ntegral to the
l i ftgate l i cense pl ate l amp housi ng. (Refer to 23 -
BODY/DECKLI D/HATCH/LI FTGATE/TAI LGATE/
FLI P-UP GLASS SWI TCH - REMOVAL) and (Refer
to 23 - BODY/DECKLI D/HATCH/LI FTGATE/TAI L-
GATE/FLI P-UP GLASS SWI TCH - I NSTALLATI ON).
Hard wi red ci rcui try connects the l i ftgate fl i p-up
gl ass power rel ease system components to the el ectri -
cal system of the vehi cl e. These hard wi red ci rcui ts
are i ntegral to several wi re harnesses, whi ch are
routed throughout the vehi cl e and retai ned by many
di fferent methods. These ci rcui ts may be connected to
each other, to the vehi cl e el ectri cal system and to the
l i ftgate fl i p-up gl ass power rel ease system compo-
nents through the use of a combi nati on of sol dered
OPERATION
OPERATION - POWER LOCK SYSTEM
The Passenger Door Modul e (PDM) contai ns the
power door l ock control l ogi c and a power l ock swi tch.
The Dri ver Door Modul e (DDM) contai ns a power
l ock swi tch and control s the output to the dri ver si de
front door power l ock motor, whi l e the PDM control s
the output to the power l ock motors for the remai n-
i ng doors and the l i ftgate.
When the power l ock swi tch on the DDM i s used to
l ock or unl ock the doors, the DDM sends a control
output to the dri ver si de front door power l ock motor
and sends l ock or unl ock request messages to the
PDM over the Programmabl e Communi cati ons I nter-
face (PCI ) data bus. The PDM responds to these mes-
sages by sendi ng control outputs to the power l ock
motors of the remai ni ng doors and the l i ftgate. When
the power l ock swi tch on the PDM i s used to l ock or
unl ock the doors, the PDM sends control outputs to
the power l ock motors i n the passenger si de front
door, both rear doors and the l i ftgate, then sends l ock
or unl ock request messages to the DDM over the Pro-
bus. The DDM responds to these messages by send-
i ng control outputs to the power l ock motor of the
dri ver si de front door.
I n order to support the auto door l ocks and unl ock
on exi t features, i f enabl ed, the power l ock system
l ogi c i n the PDM needs to know the door ajar swi tch
status, vehi cl e speed, and transmi ssi on gear sel ector
l ever posi ti on. The passenger si de front door ajar
swi tch i s the onl y hard wi red i nput to the PDM. The
PDM obtai ns the remai ni ng i nformati on from mes-
sages i t recei ves from other el ectroni c modul es over
the PCI data bus network.
of the power l ock system.
OPERATION - REMOTE KEYLESS ENTRY
SYSTEM
The Passenger Door Modul e (PDM) contai ns the
RKE system control l ogi c and the RKE recei ver.
When the RKE recei ver recogni zes a Lock, Unl ock or
Pani c message from a val i d RKE transmi tter, the
RKE recei ver provi des that i nput to the PDM. The
PDM ci rcui try and programmi ng responds by sendi ng
the proper messages to the other el ectroni c modul es
(PCI ) data bus.
When an RKE l ock message i s recei ved, the doors
and the l i ftgate l ock, the i nteri or l i ghti ng fades to off,
the horn chi rps (i f thi s feature i s enabl ed), the exte-
ri or l amps fl ash (i f thi s feature i s enabl ed) and, i f the
vehi cl e i s so equi pped, the Vehi cl e Theft Securi ty
System (VTSS) i s armed. When an RKE unl ock mes-
sage i s recei ved, the dri ver si de front door (or al l
doors and the l i ftgate i f thi s feature i s enabl ed)
unl ock, the i nteri or l i ghti ng i s turned on and, i f the
vehi cl e i s so equi pped, the VTSS i s di sarmed. I f the
vehi cl e i s equi pped wi th the Memory System and the
RKE Li nked to Memory feature i s enabl ed, the RKE
unl ock message al so recal l s the dri ver seat, outsi de
mi rror and radi o setti ngs assi gned to the RKE trans-
mi tter that sent the unl ock si gnal .
When an RKE pani c message i s recei ved, i t causes
the exteri or l amps (i ncl udi ng the headl i ghts) to fl ash,
and the horn to pul se for about three mi nutes, or
unti l a second pani c message i s recei ved. A vehi cl e
speed of about 24 ki l ometers-per-hour (15 mi l es-per-
hour) wi l l al so cancel the pani c event.
of the RKE system.
OPERATION - LIFTGATE FLIP-UP GLASS
POWER RELEASE SYSTEM
When the l i ftgate mounted fl i p-up gl ass rel ease
swi tch i s depressed, battery current i s di rected to the
el ectri c rel ease motor that i s i ntegral to the fl i p-up
gl ass l atch l ocated i nsi de the l i ftgate. When the
rel ease motor i s energi zed the l atch rel eases and the
fl i p-up gl ass can be opened. A l i ftgate fl i p-up gl ass
l i mi t swi tch i s i ntegral to the l i ftgate l atch actuator
mechani sm. The l i mi t swi tch automati cal l y enabl es
or di sabl es the l i ftgate fl i p-up gl ass power rel ease ci r-
cui try, dependi ng upon the posi ti on of the l i ftgate
l atch l ock mechani sm. When the l i ftgate l atch i s
unl ocked, the l i mi t swi tch cl oses and battery current
i s avai l abl e at the rel ease swi tch. When the l i ftgate
l atch i s l ocked , the l i mi t swi tch opens, and the
rel ease swi tch i s di sabl ed.
of the l i ftgate fl i p-up gl ass power rel ease system.
SYSTEM
hard wi red components and ci rcui ts of the power l ock
system. However, these tests may not prove concl u-
si ve i n the di agnosi s of thi s system. I n order to
obtai n concl usi ve testi ng of the power l ock system,
data bus network and al l of the el ectroni c modul es
power l ock system components must be checked.
di agnose the power l ock system requi res the use of a
DRBI I I scan tool and the proper Di agnosti c Proce-
dures manual . The DRBI I I scan tool can provi de
confi rmati on that the PCI data bus i s functi onal , that
al l of the el ectroni c modul es are sendi ng and recei v-
i ng the proper messages on the PCI data bus, and
that the power l ock motors are bei ng sent the proper
hard wi red outputs by the door modul es for them to
perform thei r power l ock system functi ons.
As a prel i mi nary di agnosi s for the power l ock sys-
tem, note the system operati on whi l e you actuate
both the Lock and Unl ock functi ons wi th the power
l ock swi tches and wi th the Remote Keyl ess Entry
(RKE) transmi tter. Then, proceed as fol l ows:
I f the enti re power l ock system fai l s to functi on
wi th ei ther the power l ock swi tches or the RKE
transmi tter, check the fused B(+) fuse i n the Power
Di stri buti on Center. I f the fuse i s OK, proceed to
di agnosi s of the door modul es. (Refer to 8 - ELEC-
TRI CAL/ELECTRONI C CONTROL MODULES/
DOOR MODULE - DI AGNOSI S AND TESTI NG).
I f the power l ock system functi ons wi th both
power l ock swi tches, but not wi th the RKE transmi t-
ter, proceed to di agnosi s of the Remote Keyl ess Entry
(RKE) system. (Refer to 8 - ELECTRI CAL/POWER
LOCKS - DI AGNOSI S AND TESTI NG - REMOTE
KEYLESS ENTRY SYSTEM).
I f the power l ock system functi ons wi th the RKE
transmi tter, but not wi th one or both power l ock
swi tches, proceed to di agnosi s of the door modul es.
(Refer to 8 - ELECTRI CAL/ELECTRONI C CON-
TROL MODULES/DOOR MODULE - DI AGNOSI S
AND TESTI NG).
I f the dri ver si de power l ock swi tch operates
onl y the dri ver si de front door power l ock motor, but
al l other power l ock motors operate wi th the passen-
ger si de power l ock swi tch or the RKE transmi tter,
use a DRBI I I scan tool and the appropri ate di agnos-
ti c i nformati on to di agnose the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus.
I f onl y one power l ock motor fai l s to operate
wi th both power l ock swi tches and the RKE trans-
mi tter, proceed to di agnosi s of the power l ock motor.
(Refer to 8 - ELECTRI CAL/POWER LOCKS/POWER
LOCK MOTOR - DI AGNOSI S AND TESTI NG).
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY SYSTEM
Remote Keyl ess Entry (RKE) system. However, these
tests may not prove concl usi ve i n the di agnosi s of
thi s system. I n order to obtai n concl usi ve testi ng of
the RKE system, the Programmabl e Communi cati ons
I nterface (PCI ) data bus network and al l of the el ec-
troni c modul es that provi de i nputs to, or recei ve out-
puts from the RKE system components must be
checked.
di agnose the RKE system requi res the use of a
DRBI I I scan tool and the appropri ate di agnosti c
i nformati on. The DRBI I I scan tool can provi de con-
fi rmati on that the PCI data bus i s functi onal , that al l
of the el ectroni c modul es are sendi ng and recei vi ng
the proper messages on the PCI data bus, and that
the RKE recei ver i s bei ng sent the proper radi o fre-
quency si gnal s by the RKE transmi tters to perform
i ts RKE system functi ons.
As a prel i mi nary di agnosi s for the RKE system,
note the system operati on whi l e you perform both the
Lock and Unl ock functi ons wi th the power l ock
swi tches and wi th the Remote Keyl ess Entry (RKE)
transmi tter. Then, proceed as fol l ows:
I f the enti re power l ock system fai l s to functi on
wi th ei ther the power l ock swi tches or the RKE
transmi tter, check the fused B(+) fuse i n the Power
Di stri buti on Center. I f the fuse i s OK, proceed to the
di agnosi s for the door modul es. (Refer to 8 - ELEC-
DOOR MODULE - DI AGNOSI S AND TESTI NG).
I f the power l ock system functi ons wi th both
power l ock swi tches, but not wi th the RKE transmi t-
ter, proceed to the di agnosi s for the RKE transmi tter.
(Refer to 8 - ELECTRI CAL/POWER LOCKS/RE-
MOTE KEYLESS ENTRY TRANSMI TTER - DI AG-
NOSI S AND TESTI NG).
I f the dri ver si de power l ock swi tch operates
onl y the dri ver si de front door power l ock motor, but
al l other power l ock motors operate wi th the passen-
ger si de power l ock swi tch or the RKE transmi tter,
use a DRBI I I scan tool and the appropri ate di agnos-
ti c i nformati on to di agnose the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus.
I f the probl em bei ng di agnosed i nvol ves onl y the
Sound Horn on Lock or the Fl ash Li ghts wi th Locks
features, be certai n that these programmabl e fea-
tures are enabl ed. I f the features are enabl ed and the
servi ce horn and turn si gnal s sti l l operate, the Body
Control Modul e (BCM) and the PCI data bus must be
tested. For di agnosi s of the BCM or the PCI data
bus, the use of a DRBI I I scan tool and the appropri -
ate di agnosti c i nformati on are requi red.
DIAGNOSIS AND TESTING - LIFTGATE FLIP-UP
GLASS POWER RELEASE SYSTEM
(1) Check the fused B(+) fuse i n the Juncti on
Bl ock (JB). I f OK, go to Step 2. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
i n the JB. I f OK, go to Step 3. I f not OK, repai r the
Center (PDC) as requi red.
(3) Di sconnect the l i ftgate wi re harness connector
for the l i ftgate l ock motor and fl i p-up gl ass l i mi t
swi tch from the motor and swi tch connector recepta-
cl e. Check for battery vol tage at the fused B(+) ci r-
cui t cavi ty of the l i ftgate wi re harness connector for
the l i ftgate l ock motor and fl i p-up gl ass l i mi t swi tch.
I f OK, go to Step 4. I f not OK, repai r the open fused
B(+) ci rcui t between the l i ftgate l ock motor and
fl i p-up gl ass l i mi t swi tch and the JB as requi red.
(4) Check for conti nui ty between the two l i ftgate
fl i p-up gl ass l i mi t swi tch termi nal s. There shoul d be
conti nui ty wi th the l i ftgate l atch unl ocked, and no
conti nui ty wi th the l atch l ocked. I f OK, go to Step 5.
I f not OK, repl ace the faul ty l i ftgate l atch actuator
(brai npl ate) uni t.
for the l i ftgate fl i p-up gl ass rel ease swi tch from the
swi tch connector receptacl e. Wi th the l i ftgate l atch
unl ocked, check for battery vol tage at the l i ftgate
fl i p-up gl ass l i mi t swi tch output ci rcui t cavi ty of the
l i ftgate wi re harness connector for the rel ease swi tch.
I f OK, go to Step 6. I f not OK, repai r the open l i ft-
gate fl i p-up gl ass l i mi t swi tch output ci rcui t between
the rel ease swi tch and the l i mi t swi tch as requi red.
(6) Check for conti nui ty between the two termi nal s
of the l i ftgate fl i p-up gl ass rel ease swi tch. There
shoul d be no conti nui ty. Depress the swi tch, there
shoul d now be conti nui ty. I f OK, go to Step 7. I f not
OK, repl ace the faul ty l i ftgate fl i p-up gl ass rel ease
swi tch.
for the l i ftgate fl i p-up gl ass l atch motor from the
motor connector receptacl e. Check for conti nui ty
between the ground ci rcui t cavi ty of the l i ftgate wi re
harness connector for the l atch motor and a good
as requi red.
(8) Wi th the l i ftgate l atch unl ocked and the fl i p-up
gl ass rel ease swi tch depressed, check for battery vol t-
age at the l i ftgate fl i p-up gl ass rel ease swi tch output
ci rcui t cavi ty of the l i ftgate wi re harness connector
for the l atch motor. I f OK, repl ace the faul ty l i ftgate
fl i p-up gl ass l atch uni t. I f not OK, repai r the open
l i ftgate fl i p-up gl ass rel ease swi tch output ci rcui t
between the l atch motor and the rel ease swi tch as
requi red.
DOOR CYLINDER LOCK
SWITCH
DESCRIPTION
The dri ver cyl i nder l ock swi tch i s i ntegral to the
key l ock cyl i nder i nsi de the dri ver si de front door.
The dri ver cyl i nder l ock swi tch i s a resi sti ve mul ti -
pl exed swi tch that i s hard wi red between a body
ground and the Dri ver Door Modul e (DDM) through
the front door wi re harness. I t mai ntai ns a path to
ground, and changes vol tages through an i nternal
resi stor when the l ock cyl i nder i s rotated to the l ock
or unl ock posi ti on.
The dri ver cyl i nder l ock swi tch cannot be adjusted
or repai red and, i f faul ty or damaged, the dri ver si de
front door l ock cyl i nder uni t must be repl aced. (Refer
to 23 - BODY/DOOR - FRONT/LOCK CYLI NDER -
REMOVAL) and (Refer to 23 - BODY/DOOR -
FRONT/LOCK CYLI NDER - I NSTALLATI ON). Refer
and connector repai r procedures, further detai l s on
wi re harness routi ng and retenti on, as wel l as pi n-
out and l ocati on vi ews for the vari ous wi re harness
connectors, spl i ces and grounds.
OPERATION
The dri ver cyl i nder l ock swi tch i s actuated by the
key l ock cyl i nder when the key i s i nserted i n the l ock
cyl i nder and turned to the unl ock posi ti on. The
dri ver cyl i nder l ock swi tch mai ntai ns a path to
ground and changes vol tages through an i nternal
resi stor for the DDM when the dri ver door key l ock
cyl i nder i s i n the l ock or unl ock posi ti on. The DDM
reads the swi tch status through an i nternal pul l -up,
then sends the proper swi tch status messages to
other el ectroni c modul es over the Programmabl e
The dri ver cyl i nder l ock swi tch unl ock status mes-
sage i s used by the BCM as an i nput for Vehi cl e
Theft Securi ty System (VTSS) operati on and i nteri or
l i ghti ng.
POWER LOCK MOTOR
DESCRIPTION
Power operated front door, rear door, and l i ftgate
l ocki ng mechani sms are standard equi pment on thi s
model . The l ock mechani sms are actuated by a
reversi bl e el ectri c motor mounted wi thi n each door
and the l i ftgate. The power l ock motors for the doors
are i ntegral to the door l atch uni ts. The l i ftgate
power l ock motor i s a separate uni t secured to the
l atch brai npl ate near the center of the l i ftgate and
operates the l i ftgate l atch l ock mechani sm through a
connecti ng l i nkage rod.
The power l ock motors for the four doors cannot be
enti re door l atch uni t must be repl aced. The l i ftgate
power l ock motor cannot be adjusted or repai red and,
i f faul ty or damaged, the enti re l i ftgate l atch actua-
tor (brai npl ate) uni t must be repl aced.
OPERATION
The dri ver si de front door power l ock motor i s con-
trol l ed by the Dri ver Door Modul e (DDM). The
remai ni ng power door l ock motors and the l i ftgate
power l ock motor are control l ed by the Passenger
Door Modul e (PDM). A posi ti ve and negati ve battery
connecti on to the two motor termi nal s wi l l cause the
power l ock motor pl unger to move i n one di recti on.
Reversi ng the current through these same two con-
necti ons wi l l cause the power l ock motor pl unger to
move i n the opposi te di recti on.
MOTOR
Remember, the Dri ver Door Modul e (DDM) ci r-
cui try control s the output to the dri ver si de front
door power l ock motor. The Passenger Door Modul e
(PDM) ci rcui try control s the output to the power l ock
motors for the remai ni ng doors and the l i ftgate.
Refer to the appropri ate wi ri ng i nformati on. The wi r-
i ng i nformati on i ncl udes wi ri ng di agrams, proper
(1) Check each power l ock motor for correct opera-
ti on whi l e movi ng the power l ock swi tch to both the
Lock and Unl ock posi ti ons. I f al l of the power l ock
motors are i noperati ve, go to Step 2. I f one power
l ock motor i s i noperati ve, go to Step 3.
(2) I f al l of the power l ock motors except the dri ver
si de front door are i noperati ve, the probl em may be
caused by one shorted motor. Di sconnecti ng a shorted
power l ock motor from the power l ock ci rcui t wi l l
al l ow the good power l ock motors to operate. Di scon-
nect the wi re harness connector from each PDM-con-
trol l ed power l ock motor, one at a ti me, and recheck
both the l ock and unl ock functi ons by operati ng the
power l ock swi tch. I f al l of the PDM-control l ed power
l ock motors are sti l l i noperati ve after the above test,
check for a short or open ci rcui t between the power
l ock motors and the PDM. I f di sconnecti ng one power
l ock motor causes the other motors to become func-
ti onal , go to Step 3 to test the power l ock motor that
was l ast di sconnected.
(3) Once i t i s determi ned whi ch power l ock motor
i s i noperati ve, that motor can be tested as fol l ows.
Di sconnect the door or l i ftgate wi re harness connec-
tor from the i noperati ve power l ock motor. Appl y 12
vol ts to the l ock and unl ock dri ver ci rcui t cavi ti es of
the power l ock motor connector to check i ts operati on
i n one di recti on. Reverse the pol ari ty to check the
motor operati on i n the opposi te di recti on. I f OK,
repai r the shorted or open ci rcui ts between the l ock
motor and the DDM or PDM as requi red. I f not OK,
repl ace the faul ty power l ock motor.
POWER LOCK SWITCH
DESCRIPTION
The power l ock motors are control l ed by a two-way
momentary swi tch mounted on the tri m panel of each
front door. Each power l ock swi tch i s i l l umi nated by
a Li ght-Emi tti ng Di ode (LED) that i s i ntegral to the
swi tch paddl e.
The dri ver si de front door power l ock swi tch i s
i ntegral to the Dri ver Door Modul e (DDM), and the
passenger si de front door power l ock swi tch i s i nte-
gral to the Passenger Door Modul e (PDM). The
power l ock swi tches and thei r l amps cannot be
enti re DDM or PDM uni t must be repl aced. (Refer to
8 - ELECTRI CAL/ELECTRONI C CONTROL MOD-
OPERATION
The front door power l ock swi tches provi de a l ock
and unl ock si gnal to the door modul e ci rcui try. The
Dri ver Door Modul e (DDM) ci rcui try control s the out-
put to the dri ver si de front door power l ock motor,
whi l e the Passenger Door Modul e (PDM) ci rcui try
control s the output to the passenger si de front door,
both rear door and the l i ftgate power l ock motors.
When the DDM-i ntegrated power l ock swi tch i s
actuated, the DDM ci rcui try sends control outputs to
the dri ver si de front door power l ock motor and sends
a message to the PDM over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus to control the
output to the passenger si de front door, both rear
door and the l i ftgate power l ock motors. When the
PDM-i ntegrated power l ock swi tch i s actuated, the
PDM ci rcui try sends control outputs to the passenger
si de front door, both rear door and the l i ftgate power
l ock motors and sends a message to the DDM over
data bus to control the output to the dri ver si de front
door power l ock motor.
Each power l ock swi tch i s i l l umi nated by a Li ght-
Emi tti ng Di ode (LED) when the i gni ti on swi tch i s
turned to the On posi ti on. See the owners manual i n
the vehi cl e gl ove box for more i nformati on on the fea-
tures, use and operati on of the power l ock swi tches.
POWER LOCK MOTOR (Continued)
REMOTE KEYLESS ENTRY
MODULE
DESCRIPTION
The Remote Keyl ess Entry (RKE) recei ver i s a
radi o frequency uni t contai ned wi thi n the Passenger
Door Modul e (PDM). The PDM al so contai ns the pro-
gram l ogi c ci rcui try for the RKE system. The PDM i s
secured wi th screws to the back of the tri m panel
i nsi de the passenger si de front door. The RKE
recei ver has a memory functi on to retai n the vehi cl e
access codes of up to four RKE transmi tters. The
recei ver i s desi gned to retai n the transmi tter codes i n
memory, even i f the battery i s di sconnected.
For di agnosi s of the RKE recei ver, the PDM, or the
bus a DRBI I I scan tool and the appropri ate di agnos-
ti c i nformati on are requi red. The RKE recei ver i s
onl y servi ced as a uni t wi th the PDM and, i f faul ty
or damaged, the enti re PDM uni t must be repl aced.
(Refer to 8 - ELECTRI CAL/ELECTRONI C CON-
TROL MODULES/DOOR MODULE - DESCRI P-
TI ON).
OPERATION
The RKE recei ver i s energi zed by one of three mes-
sages from the RKE transmi tter: Unl ock, Lock, or
Pani c. The PDM ci rcui try responds to these messages
to l ock or unl ock the power l ock motors that i t con-
trol s. The PDM ci rcui try al so sends Lock, Unl ock,
and Pani c messages to other el ectroni c modul es over
data bus. These messages wi l l resul t i n the Dri ver
Door Modul e (DDM) l ocki ng or unl ocki ng the dri ver
si de front door, and the other el ectroni c modul es i n
the vehi cl e respondi ng as thei r programmi ng di c-
tates.
REMOTE KEYLESS ENTRY
TRANSMITTER
DESCRIPTION
The Remote Keyl ess Entry (RKE) system Radi o
Frequency (RF) transmi tter i s equi pped wi th three
buttons, l abel ed Lock, Unl ock, and Pani c. I t i s al so
equi pped wi th a key ri ng and i s desi gned to serve as
a key fob. The operati ng range of the transmi tter
radi o si gnal i s up to 10 meters (30 feet) from the
RKE recei ver.
Each RKE transmi tter has a di fferent vehi cl e
access code, whi ch must be programmed i nto the
memory of the RKE recei ver i n the vehi cl e i n order
to operate the RKE system. Two transmi tters are
provi ded wi th the vehi cl e, but the RKE recei ver can
retai n the access codes of up to four transmi tters i n
i ts memory. (Refer to 8 - ELECTRI CAL/POWER
LOCKS/REMOTE KEYLESS ENTRY TRANSMI T-
TER - STANDARD PROCEDURE - RKE TRANS-
MI TTER PROGRAMMI NG).
I n addi ti on, the RKE transmi tters for vehi cl es
equi pped wi th the opti onal Memory System are col or-
coded and have a number 1 or 2 mol ded i nto the
transmi tter case to coi nci de wi th the Dri ver 1
(Bl ack) and Dri ver 2 (Gray) buttons of the memory
swi tch on the dri ver si de front door tri m panel . These
transmi tters must al so have thei r access codes pro-
grammed i nto the RKE recei ver so that they coi nci de
wi th the Dri ver 1 and Dri ver 2 buttons of the
memory swi tch. (Refer to 8 - ELECTRI CAL/POWER
SEATS - DESCRI PTI ON - MEMORY SYSTEM).
The RKE transmi tter operates on two Panasoni c
CR2016 (or equi val ent) batteri es. Typi cal battery l i fe
i s from one to two years. The RKE transmi tter can-
not be repai red and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
of the Remote Keyl ess Entry (RKE) transmi tters.
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY TRANSMITTER
(1) Repl ace the Remote Keyl ess Entry (RKE)
transmi tter batteri es. (Refer to 8 - ELECTRI CAL/
POWER LOCKS/REMOTE KEYLESS ENTRY
TRANSMI TTER - STANDARD PROCEDURE - RKE
TRANSMI TTER BATTERI ES). Test each of the RKE
transmi tter functi ons. I f OK, di scard the faul ty bat-
teri es. I f not OK, go to Step 2.
(2) Program the suspect RKE transmi tter and
another known good transmi tter i nto the RKE
recei ver. Use a DRBI I I scan tool , as descri bed i n the
appropri ate di agnosti c i nformati on. (Refer to 8 -
ELECTRI CAL/POWER LOCKS/REMOTE KEYLESS
ENTRY TRANSMI TTER - STANDARD PROCE-
DURE - RKE TRANSMI TTER PROGRAMMI NG).
(3) Test the RKE system operati on wi th both
transmi tters. I f both transmi tters fai l to operate the
power l ock system, use a DRBI I I scan tool and the
appropri ate di agnosti c i nformati on for further di ag-
nosi s of the RKE system. I f the known good RKE
transmi tter operates the power l ocks and the suspect
transmi tter does not, repl ace the faul ty RKE trans-
mi tter.
NOTE: Be certain to perform the RKE Transmitter
Programming procedure again following this test.
This procedure will erase the access code of the
test transmitter from the RKE receiver.
STANDARD PROCEDURE
STANDARD PROCEDURE - RKE TRANSMITTER
PROGRAMMING
To program the Remote Keyl ess Entry (RKE)
transmi tter access codes i nto the RKE recei ver i n the
Passenger Door Modul e (PDM) requi res the use of a
ti c i nformati on.
STANDARD PROCEDURE - RKE TRANSMITTER
BATTERIES
The Remote Keyl ess Entry (RKE) transmi tter case
snaps open and shut for battery access. To repl ace
the RKE transmi tter batteri es:
(1) Usi ng a tri m sti ck or a thi n coi n, gentl y pry at
the notch i n the center seam of the RKE transmi tter
case hal ves near the key ri ng unti l the two hal ves
unsnap.
(2) Li ft the back hal f of the transmi tter case off of
the RKE transmi tter.
(3) Remove the two batteri es from the RKE trans-
mi tter.
(4) Repl ace the two batteri es wi th new Panasoni c
CR2016, or thei r equi val ent. Be certai n that the bat-
teri es are i nstal l ed wi th thei r pol ari ty correctl y ori -
ented.
(5) Al i gn the two RKE transmi tter case hal ves
wi th each other, and squeeze them fi rml y and evenl y
together unti l they snap back i nto pl ace.
NOTE: The RKE system for this model uses a roll-
ing code security strategy. This strategy requires
that synchronization be maintained between the
RKE transmitter and the RKE receiver. RKE trans-
mitter battery removal or replacement can cause a
loss of synchronization. If the RKE receiver fails to
respond to the RKE transmitter following battery
removal or replacement, depress and release the
RKE transmitter Unlock button repeatedly while lis-
tening carefully for the power door locks in the
vehicle to cycle. After between five and eight
presses of the Unlock button, the power door locks
should cycle, indicating that re-synchronization has
occurred.
REMOTE KEYLESS ENTRY TRANSMITTER (Continued)
POWER MIRRORS
TABLE OF CONTENTS
page page
POWER MIRRORS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - POWER
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AUTOMATIC DAY/NIGHT MIRROR
DESCRIPTION
DESCRIPTION - REAR VIEW MIRROR . . . . . 12
DESCRIPTION - OUTSIDE REAR VIEW
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION
OPERATION - REAR VIEW MIRROR . . . . . . . 13
OPERATION - OUTSIDE REAR VIEW
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - AUTOMATIC DAY
/ NIGHT MIRROR . . . . . . . . . . . . . . . . . . . . . . 13
POWER FOLD-AWAY MIRROR - EXPORT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FOLD-AWAY MIRROR - EXPORT . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
POWER MIRROR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SIDEVIEW MIRROR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - SIDEVIEW
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
POWER MIRRORS
DESCRIPTION
Dri ver and passenger si de power operated outsi de
rear vi ew mi rrors are standard factory-i nstal l ed
equi pment on thi s model . The power mi rror system
al l ows the dri ver to adjust both outsi de mi rrors el ec-
tri cal l y from the dri ver seat posi ti on by operati ng a
swi tch on the dri ver si de front door tri m panel . The
power mi rror system recei ves non-swi tched battery
current through a fuse i n the Power Di stri buti on
Center (PDC) so that the power mi rrors remai n oper-
ati onal , regardl ess of the i gni ti on swi tch posi ti on.
The standard equi pment power operated outsi de
rear vi ew mi rrors are al so equi pped wi th the heated
mi rror system, whi ch wi l l onl y operate when the
i gni ti on swi tch i s i n the On posi ti on and the rear
wi ndow defogger swi tch i s turned on. When the rear
wi ndow defogger swi tch i s i n the On posi ti on, el ectri c
heater gri ds on the rear wi ndow gl ass and behi nd
both outsi de rear vi ew mi rror gl asses are energi zed.
These el ectri c heater gri ds produce heat to hel p cl ear
the rear wi ndow gl ass and outsi de rear vi ew mi rrors
of i ce, snow, or fog. (Refer to 8 - ELECTRI CAL/
HEATED MI RRORS - DESCRI PTI ON) for more
i nformati on on thi s feature.
A dri ver si de automati c di mmi ng outsi de mi rror
that di ms the mi rror to reduce the gl are of bri ght
l i ghts approachi ng the vehi cl e from behi nd, and a
memory system that automati cal l y posi ti ons the
power mi rrors for two di fferent dri vers are opti onal
factory-i nstal l ed equi pment on thi s model . (Refer to 8
- ELECTRI CAL/POWER MI RRORS/AUTOMATI C
DAY / NI GHT MI RROR - DESCRI PTI ON) for more
i nformati on. (Refer to 8 - ELECTRI CAL/POWER
SEATS - DESCRI PTI ON) for more i nformati on.
power mi rror system:
Power mi rrors
Power mi rror swi tch.
Certai n functi ons and features of the power mi rror
system rel y upon resources shared wi th other el ec-
troni c modul es i n the vehi cl e over the Programmabl e
The PCI data bus network al l ows the shari ng of sen-
sor i nformati on. Thi s hel ps to reduce wi re harness
compl exi ty, i nternal control l er hardware, and compo-
nent sensor current l oads. At the same ti me, thi s sys-
tem provi des i ncreased rel i abi l i ty, enhanced
modul es or of the PCI data bus network, the use of a
manual are recommended.
mi rror system operati on are as fol l ows:
Body Control Module (BCM) (Refer to 8 -
Driver Door Module (DDM) (Refer to 8 -
WJ POWER MIRRORS 8N - 11
Passenger Door Module (PDM)(Refer to 8 -
OPERATION
The Dri ver Door Modul e (DDM) and the Passenger
Door Modul e (PDM) each contai n the power mi rror
control l ogi c for the mi rror on i ts respecti ve door. The
DDM al so houses the power mi rror swi tch. Each door
modul e control s the posi ti oni ng of i ts respecti ve out-
si de mi rror through hard wi red outputs to that mi r-
ror. When the power mi rror swi tch on the DDM i s
used to posi ti on the passenger si de outsi de mi rror,
the DDM sends mi rror posi ti oni ng messages to the
PDM over the Programmabl e Communi cati ons I nter-
face (PCI ) data bus. The PDM responds to these mes-
sages by sendi ng control outputs to move the
passenger si de mi rror accordi ngl y.
Both the PDM and DDM respond to the defogger
swi tch status messages sent by the Body Control
Modul e (BCM) over the PCI data bus to control the
el ectri c heater gri ds of thei r respecti ve mi rrors.
(Refer to 8 - ELECTRI CAL/HEATED MI RRORS -
DESCRI PTI ON) for more i nformati on on thi s fea-
ture.
On model s equi pped wi th the opti onal memory sys-
tem, each door modul e al so recei ves a hard wi red
i nput from the two power mi rror motor posi ti on
potenti ometers that are i ntegral to each power mi r-
ror. Each door modul e then stores the Dri ver 1 and
Dri ver 2 mi rror posi ti on i nformati on for i ts respecti ve
mi rror. When the DDM recei ves a Dri ver 1 or Dri ver
2 memory recal l message from the memory swi tch on
the dri ver si de front door tri m panel or from the
Remote Keyl ess Entry (RKE) recei ver i n the PDM,
the DDM posi ti ons the dri ver si de mi rror and sends
a memory recal l message back to the PDM over the
PCI data bus to posi ti on the passenger si de mi rror.
of the power mi rror system.
DIAGNOSIS AND TESTING - POWER MIRRORS
hard wi red components and ci rcui ts of the power mi r-
ror system. However, these tests may not prove con-
cl usi ve i n the di agnosi s of thi s system. I n order to
obtai n concl usi ve testi ng of the power mi rror system,
data bus network and al l of the el ectroni c modul es
power mi rror system components must be checked.
di agnose the power mi rror system requi res the use of
a DRB scan tool and the proper Di agnosti c Proce-
dures manual . The DRB scan tool can provi de confi r-
mati on that the PCI data bus i s functi onal , that al l
the proper messages on the PCI data bus, that the
power mi rror motors are bei ng sent the proper hard
wi red outputs, and that the mi rror posi ti on potenti -
ometers are returni ng the proper outputs to the door
modul es for them to perform thei r power mi rror sys-
tem functi ons.
AUTOMATIC DAY/NIGHT
MIRROR
DESCRIPTION
DESCRIPTION - REAR VIEW MIRROR
An automati c day/ni ght mi rror system i s an avai l -
abl e factory-i nstal l ed opti on on thi s model . The auto-
mati c di mmi ng i nsi de day/ni ght rear vi ew mi rror
system i s a compl etel y sel f-contai ned uni t that
repl aces the standard equi pment i nsi de rear vi ew
mi rror. Thi s system wi l l automati cal l y change the
refl ectance of the i nsi de rear vi ew mi rror to protect
the dri ver from the unwanted headl i ght gl are of
trai l i ng vehi cl es whi l e dri vi ng at ni ght. The auto-
mati c day/ni ght i nsi de mi rror recei ves i gni ti on
swi tched battery current through a fuse i n the junc-
ti on bl ock, and wi l l onl y operate when the i gni ti on
swi tch i s i n the On posi ti on.
Vehi cl es equi pped wi th the automati c day/ni ght
mi rror system are al so avai l abl e wi th an opti onal fac-
tory-i nstal l ed automati c di mmi ng outsi de rear vi ew
mi rror for the dri ver si de of the vehi cl e. (Refer to 8 -
ELECTRI CAL/POWER MI RRORS/SI DEVI EW MI R-
ROR - DESCRI PTI ON) for more i nformati on on thi s
opti on.
The automati c day/ni ght mi rror sensi ti vi ty cannot
be repai red or adjusted. I f any component of thi s uni t
i s faul ty or damaged, the enti re automati c day/ni ght
i nsi de rear vi ew mi rror uni t must be repl aced. Refer
8N - 12 POWER MIRRORS WJ
POWER MIRRORS (Continued)
DESCRIPTION - OUTSIDE REAR VIEW MIRROR
An automati c di mmi ng outsi de rear vi ew mi rror i s
an avai l abl e factory-i nstal l ed opti on for the dri ver
si de of the vehi cl e, i f the vehi cl e i s al so equi pped
wi th the automati c day/ni ght i nsi de rear vi ew mi rror.
The automati c di mmi ng outsi de mi rror i s compl etel y
control l ed by the ci rcui try of the automati c day/ni ght
i nsi de rear vi ew mi rror. The automati c di mmi ng out-
si de mi rror wi l l automati cal l y change the refl ectance
of the dri ver si de outsi de rear vi ew mi rror to protect
the dri ver from the unwanted headl i ght gl are of
trai l i ng vehi cl es whi l e dri vi ng at ni ght. The auto-
mati c di mmi ng outsi de mi rror wi l l onl y operate when
the i gni ti on swi tch i s i n the On posi ti on.
The automati c di mmi ng outsi de mi rror sensi ti vi ty
cannot be repai red or adjusted. I f any component of
thi s uni t i s faul ty or damaged, the enti re automati c
di mmi ng outsi de mi rror uni t must be repl aced. (Refer
to 8 - ELECTRI CAL/POWER MI RRORS/SI DEVI EW
MI RROR - DI AGNOSI S AND TESTI NG). Refer to
OPERATION
OPERATION - REAR VIEW MIRROR
The automati c day/ni ght mi rror swi tch al l ows the
dri ver a manual control of whether the automati c
di mmi ng feature i s operati onal . Thi s swi tch i s a
momentary rocker-type swi tch l ocated on the l ower
rear-faci ng surface of the mi rror housi ng. When Auto
i s sel ected, a Li ght-Emi tti ng Di ode (LED) on the mi r-
ror housi ng just to the ri ght of the swi tch i l l umi nates
to i ndi cate that automati c day/ni ght mi rror i s turned
on. When Off i s sel ected, the LED i s turned off. The
mi rror al so senses the backup l amp ci rcui t, and wi l l
automati cal l y di sabl e i ts sel f-di mmi ng feature when-
ever the transmi ssi on gear sel ector i s i n the Reverse
posi ti on.
A thi n l ayer of el ectrochromati c materi al between
two pi eces of conducti ve gl ass make up the face of
the mi rror. Two photocel l sensors are used to moni tor
l i ght l evel s and adjust the refl ectance of the mi rror.
The ambi ent photocel l sensor faces forward, to detect
the outsi de l i ght l evel s. The headl amp sensor i s
l ocated on the mi rror housi ng just to the l eft of the
swi tch and faci ng rearward, to detect the l i ght l evel
recei ved at the rear wi ndow si de of the mi rror. When
the di fference between the two l i ght l evel s becomes
too great (the l i ght l evel recei ved at the rear of the
mi rror i s much hi gher than that at the front of the
mi rror), the mi rror begi ns to darken.
On model s wi th an opti onal dri ver si de automati c
di mmi ng outsi de mi rror, the si gnal to control the
di mmi ng of that mi rror i s generated by the auto-
mati c day/ni ght i nsi de rear vi ew mi rror ci rcui try.
That si gnal i s then del i vered to the dri ver si de out-
si de rear vi ew mi rror on a hard wi red ci rcui t.
of the automati c day/ni ght mi rror system.
OPERATION - OUTSIDE REAR VIEW MIRROR
The automati c di mmi ng outsi de mi rror i s operated
by the same control s and ci rcui try as the automati c
day/ni ght mi rror. When the automati c day/ni ght mi r-
ror i s turned on or off, the automati c di mmi ng out-
si de mi rror i s l i kewi se turned on or off. Li ke i n the
automati c day/ni ght mi rror, a thi n l ayer of el ectro-
chromati c materi al between two pi eces of conducti ve
gl ass make up the face of the automati c di mmi ng
outsi de mi rror. However, the si gnal to control the
di mmi ng of the outsi de mi rror i s generated by the
automati c day/ni ght i nsi de rear vi ew mi rror ci rcui try.
of the automati c di mmi ng outsi de mi rror.
DIAGNOSIS AND TESTING - AUTOMATIC DAY /
NIGHT MIRROR
(1) Check the fused i gni ti on swi tch output (run/
start) fuse i n the juncti on bl ock. I f OK, go to Step 2.
I f not OK, repai r the shorted ci rcui t or component as
output (run/start) fuse i n the juncti on bl ock. I f OK,
go to Step 3. I f not OK, repai r the open fused i gni ti on
swi tch output (run/start) ci rcui t to the i gni ti on swi tch
as requi red.
(3) Di sconnect the overhead wi re harness connec-
tor from the automati c day/ni ght mi rror connector
receptacl e. Check for battery vol tage at the fused
i gni ti on swi tch output (run/start) ci rcui t cavi ty of the
overhead wi re harness connector for the automati c
day/ni ght mi rror. I f OK, go to Step 4. I f not OK,
repai r the open fused i gni ti on swi tch output (run/
start) ci rcui t to the fuse i n the juncti on bl ock as
requi red.
AUTOMATIC DAY/NIGHT MIRROR (Continued)
Check for conti nui ty between the ground ci rcui t cav-
i ty of the overhead wi re harness connector for the
automati c day/ni ght mi rror and a good ground. There
repai r the open ground ci rcui t to ground as requi red.
(5) Turn the i gni ti on swi tch to the On posi ti on. Set
the parki ng brake. Pl ace the transmi ssi on gear sel ec-
tor l ever i n the Reverse posi ti on. Check for battery
vol tage at the backup l amp swi tch output ci rcui t cav-
i ty of the overhead wi re harness connector for the
automati c day/ni ght mi rror. I f OK, reconnect the
overhead wi re harness connector to the automati c
day/ni ght mi rror connector receptacl e and go to Step
6. I f not OK, repai r the open backup l amp swi tch
output ci rcui t as requi red.
(6) Pl ace the transmi ssi on gear sel ector l ever i n
the Neutral posi ti on. Pl ace the automati c day/ni ght
mi rror swi tch i n the Auto (LED next to the swi tch i s
l i ghted) posi ti on (Fi g. 1). Cover the forward faci ng
ambi ent photocel l sensor to keep out any ambi ent
l i ght.
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7) Shi ne a l i ght i nto the rearward faci ng head-
l amp photocel l sensor. The automati c day/ni ght mi r-
ror shoul d darken. I f OK, go to Step 8. I f not OK,
repl ace the faul ty automati c day/ni ght mi rror uni t.
(8) Wi th the mi rror darkened, pl ace the transmi s-
si on gear sel ector l ever i n the Reverse posi ti on. The
automati c day/ni ght mi rror shoul d return to i ts nor-
mal refl ectance. I f not OK, repl ace the faul ty auto-
mati c day/ni ght mi rror uni t.
POWER FOLD-AWAY MIRROR -
EXPORT
DESCRIPTION
Some vehi cl es are equi pped wi th Power Fol d-Away
Si de Vi ew Mi rrors. Thi s feature al l ows both the
dri ver and passenger si de vi ew mi rrors to fol d
i nward (retract) on demand. Thi s feature i s con-
trol l ed by an addi ti onal swi tch l ocated on the power
mi rror swi tch.
The fol d-away si de vi ew mi rror i s attached to the
vehi cl es door i n the same manner as mi rrors wi thout
the fol d-away opti on. The fol d-away mi rrors uni que
opti on i s the i nternal motor whi ch al l ows the mi rrors
to fol d i nward on demand. the fol d-away mi rror
motor i s not servi ceabl e separatel y, and i f a motor i s
found to be faul ty the enti re si de vi ew mi rror must
be repl aced.
OPERATION
When the mi rror retract swi tch i s depressed, both
of the si de vi ew mi rrors wi l l fol d i nward, thus mak-
i ng the overal l wi dth of the vehi cl e the smal l est pos-
si bl e. Thi s can be very hel pful where parki ng space i s
an absol ute mi ni mum.
FOLD-AWAY MIRROR - EXPORT
The most rel i abl e, effi ci ent and accurate means to
di agnose the power mi rror system requi res the use of
a DRB scan tool and the proper Di agnosti c Proce-
the proper messages on the PCI data bus, that the
power mi rror motors are bei ng sent the proper hard
wi red outputs, and that the mi rror posi ti on potenti -
ometers are returni ng the proper outputs to the door
modul es for them to perform thei r power mi rror sys-
tem functi ons.
REMOVAL
The fol d-away mi rror motor i s not servi ceabl e sep-
aratel y, and i f a motor i s found to be faul ty the enti re
si de vi ew mi rror must be repl aced. (Refer to 8 -
ELECTRI CAL/POWER MI RRORS/SI DEVI EW MI R-
ROR - REMOVAL).
Fig. 1 Automatic Day/Night Mirror
1 - LED INDICATOR
2 - SWITCH
3 - HEADLAMP SENSOR
AUTOMATIC DAY/NIGHT MIRROR (Continued)
POWER MIRROR SWITCH
DESCRIPTION
Both the ri ght and l eft power outsi de mi rrors are
control l ed by a si ngl e mul ti -functi on swi tch uni t
l ocated on the dri ver si de front door tri m panel . The
power mi rror swi tch uni t i ncl udes a three-posi ti on
rocker sel ector swi tch and four momentary di rec-
ti onal push button swi tches.
The power mi rror swi tch uni t i s i ntegral to the
Dri ver Door Modul e (DDM). The power mi rror swi tch
cannot be repai red or adjusted and, i f faul ty or dam-
aged, the enti re DDM uni t must be repl aced. (Refer
MODULES/DRI VER DOOR MODULE - REMOVAL)
for the DDM servi ce procedures.
OPERATION
The power mi rror sel ector swi tch i s moved ri ght
(ri ght mi rror control ), l eft (l eft mi rror control ), or
center to turn the power outsi de mi rror system off.
When the sel ector swi tch i s i n the ri ght mi rror con-
trol or l eft mi rror control posi ti on, one of the four
di recti onal control buttons i s depressed to control
movement of the sel ected mi rror up, down, ri ght, or
l eft. When the sel ector swi tch i s i n the Off posi ti on,
depressi ng any of the di recti onal swi tches wi l l not
change ei ther mi rror posi ti on.
of the power mi rror swi tches.
SIDEVIEW MIRROR
DESCRIPTION
Mechani cal l y fol di ng, power operated outsi de rear
vi ew mi rrors are standard equi pment on thi s model .
Each power mi rror housi ng contai ns two el ectri c
motors, two dri ve mechani sms, an el ectri c heati ng
gri d, the mi rror gl ass case and the mi rror gl ass. One
motor and dri ve control s mi rror up-and-down (verti -
cal ) movement, and the other control s ri ght-and-l eft
(hori zontal ) movement. I f the vehi cl e i s equi pped
wi th the opti onal memory system, each mi rror head
al so contai ns two posi ti on potenti ometers. One posi -
ti on potenti ometer moni tors the verti cal mi rror
motor, and the other moni tors the hori zontal mi rror
motor.
An opti onal dri ver si de automati c di mmi ng mi rror
i s abl e to automati cal l y change i ts refl ectance l evel .
Thi s mi rror i s control l ed by the ci rcui try of the auto-
mati c day/ni ght i nsi de rear vi ew mi rror. A thi n l ayer
of el ectrochromi c materi al between two pi eces of con-
ducti ve gl ass make up the face of the mi rror. (Refer
to 8 - ELECTRI CAL/POWER MI RRORS/AUTO-
MATI C DAY /NI GHT MI RROR - DESCRI PTI ON) for
more i nformati on on thi s feature.
The power mi rror uni t cannot be repai red. Onl y
the mi rror gl ass and gl ass case are servi ced sepa-
ratel y. The repl acement mi rror gl ass i s suppl i ed wi th
an i nstructi on sheet that detai l s the recommended
repl acement procedure. I f any other component of the
power mi rror uni t i s faul ty or damaged, the enti re
power mi rror uni t must be repl aced.
OPERATION
Each of the two outsi de power mi rrors i ncl udes two
reversi bl e el ectri c motors that are secured wi thi n the
power mi rror housi ng. Each motor moves the mi rror
case and gl ass through an i ntegral dri ve uni t. When
a power mi rror motor i s suppl i ed wi th battery cur-
rent and ground, i t moves the mi rror case and gl ass
through i ts dri ve uni t i n one di recti on. When the bat-
tery current and ground feeds to the motor are
reversed, i t moves the mi rror case and gl ass i n the
opposi te di recti on.
The power mi rrors are equi pped wi th a standard
equi pment el ectri c heati ng gri d that i s appl i ed to the
back of each outsi de rear vi ew mi rror gl ass. When an
el ectri cal current i s passed through the resi stor wi re
of the heati ng gri d, i t warms the mi rror gl ass. (Refer
to 8 - ELECTRI CAL/HEATED MI RRORS -
DESCRI PTI ON) for more i nformati on on the opera-
ti on of the heated mi rrors and the rear wi ndow
defogger system.
I f the dri ver si de mi rror i s equi pped wi th the auto-
mati c di mmi ng outsi de mi rror opti on, two photocel l
sensors on the i nsi de rear vi ew mi rror are used to
moni tor l i ght l evel s and adjust the refl ectance of both
the i nsi de and dri ver si de outsi de mi rrors. Thi s
change i n refl ectance hel ps to reduce the gl are of
headl amps approachi ng the vehi cl e from the rear.
(Refer to 8 - ELECTRI CAL/POWER MI RRORS/AU-
TOMATI C DAY / NI GHT MI RROR - OPERATI ON)
for more i nformati on on thi s feature.
I f the vehi cl e i s equi pped wi th the opti onal mem-
ory system, the Dri ver Door Modul e (DDM) and the
Passenger Door Modul e (PDM) store the mi rror posi -
ti on i nformati on as moni tored through the mi rror
motor posi ti on potenti ometers. When the memory
system requests a recal l of the stored mi rror posi ti on,
the DDM and the PDM are abl e to dupl i cate the
stored mi rror posi ti ons by movi ng the mi rror motors
unti l the potenti ometer readi ngs match the stored
val ues.
DIAGNOSIS AND TESTING - SIDEVIEW
MIRROR
BOTH MIRRORS INOPERATIVE
(1) Check the operati on of the power l ock swi tch
on the dri ver si de front door. I f al l of the doors l ock
and unl ock, repl ace the faul ty Dri ver Door Modul e
(DDM). I f not OK, go to Step 2.
on the passenger si de front door. I f al l of the doors
l ock and unl ock, repl ace the faul ty DDM. I f not OK,
go to Step 3.
buti on Center (PDC). I f OK, go to Step 4. I f not OK,
repai r the shorted ci rcui t or component as requi red
and repl ace the faul ty fuse.
i n the PDC. I f OK, go to Step 5. I f not OK, repai r the
open fused B(+) ci rcui t to the battery as requi red.
cabl e. Remove the tri m panel from the dri ver si de
front door. Di sconnect the 15-way door wi re harness
connector from the DDM connector receptacl e. Check
for conti nui ty between the ground ci rcui t cavi ty of
the 15-way door wi re harness connector for the DDM
and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 6. I f not OK, repai r the open ground
ci rcui t to ground as requi red.
15-way door wi re harness connector for the DDM. I f
OK, repl ace the faul ty DDM. I f not OK, repai r the open
fused B(+) ci rcui t to the fuse i n the PDC as requi red.
ONE MIRROR INOPERATIVE
(1) I f the one i noperati ve mi rror i s on the passen-
ger si de, go to Step 2. I f the one i noperati ve mi rror i s
on the dri ver si de, go to Step 3.
(2) Check i f the passenger front door wi l l l ock and
unl ock usi ng the power l ock swi tch on the dri ver si de
front door. I f OK, go to Step 3. I f not OK, go to Step 6.
cabl e. Remove the tri m panel from the front door.
Di sconnect the 12-way mi rror wi re harness connector
from the door wi re harness connector.
(4) Usi ng two jumper wi res, test the mi rror as
shown i n the Mi rror Test chart (Fi g. 2). I f the mi rror
tests OK, go to Step 5. I f the mi rror does not test
OK, repl ace the faul ty mi rror.
(5) Di sconnect the 12-way door wi re harness con-
nector from the door modul e connector receptacl e.
Check al l of the ci rcui ts of the door wi re harness
between the connector for the mi rror and the connec-
tor for the door modul e for opens or shorts. I f al l of
the ci rcui ts are OK, repl ace the faul ty door modul e.
I f any of the ci rcui ts are not OK, repai r the open or
shorted ci rcui t(s) as requi red.
(6) Use a DRB scan tool and the proper Di agnosti c
Procedures manual to test and repai r the faul ty Pro-
communi cati on between the two door modul es.
NO MIRROR HEAT
I f one or both mi rror heaters are i noperati ve,
(Refer to 8 - ELECTRI CAL/HEATED MI RRORS -
DESCRI PTI ON).
cabl e. Remove the front door tri m panel on the si de
of the i noperati ve mi rror heater.
Check for conti nui ty between the heater swi tched
ground ci rcui t cavi ty and the heater 12V suppl y ci r-
cui t cavi ty of the 12-way door wi re harness connector
Fig. 2 Mirror Test
POWER MIRROR TEST TABLE
APPLY 12
VOLTS TO:
APPLY
GROUND TO:
MIRROR
REACTION
DRIVER SIDE
1 7 LEFT
7 1 RIGHT
8 7 UP
7 8 DOWN
PASSENGER SIDE
1 7 LEFT
7 1 RIGHT
8 7 UP
7 8 DOWN
SIDEVIEW MIRROR (Continued)
for the door modul e. There shoul d be conti nui ty. I f
OK, use a DRB scan tool and the proper Di agnosti c
Procedures manual to test the door modul e and the
PCI data bus. I f not OK, repl ace the faul ty power
mi rror uni t.
NO MIRROR DIMMING (Driver Side Only)
(1) Test the operati on of the automati c day/ni ght
mi rror. (Refer to 8 - ELECTRI CAL/POWER MI R-
RORS/AUTOMATI C DAY / NI GHT MI RROR -
OPERATI ON). I f OK, go to Step 2. I f not OK, repai r
the automati c day/ni ght mi rror uni t as requi red.
cabl e. Remove the dri ver si de front door tri m panel .
from the power mi rror wi re harness connector. Con-
nect a vol tmeter between the el ectrochromati c (+)
and el ectrochromati c () ci rcui t cavi ti es of the door
wi re harness connector for the power mi rror. Turn on
the automati c day/ni ght mi rror system whi l e observ-
i ng the vol tmeter. A vol tmeter readi ng of 1.45 0.05
vol ts i ndi cates a proper di mmi ng si gnal i s bei ng
recei ved at the door wi re harness connector for the
power mi rror. I f OK, repl ace the faul ty power mi rror.
I f not OK, repai r the shorted or open el ectrochro-
mati c (+) or el ectrochromati c () ci rcui t(s) to the
automati c day/ni ght mi rror as requi red.
NO MIRROR MEMORY
For di agnosi s of the memory system, the use of a
manual are recommended. (Refer to 8 - ELECTRI -
CAL/POWER SEATS - DESCRI PTI ON).
SIDEVIEW MIRROR (Continued)
POWER SEAT SYSTEM
TABLE OF CONTENTS
page page
POWER SEAT SYSTEM
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION - MEMORY SYSTEM . . . . . . . 19
OPERATION
OPERATION - POWER SEAT SYSTEM . . . . . 20
OPERATION - MEMORY SYSTEM . . . . . . . . . 20
DIAGNOSIS & TESTING - POWER SEAT
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS & TESTING - MEMORY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DRIVER SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - DRIVER SEAT
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
LUMBAR CONTROL SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING - POWER LUMBAR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
LUMBAR MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MEMORY SET SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING - MEMORY
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
PASSENGER SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
RECLINER MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING - RECLINER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
POWER SEAT TRACK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING - POWER SEAT
TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
POWER SEAT SYSTEM
DESCRIPTION
DESCRIPTION
Dri ver and passenger power front seats are an
avai l abl e factory-i nstal l ed opti on for thi s vehi cl e. The
power seat system opti on al l ows the dri ver and front
seat passenger to el ectri cal l y adjust thei r seati ng
posi ti ons for opti mum control and comfort usi ng the
power seat swi tches l ocated on the outboard seat
cushi on si de shi el d of each front seat. The power seat
system recei ves battery current through a fuse i n the
Power Di stri buti on Center (PDC) and a ci rcui t
breaker i n the juncti on bl ock so that the power seats
remai n operati onal , regardl ess of the i gni ti on swi tch
posi ti on.
Four power seat opti ons are offered on thi s vehi cl e,
dependi ng upon the model . They are as fol l ows:
Six-way power drivers seat with manual
passenger seat - Thi s power seat package i s an
opti on on Laredo model s equi pped wi th cl oth-
tri mmed seats and i ncl udes a si x-way adjustabl e
dri ver seat track wi th manual seat back recl i ners.
Six-way power driver and passenger seat -
Thi s power seat package i s an opti on on Laredo mod-
el s equi pped wi th cl oth or l eather-tri mmed seats and
i ncl udes si x-way adjustabl e seat tracks wi th manual
seat back recl i ners. Heated Seats are avai l abl e on
l eather-tri mmed seats.
Ten-way power drivers seat with Memory
and Six-way power passenger seat - Thi s power
seat package i s standard on Li mi ted model s. Thi s
opti on i ncl udes a si x-way adjustabl e seat track wi th
power seat back recl i ners and power l umbar supports
for the dri ver and si x-way onl y for the passenger.
8N - 18 POWER SEAT SYSTEM WJ
Ten-way power drivers and passenger seats
with Memory - Thi s power seat opti on i s standard
on Overl and model s and opti onal on Li mi ted model s.
Thi s opti on i ncl udes a si x-way adjustabl e seat cush-
i on track wi th power seat back recl i ners and power
l umbar supports. Heated Seats are standard wi th
thi s opti on.
Refer to Heated Seat System for more i nforma-
ti on on the heated seat opti on. Refer to Memory
System i n the Memory System secti on of thi s group
for more i nformati on on the memory system.
The power seat system i ncl udes the fol l owi ng com-
ponents:
Power l umbar adjuster (ten-way power seat
onl y)
Power l umbar swi tch (ten-way power seat onl y)
Power seat recl i ner (ten-way power seat onl y)
Power seat swi tch
Power seat track.
Refer to Power Seat i n Wi ri ng Di agrams for com-
pl ete ci rcui t di agrams. Fol l owi ng are general descri p-
ti ons of the major components i n the power seat/
memory seat system.
DESCRIPTION - MEMORY SYSTEM
An el ectroni c memory system i s standard equi p-
ment on the Li mi ted model . The memory system i s
abl e to store and recal l the dri ver si de power seat
posi ti ons (i ncl udi ng the power recl i ner posi ti on), and
both outsi de power mi rror posi ti ons for two dri vers.
For vehi cl es wi th a radi o connected to the Program-
work, the memory system i s al so abl e to store and
recal l up to twenty - ten AM and ten FM - radi o sta-
ti on presets for two dri vers. The memory system al so
wi l l store and recal l the l ast stati on l i stened to for
each dri ver, even i f i t i s not one of the twenty preset
stati ons.
The memory system wi l l automati cal l y return to
al l of these setti ngs when the correspondi ng num-
bered and col or-coded button (Dri ver 1 - Bl ack, or
Dri ver 2 - Gray) of the memory swi tch on the dri ver
si de front door tri m panel i s depressed, or when the
doors are unl ocked usi ng the correspondi ng num-
bered and col or-coded (Dri ver 1 - Bl ack, or Dri ver 2 -
Gray) Remote Keyl ess Entry (RKE) transmi tter. A
customer programmabl e feature of the memory sys-
tem al l ows the RKE recal l of memory features to be
di sabl ed i n cases where there are more than two
dri vers of the vehi cl e.
The memory system al so has a customer program-
mabl e easy exi t feature that wi l l move the dri ver
seat rearward 55 mi l l i meters (two i nches) or to the
end of i ts travel , whi chever occurs fi rst, when the key
i s removed from the i gni ti on swi tch l ock cyl i nder.
A Memory Seat Modul e (MSM) or Memory Heated
Seat Modul e (MHSM) are used on thi s model to con-
trol and i ntegrate the many el ectroni c functi ons and
features i ncl uded i n the memory system. On vehi cl es
equi pped wi th the heated seat system opti on, the
MHSM al so control s the functi ons and features of
that system.
The memory system i ncl udes the fol l owi ng compo-
nents:
Memory seat modul e (or memory heated seat
modul e)
Memory swi tch
Posi ti on potenti ometers on both outsi de power
mi rrors
Posi ti on potenti ometers on the dri ver si de power
seat track and power seat recl i ner motors.
Radi o recei ver (i f PCI data bus capabl e).
Certai n functi ons and features of the memory sys-
tem rel y upon resources shared wi th other el ectroni c
are recommended.
The other el ectroni c modul es that may affect mem-
ory system operati on are as fol l ows:
Body Control Module (BCM) - Refer to Body
Control Module i n El ectroni c Control Modul es for
more i nformati on.
Driver Door Module (DDM) - Refer to Door
Module i n El ectroni c Control Modul es for more
i nformati on.
(EVIC) - Refer to Electronic Vehicle Information
Center i n Overhead Consol e Systems for more i nfor-
mati on.
Passenger Door Module (PDM) - Refer to
Door Module i n El ectroni c Control Modul es for
more i nformati on.
Powertrain Control Module (PCM) - Refer to
Powertrain Control Module i n El ectroni c Control
Modul es for more i nformati on.
Radio Receiver - Refer to Radio Receiver i n
Audi o Systems for more i nformati on.
Refer to Heated Seat System for more i nforma-
ti on on thi s system. Refer to Remote Keyless Entry
Systemi n Power Lock Systems for more i nformati on
on the RKE system. Refer to Power Mirror i n
Power Mi rror Systems for more i nformati on on the
WJ POWER SEAT SYSTEM 8N - 19
POWER SEAT SYSTEM (Continued)
mi rror posi ti on potenti ometers. Refer to Power Seat
Track and Power Seat Recliner i n the Power Seat
System secti on of thi s group for more i nformati on on
the dri ver si de power seat posi ti on potenti ometers.
Refer to Power Seat i n Wi ri ng Di agrams for com-
pl ete ci rcui t di agrams. Fol l owi ng are general descri p-
ti ons of the remai ni ng major components i n the
factory-i nstal l ed memory system.
OPERATION
OPERATION - POWER SEAT SYSTEM
The power seat system al l ows the dri ver and/or
front passenger seati ng posi ti ons to be adjusted el ec-
tri cal l y and i ndependentl y usi ng the separate power
seat swi tches found on the outboard seat cushi on
si de shi el d of each front seat. See the owners manual
i n the vehi cl e gl ove box for more i nformati on on the
features, use and operati on of the power seat system.
OPERATION - MEMORY SYSTEM
more i nformati on on the features, use and operati on of
the memory system. For di agnosi s of the MSM, the PCI
data bus, or the other el ectroni c modul es on the PCI
data bus that provi de i nputs and outputs for the mem-
ory system, the use of a DRB scan tool and the proper
Di agnosti c Procedures manual are recommended.
DRIVER AND PASSENGER DOOR MODULES
The Dri ver Door Modul e (DDM) moni tors the mem-
ory swi tch through a hard wi red ci rcui t. I t al so mon-
i tors the unl ock messages from the Remote Keyl ess
Entry (RKE) recei ver i n the Passenger Door Modul e
(PDM) sent over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The DDM i s programmed to
send memory recal l messages and memory system
status messages over the PCI data bus to the other
el ectroni c modul es when i t detects a memory recal l
request.
Refer to Door Module i n El ectroni c Control Mod-
ul es for more i nformati on on the DDM and PDM.
ELECTRONIC VEHICLE INFORMATION CENTER
serves as the user i nterface for the memory system. I t
di spl ays memory system status messages and provi des
the user wi th the means for enabl i ng and di sabl i ng
the many customer programmabl e features avai l abl e
on the vehi cl e, i ncl udi ng those for the memory system.
of the EVI C. Refer to Electronic Vehicle Informa-
tion Center i n Overhead Consol e Systems for more
i nformati on on the EVI C.
DIAGNOSIS & TESTING - POWER SEAT
SYSTEM
hard wi red components and ci rcui ts of the power seat
system. However, i f the vehi cl e i s al so equi pped wi th
the opti onal memory system, these tests may not
prove concl usi ve i n the di agnosi s of the dri ver si de
power seat. I n order to obtai n concl usi ve testi ng of
the dri ver si de power seat wi th the memory system
opti on, the Programmabl e Communi cati ons I nterface
(PCI ) data bus network and al l of the el ectroni c mod-
ul es that provi de i nputs to, or recei ve outputs from
the memory system components must be checked.
di agnose the dri ver si de power seat wi th the memory
system opti on requi res the use of a DRB scan tool
and the proper Di agnosti c Procedures manual . The
DRB scan tool can provi de confi rmati on that the
PCI data bus i s functi onal , that al l of the el ectroni c
modul es are sendi ng and recei vi ng the proper mes-
sages on the PCI data bus, and that the memory sys-
tem i s recei vi ng the proper hard wi red i nputs and
rel ayi ng the proper hard wi red outputs to perform i ts
dri ver si de power seat functi ons.
Before any testi ng of the power seat system i s
attempted, the battery shoul d be ful l y-charged and
al l of the power seat system wi re harness connecti ons
and pi ns cl eaned and ti ghtened to ensure proper ci r-
cui t conti nui ty and ground paths. For compl ete ci r-
cui t di agrams, refer to Power Seat i n Wi ri ng
Di agrams.
Wi th the dome l amp on, appl y the power seat
swi tch i n the di recti on of the fai l ure. I f the dome
l amp di ms, the seat may be jammi ng. Check under
and behi nd the seat for bi ndi ng or obstructi ons. I f
the dome l amp does not di m, proceed wi th testi ng of
the i ndi vi dual components and ci rcui ts.
DIAGNOSIS & TESTING - MEMORY SYSTEM
components and ci rcui ts that provi de hard wi red
i nputs to the memory system. However, these tests
may not prove concl usi ve i n the di agnosi s of thi s sys-
tem. I n order to obtai n concl usi ve testi ng of the
memory system, the Programmabl e Communi cati ons
I nterface (PCI ) data bus network and al l of the el ec-
troni c modul es that provi de i nputs to, or recei ve out-
puts from the memory system components must be
checked.
di agnose the memory system requi res the use of a
DRB scan tool and the proper Di agnosti c Proce-
dures manual . The DRB scan tool can provi de con-
fi rmati on that the PCI data bus i s functi onal , that al l
the memory system i s recei vi ng the proper hard
wi red i nputs and rel ayi ng the proper hard wi red out-
puts to perform i ts functi ons.
DRIVER SEAT SWITCH
DESCRIPTION
Two di fferent power seat swi tches are used on thi s
vehi cl e, dependi ng upon the opti onal power seat sys-
tem i nstal l ed i n the vehi cl e. The si x-way power seats
are each equi pped wi th a swi tch featuri ng three
swi tch control knobs ganged together on the outboard
seat cushi on si de shi el d (Fi g. 1). The ten-way power
seats are each equi pped wi th a swi tch featuri ng two
knobs ganged together on the outboard seat cushi on
si de shi el d (Fi g. 2).
The swi tch uni ts for both power seat types are
secured to the back of the seat cushi on si de shi el d
wi th two screws. However, the control knobs for the
si x-way power seat swi tch uni t remai n i nstal l ed dur-
i ng swi tch uni t removal and i nstal l ati on, whi l e both
knobs for the ten-way power seat swi tch uni t must
be removed.
The i ndi vi dual swi tches i n both power seat swi tch
uni ts cannot be repai red. I f one swi tch i s damaged or
faul ty, the enti re power seat swi tch uni t must be
repl aced.
OPERATION
The power seat tracks of both the si x-way and the
ten-way power seat systems can be adjusted i n si x
di fferent ways usi ng the power seat swi tches. The
ten-way system has the addi ti onal power seat
recl i ner swi tch i ntegral to the power seat swi tch and
al so has a separate, stand-al one swi tch to control the
power l umbar adjuster. See the owners manual i n
the vehi cl e gl ove box for more i nformati on on the
power seat swi tch functi ons and the seat adjusti ng
procedures.
When a power swi tch control knob or knobs are
actuated, a battery feed and a ground path are
appl i ed through the swi tch contacts to the power seat
track or recl i ner adjuster motor. The sel ected
adjuster motor operates to move the seat track or
recl i ner through i ts dri ve uni t i n the sel ected di rec-
ti on unti l the swi tch i s rel eased, or unti l the travel
l i mi t of the adjuster i s reached. When the swi tch i s
moved i n the opposi te di recti on, the battery feed and
ground path to the motor are reversed through the
swi tch contacts. Thi s causes the adjuster motor to
run i n the opposi te di recti on.
No power seat swi tch shoul d be hel d appl i ed i n any
di recti on after the adjuster has reached i ts travel
l i mi t. The power seat adjuster motors each contai n a
sel f-resetti ng ci rcui t breaker to protect them from
overl oad. However, consecuti ve or frequent resetti ng
of the ci rcui t breaker must not be al l owed to con-
ti nue, or the motor may be damaged.
Fig. 1 Six-Way Power Seat Switches - Typical
1 - OUTBOARD SEAT CUSHION SIDE SHIELD
2 - POWER SEAT TRACK SWITCHES
3 - MECHANICAL SEAT BACK RECLINER LEVER
Fig. 2 Ten-Way Power Seat Switches - Typical
1 - OUTBOARD CUSHION SIDE SHIELD
2 - POWER SEAT RECLINER SWITCH
3 - POWER SEAT TRACK SWITCH
4 - POWER LUMBAR SWITCH
DIAGNOSIS AND TESTING - DRIVER SEAT
SWITCH
Diagrams.
cabl e.
(2) Remove the power seat swi tch from the out-
board seat cushi on si de shi el d. Refer to the procedure
i n thi s secti on of the manual .
(3) Use an ohmmeter to test the conti nui ty of the
power seat swi tch i n each swi tch posi ti on. See the
Power Seat Swi tch Conti nui ty chart (Fi g. 3) or (Fi g.
4). I f OK, refer to Diagnosis and Testing Power
Seat Track or Diagnosis and Testing Power Seat
Recliner i n thi s secti on. I f not OK, repl ace the
faul ty power seat swi tch.
SWITCH
POSITION
CONTINUITY BETWEEN PINS
LEFT SEAT RIGHT SEAT
OFF PIN 1 to 2 PIN 1 to 2
PIN 1 to 3 PIN 1 to 3
FRONT RISER
UP
FRONT RISER
DOWN
CENTER
SWITCH
FORWARD
CENTER
SWITCH
REARWARD
REAR RISER
UP
REAR RISER
DOWN
RECLINER UP PIN 1 to 4 PIN 1 to 4
RECLINER
DOWN
Fig. 3 Rear Of Six-Way Power Seat Switch
SIX-WAY POWER SEAT SWITCH TEST
LEFT SWITCH
POSITION
RIGHT SWITCH
POSITION
CONTINUITY
BETWEEN
OFF OFF
B-N, B-J, B-M,
B-E, B-L, B-K
VERTICAL UP
VERTICAL
DOWN
A-J, A-N, B-M,
B-E
VERTICAL
DOWN
VERTICAL UP
A-E, A-M, B-N,
B-J
HORIZONTAL
FORWARD
HORIZONTAL
REARWARD
A-K, B-L
FRONT TILT UP
FRONT TILT
DOWN
A-J, B-E
FRONT TILT
DOWN
FRONT TILT UP A-E, B-J
REAR TILT UP
REAR TILT
DOWN
A-N, B-M
REAR TILT
DOWN
REAR TILT UP A-M, B-N
Fig. 4 Ten-Way Power Seat
Switch Connector Receptacle
DRIVER SEAT SWITCH (Continued)
REMOVAL
cabl e.
(2) On model s wi th the ten-way power seat system
onl y, usi ng a push pi n remover or another sui tabl e
wi de fl at-bl aded tool , gentl y pry the power seat and
power recl i ner swi tch knobs off of the swi tch stems
(Fi g. 5).
(3) Remove the three screws that secure the out-
board seat cushi on si de shi el d to the seat cushi on
frame.
(4) Pul l the outboard seat cushi on si de shi el d away
from the seat cushi on frame far enough to access the
power seat swi tch wi re harness connector.
(5) Di sconnect the power seat wi re harness connec-
tor from the power seat swi tch connector receptacl e.
(6) Remove the two screws that secure the power
seat swi tch to the i nsi de of the outboard seat cushi on
si de shi el d (Fi g. 6) or (Fi g. 7).
board seat cushi on si de shi el d.
INSTALLATION
(1) Posi ti on the power seat swi tch onto the out-
the power seat swi tch to the i nsi de of the outboard
seat cushi on si de shi el d. Ti ghten the screws to 1.5
Nm (14 i n. l bs.).
(3) Reconnect the power seat wi re harness connec-
tor to the power seat swi tch connector receptacl e.
(4) Posi ti on the outboard seat cushi on si de shi el d
onto the seat cushi on frame
the outboard seat cushi on si de shi el d to the seat
cushi on frame. Ti ghten the screws to 1.5 Nm (14 i n.
l bs.).
onl y, posi ti on the power seat and power recl i ner
swi tch knobs onto the swi tch stems and push on
them fi rml y and evenl y unti l they snap i nto pl ace.
Fig. 5 Removing Switch Control Knobs - Typical
Fig. 6 Six-Way Power Seat Switches Remove/Install
1 - SEAT SIDE SHIELD
2 - POWER SEAT SWITCH
3 - SCREWS
Fig. 7 Ten-Way Power Seat Switches Remove/Install
2 - SCREWS (2)
4 - SEAT CUSHION SIDE SHIELD
DRIVER SEAT SWITCH (Continued)
LUMBAR CONTROL SWITCH
DESCRIPTION
The ten-way power seat opti on i ncl udes an el ectri -
cal l y operated l umbar support mechani sm. A si ngl e
two-way momentary power l umbar swi tch i s l ocated
on the outboard seat cushi on si de shi el d of each front
seat, just forward of the other power seat swi tches
(Fi g. 8). The power l umbar swi tch i s secured to the
back of the seat cushi on si de shi el d wi th two screws,
and the swi tch paddl e protrudes through a hol e to
the outsi de of the shi el d. The swi tch paddl e i s l ocated
i n a shal l ow depressi on mol ded i nto the outer surface
of the seat cushi on si de shi el d that hel ps to shroud i t
from uni ntenti onal actuati on when enteri ng or l eav-
i ng the vehi cl e.
The power l umbar swi tches cannot be adjusted or
repai red and, i f faul ty or damaged, they must be
repl aced.
OPERATION
When the power l umbar swi tch paddl e i s actuated,
a battery feed and a ground path are appl i ed through
the swi tch contacts to the power l umbar adjuster
motor. The motor operates to move the l umbar
adjuster through i ts dri ve uni t i n the sel ected di rec-
swi tch contacts. Thi s causes the motor to run i n the
opposi te di recti on.
The power l umbar swi tch shoul d not be hel d
appl i ed i n ei ther di recti on after the adjuster has
reached i ts travel l i mi t. The power l umbar adjuster
motor contai ns a sel f-resetti ng ci rcui t breaker to pro-
tect i t from overl oad. However, consecuti ve or fre-
quent resetti ng of the ci rcui t breaker must not be
al l owed to conti nue, or the motor may be damaged.
SWITCH
Diagrams.
cabl e.
(2) Remove the power l umbar swi tch from the out-
power l umbar swi tch i n each swi tch posi ti on. See the
Power Lumbar Swi tch Conti nui ty chart (Fi g. 9). I f
OK, refer to Power Lumbar Adjuster Diagnosis
and Testing i n thi s group. I f not OK, repl ace the
faul ty power l umbar swi tch.
REMOVAL
cabl e.
Fig. 8 Ten-Way Power Seat Switches
Fig. 9 Power Lumbar Switch
POWER LUMBAR SWITCH
LEFT SWITCH
POSITION
RIGHT
SWITCH
POSITION
CONTINUITY
BETWEEN
Off Off 2-4, 3-5
Forward Rearward 3-5, 4-6
Rearward Forward 2-4, 3-6
frame.
power l umbar swi tch wi re harness connector.
tor from the power l umbar swi tch connector recepta-
cl e (Fi g. 10).
l umbar swi tch to the i nsi de of the outboard seat
cushi on si de shi el d.
(6) Remove the power l umbar swi tch from the out-
INSTALLATION
(1) Posi ti on the power l umbar swi tch onto the out-
the power l umbar swi tch to the i nsi de of the out-
board seat cushi on si de shi el d. Ti ghten the screws to
1.5 Nm (14 i n. l bs.).
tor to the power l umbar swi tch connector receptacl e.
the outboard seat cushi on si de shi el d to the seat cush-
i on frame. Ti ghten the screws to 1.5 Nm (14 i n. l bs.).
LUMBAR MOTOR
DESCRIPTION
cal l y operated l umbar support mechani sm. The onl y
vi si bl e evi dence of thi s opti on i s the separate power
l umbar swi tch control paddl e that i s l ocated on the
outboard seat cushi on si de shi el d, just forward of the
other power seat swi tch control knobs. The power
l umbar adjuster and motor are conceal ed beneath the
seat back tri m cover and paddi ng, where they are
secured to a mol ded pl asti c back panel and to the
seat back frame (Fi g. 11).
The power l umbar adjuster cannot be repai red, and
i s servi ced onl y as a uni t wi th the seat back frame. I f
the power l umbar adjuster or the seat back frame
are damaged or faul ty, the enti re seat back frame
Fig. 10 Power Lumbar Switch Remove/Install
4 - SCREWS (2)
Fig. 11 Power Lumbar Adjuster
1 - SEAT BACK FRAME
2 - SEAT BACK PANEL
3 - LUMBAR MOTOR PIGTAIL TO SEAT WIRE HARNESS
4 - TIE WRAP
5 - SCREW (3)
6 - POWER LUMBAR ADJUSTER
7 - SEAT BACK TRIM COVER AND PADDING
LUMBAR CONTROL SWITCH (Continued)
OPERATION
The power l umbar adjuster mechani sm i ncl udes a
reversi bl e el ectri c motor that i s secured to the
i nboard si de of the seat back panel and i s connected
to a worm-dri ve gearbox. The motor and gearbox
operate the l umbar adjuster mechani sm i n the center
of the seat back by extendi ng and retracti ng a cabl e
that actuates a l ever. The acti on of thi s l ever com-
presses or rel axes a gri d of fl exi bl e sl ats. The more
thi s gri d i s compressed, the more the sl ats bow out-
ward agai nst the center of the seat back paddi ng,
provi di ng addi ti onal l umbar support.
ADJUSTER
Actuate the power l umbar swi tch to move the
power l umbar adjuster i n each di recti on. The power
l umbar adjuster shoul d move i n both di recti ons. I t
shoul d be noted that the power l umber adjuster nor-
mal l y operates very qui etl y and exhi bi ts l i ttl e vi si bl e
movement. I f the power l umbar adjuster fai l s to oper-
ate i n onl y one di recti on, move the adjuster a short
di stance i n the opposi te di recti on and test agai n to be
certai n that the adjuster i s not at i ts travel l i mi t. I f
the power l umbar adjuster sti l l fai l s to operate i n
onl y one di recti on, refer to Diagnosis and Testing
Power Lumbar Switch i n thi s group. I f the power
l umbar adjuster fai l s to operate i n ei ther di recti on,
perform the fol l owi ng tests. For compl ete ci rcui t di a-
grams, refer to Wiring Diagrams.
(1) Check the power seat ci rcui t breaker i n the
juncti on bl ock. I f OK, go to Step 2. I f not OK, repl ace
the faul ty power seat ci rcui t breaker.
(2) Check for battery vol tage at the power seat ci r-
cui t breaker i n the juncti on bl ock. I f OK, go to Step
3. I f not OK, repai r the open fused B(+) ci rcui t to the
fuse i n the Power Di stri buti on Center as requi red.
(3) Remove the outboard seat cushi on si de shi el d
from the seat. Di sconnect the seat wi re harness con-
nector from the power l umbar swi tch connector
receptacl e. Check for battery vol tage at the fused
B(+) ci rcui t cavi ty of the power seat wi re harness
connector for the power l umbar swi tch. I f OK, go to
Step 4. I f not OK, repai r the open fused B(+) ci rcui t
to the power seat ci rcui t breaker i n the juncti on
bl ock as requi red.
cui t cavi ty of the power seat wi re harness connector
for the power l umbar swi tch and a good ground.
OK, repai r the open ground ci rcui t to ground as
requi red.
(5) Test the power l umbar swi tch. Refer to Diag-
nosis and Testing Power Lumbar Switch i n thi s
group. I f the swi tch tests OK, test the ci rcui ts of the
power seat wi re harness between the power l umbar
adjuster motor and the power l umbar swi tch for
shorts or opens. I f the ci rcui ts check OK, repl ace the
faul ty seat back frame assembl y. I f the ci rcui ts are
not OK, repai r the power seat wi re harness as
requi red.
MEMORY SET SWITCH
DESCRIPTION
Vehi cl es equi pped wi th the memory system have a
memory swi tch mounted to the dri ver si de front door
tri m panel (Fi g. 12). Thi s swi tch i s used to set and
recal l al l of the memory system setti ngs for up to two
dri vers. The memory swi tch i s a resi stor mul ti pl exed
uni t that i s hard wi red to the Dri ver Door Modul e
(DDM), whi ch i s al so l ocated on the dri ver si de front
door tri m panel . The DDM sends out the memory
system set and recal l requests to the other el ectroni c
I nterface (PCI ) data bus.
The memory swi tch cannot be adjusted or repai red
and, i f faul ty or damaged, i t must be repl aced. For
compl ete ci rcui t di agrams, refer to Wiring Diagrams.
OPERATION
The memory swi tch has three momentary swi tch
buttons l abel ed Set, 1 and 2. The Dri ver 1 and Dri ver
2 buttons are back-l i t wi th Li ght-Emi tti ng Di odes
Fig. 12 WJ/WG MEMORY SELECT/SET SWITCH
1 - DRIVER TRIM PANEL
2 - MEMORY SWITCH
LUMBAR MOTOR (Continued)
(LED) for vi si bi l i ty, and are al so col or-coded to coi n-
ci de wi th the col or-coded Dri ver 1 and Dri ver 2
Remote Keyl ess Entry (RKE) transmi tters. The
Dri ver 1 memory swi tch button and RKE transmi tter
are bl ack, and the Dri ver 2 memory swi tch button
and RKE transmi tter are gray. The memory swi tch
Set button al so has an LED that wi l l i l l umi nate and
fl ash to i ndi cate that the memory system i s i n the set
mode. Thi s LED wi l l automati cal l y be exti ngui shed
when a set request has been successful l y compl eted.
of the memory swi tch. For di agnosi s of the memory
swi tch, the DDM or the PCI data bus, the use of a
DIAGNOSIS AND TESTING - MEMORY SWITCH
Diagrams.
cabl e.
(2) Remove the dri ver si de front door tri m panel .
Refer to the Body secti on for the procedure.
(3) Di sconnect the memory swi tch wi re harness
connector from the dri ver door modul e connector
receptacl e.
(4) Use an ohmmeter to test the resi stances of the
memory swi tch i n each swi tch posi ti on. See the Mem-
ory Swi tch Test chart MEMORY SWI TCH TEST . I f
OK, refer to Memory System Diagnosis and Test-
ing i n thi s group. I f not OK, repl ace the faul ty mem-
ory swi tch.
MEMORY SWITCH TEST
MEMORY
SWITCH
POSITION
RESISTANCE
BETWEEN
RESISTANCE
RANGE
(OHMS)
NEUTRAL A&D 14000 1%
MEMORY 1 A&B 4600 1%
MEMORY 2 A&B 1700 1%
SET A&B 300 1%
REMOVAL
cabl e.
(2) Remove the tri m panel from the dri ver si de
front door. Refer to Front Door TrimPanel i n Body
for the procedure.
(3) Di sconnect the memory swi tch wi re harness
connector from the dri ver door modul e connector
receptacl e.
(4) Remove the two screws that secure the memory
swi tch to the back of the dri ver si de front door tri m
panel .
(5) Remove the memory swi tch from the back of
the dri ver si de front door tri m panel .
INSTALLATION
(1) Posi ti on the memory swi tch onto the back of
the dri ver si de front door tri m panel .
the memory swi tch to the back of the dri ver si de
front door tri m panel . Ti ghten the screws to 2.2 Nm
(20 i n. l bs.).
(3) Reconnect the memory swi tch wi re harness
connector to the dri ver door modul e connector recep-
tacl e.
(4) I nstal l the tri m panel onto the dri ver si de front
door. Refer to Front Door Trim Panel i n Body for
the procedure.
PASSENGER SEAT SWITCH
DESCRIPTION
Two di fferent power seat swi tches are used on thi s
vehi cl e, dependi ng upon the opti onal power seat sys-
tem i nstal l ed i n the vehi cl e. The si x-way power seats
are each equi pped wi th a swi tch featuri ng three
swi tch control knobs ganged together on the outboard
seat cushi on si de shi el d (Fi g. 13). The ten-way power
seats are each equi pped wi th a swi tch featuri ng two
knobs ganged together on the outboard seat cushi on
si de shi el d (Fi g. 14).
The swi tch uni ts for both power seat types are
secured to the back of the seat cushi on si de shi el d
wi th two screws. However, the control knobs for the
si x-way power seat swi tch uni t remai n i nstal l ed dur-
Fig. 13 Six-Way Power Seat Switches - Typical
2 - POWER SEAT TRACK SWITCHES
3 - MECHANICAL SEAT BACK RECLINER LEVER
MEMORY SET SWITCH (Continued)
i ng swi tch uni t removal and i nstal l ati on, whi l e both
knobs for the ten-way power seat swi tch uni t must
be removed.
The i ndi vi dual swi tches i n both power seat swi tch
uni ts cannot be repai red. I f one swi tch i s damaged or
faul ty, the enti re power seat swi tch uni t must be
repl aced.
OPERATION
The power seat tracks of both the si x-way and the
ten-way power seat systems can be adjusted i n si x
di fferent ways usi ng the power seat swi tches. The
ten-way system has the addi ti onal power seat
recl i ner swi tch i ntegral to the power seat swi tch and
al so has a separate, stand-al one swi tch to control the
power l umbar adjuster. See the owners manual i n
power seat swi tch functi ons and the seat adjusti ng
procedures.
When a power swi tch control knob or knobs are
actuated, a battery feed and a ground path are
appl i ed through the swi tch contacts to the power seat
track or recl i ner adjuster motor. The sel ected
adjuster motor operates to move the seat track or
recl i ner through i ts dri ve uni t i n the sel ected di rec-
swi tch contacts. Thi s causes the adjuster motor to
run i n the opposi te di recti on.
No power seat swi tch shoul d be hel d appl i ed i n any
di recti on after the adjuster has reached i ts travel
l i mi t. The power seat adjuster motors each contai n a
sel f-resetti ng ci rcui t breaker to protect them from
overl oad. However, consecuti ve or frequent resetti ng
of the ci rcui t breaker must not be al l owed to con-
ti nue, or the motor may be damaged.
DIAGNOSIS AND TESTING - PASSENGER SEAT
SWITCH
Diagrams.
cabl e.
power seat swi tch i n each swi tch posi ti on. See the
Power Seat Swi tch Conti nui ty chart (Fi g. 15) or (Fi g.
16). I f OK, refer to Diagnosis and Testing Power
Seat Track or Diagnosis and Testing Power Seat
Recliner i n thi s secti on. I f not OK, repl ace the
faul ty power seat swi tch.
Fig. 14 Ten-Way Power Seat Switches - Typical
Fig. 15 Rear Of Six-Way Power Seat Switch
SIX-WAY POWER SEAT SWITCH TEST
LEFT SWITCH
POSITION
RIGHT
SWITCH
POSITION
CONTINUITY
BETWEEN
OFF OFF
B-N, B-J, B-M,
B-E, B-L, B-K
VERTICAL UP
VERTICAL
DOWN
A-J, A-N, B-M,
B-E
VERTICAL
DOWN
VERTICAL UP
A-E, A-M, B-N,
B-J
HORIZONTAL
FORWARD
HORIZONTAL
REARWARD
A-K, B-L
FRONT TILT
UP
FRONT TILT
DOWN
A-J, B-E
FRONT TILT
DOWN
FRONT TILT
UP
A-E, B-J
REAR TILT UP
REAR TILT
DOWN
A-N, B-M
REAR TILT
DOWN
REAR TILT UP A-M, B-N
PASSENGER SEAT SWITCH (Continued)
SWITCH
POSITION
CONTINUITY BETWEEN PINS
LEFT SEAT RIGHT SEAT
OFF PIN 1 to 2 PIN 1 to 2
FRONT RISER
UP
FRONT RISER
DOWN
CENTER
SWITCH
FORWARD
CENTER
SWITCH
REARWARD
REAR RISER
UP
REAR RISER
DOWN
RECLINER UP PIN 1 to 4 PIN 1 to 4
RECLINER
DOWN
REMOVAL
cabl e.
onl y, usi ng a push pi n remover or another sui tabl e
wi de fl at-bl aded tool , gentl y pry the power seat and
power recl i ner swi tch knobs off of the swi tch stems
(Fi g. 17).
frame.
power seat swi tch wi re harness connector.
tor from the power seat swi tch connector receptacl e.
seat swi tch to the i nsi de of the outboard seat cushi on
si de shi el d (Fi g. 18) or (Fi g. 19).
INSTALLATION
(1) Posi ti on the power seat swi tch onto the out-
the power seat swi tch to the i nsi de of the outboard
seat cushi on si de shi el d. Ti ghten the screws to 1.5
Nm (14 i n. l bs.).
tor to the power seat swi tch connector receptacl e.
Fig. 16 Ten-Way Power Seat
Switch Connector Receptacle
Fig. 17 Removing Switch Control Knobs - Typical
the outboard seat cushi on si de shi el d to the seat
cushi on frame. Ti ghten the screws to 1.5 Nm (14 i n.
l bs.).
onl y, posi ti on the power seat and power recl i ner
swi tch knobs onto the swi tch stems and push on
them fi rml y and evenl y unti l they snap i nto pl ace.
RECLINER MOTOR
DESCRIPTION
cal l y operated seat back recl i ner mechani sm. The
onl y vi si bl e evi dence of thi s opti on i s the separate
power seat recl i ner swi tch control knob that i s
l ocated on the outboard seat cushi on si de shi el d, just
behi nd the other power seat swi tch control knob. The
power seat recl i ner swi tch i s i ntegral to the ten-way
power seat swi tch uni t, but i s actuated wi th a sepa-
rate swi tch knob.
The power seat recl i ner uni t i s mounted i n the
pl ace of a seat hi nge on the outboard si de of the seat
(Fi g. 20). The upper hi nge pl ate of the power seat
recl i ner mechani sm i s secured wi th two screws to the
seat back frame and i s conceal ed beneath the seat
back tri m cover and paddi ng. The l ower hi nge pl ate
and the motor and dri ve uni t of the power seat
recl i ner mechani sm i s secured wi th two screws to the
seat cushi on frame, and i s conceal ed by the outboard
seat cushi on si de shi el d.
The power seat recl i ner cannot be repai red. I f the
uni t i s faul ty or damaged, i t must be repl aced. Refer
to Bucket Seat Recliner i n Body for the servi ce
procedure.
OPERATION
The power seat recl i ner i ncl udes a reversi bl e el ec-
tri c motor that i s secured to the l ower hi nge pl ate of
the recl i ner uni t. The motor i s connected to a gearbox
that moves the upper hi nge pl ate of the power seat
recl i ner through a screw-type dri ve uni t. The dri ver
si de power seat recl i ner motor used on model s
equi pped wi th the opti onal memory system al so has
a posi ti on potenti ometer i ntegral to the motor assem-
bl y, whi ch el ectroni cal l y moni tors the motor posi ti on.
DIAGNOSIS AND TESTING - RECLINER MOTOR
Actuate the power seat recl i ner swi tch to move the
power seat recl i ner adjuster i n each di recti on. The
power seat recl i ner adjuster shoul d move i n both
di recti ons. I f the power seat recl i ner adjuster fai l s to
operate i n onl y one di recti on, move the adjuster a
short di stance i n the opposi te di recti on and test
agai n to be certai n that the adjuster i s not at i ts
travel l i mi t. I f the power seat recl i ner adjuster sti l l
fai l s to operate i n onl y one di recti on, refer to Power
Seat Switch Diagnosis and Testing i n thi s group.
I f the power recl i ner adjuster fai l s to operate i n
ei ther di recti on, perform the fol l owi ng tests. For com-
pl ete ci rcui t di agrams, refer to Wiring Diagrams.
Fig. 18 Six-Way Power Seat Switches Remove/
Install
1 - SEAT SIDE SHIELD
3 - SCREWS
Fig. 19 Ten-Way Power Seat Switches Remove/
Install
2 - SCREWS (2)
4 - SEAT CUSHION SIDE SHIELD
nector from the power seat swi tch connector recepta-
cl e. Check for battery vol tage at the fused B(+)
ci rcui t cavi ty of the power seat wi re harness connec-
tor for the power seat swi tch. I f OK, go to Step 4. I f
not OK, repai r the open fused B(+) ci rcui t to the
power seat ci rcui t breaker i n the juncti on bl ock as
requi red.
for the power seat swi tch and a good ground. There
(5) Test the power seat swi tch. Refer to Power
I f the swi tch tests OK, test the ci rcui ts of the power
seat wi re harness between the power seat recl i ner
adjuster motor and the power seat swi tch for shorts
or opens. I f the ci rcui ts check OK, repl ace the faul ty
power seat recl i ner uni t. I f the ci rcui ts are not OK,
repai r the power seat wi re harness as requi red.
POWER SEAT TRACK
DESCRIPTION
Both the si x-way and the ten-way power seat
opti ons i ncl ude a si ngl e el ectri cal l y operated power
seat track uni t l ocated under each front bucket seat
(Fi g. 21). The power seat track uni t repl aces the
standard equi pment manual seat tracks. The l ower
hal f of the power seat track i s secured at the front
wi th two screws to the fl oor panel seat cross member,
and at the rear wi th two screws to the fl oor panel .
Four nuts secure the bottom of the seat cushi on
frame to four studs on the upper hal f of the power
seat track uni t.
The power seat track uni t cannot be repai red, and i s
servi ced onl y as a compl ete uni t. I f any component i n
thi s uni t i s faul ty or damaged, the enti re power seat
track uni t must be repl aced. Refer to Bucket Seat
Track Adjuster i n Body for the servi ce procedure.
Fig. 20 Power Seat Recliner and Track - Typical
1 - SEAT BACK FRAME
2 - SEAT CUSHION PAD
3 - POWER RECLINER
5 - SHIELD
6 - POWER SEAT TRACK ADJUSTER
Fig. 21 Power Seat Track - Typical
1 - DRIVE UNITS
2 - LOWER SEAT TRACKS
3 - POWER SEAT MOTORS
RECLINER MOTOR (Continued)
OPERATION
The power seat track uni t i ncl udes three reversi bl e
el ectri c motors that are secured to the upper hal f of
the track uni t. Each motor moves the seat adjuster
through a combi nati on of worm-dri ve gearboxes and
screw-type dri ve uni ts. Each of the three dri ver si de
power seat track motors used on model s equi pped
wi th the opti onal memory system al so has a posi ti on
potenti ometer i ntegral to the motor assembl y, whi ch
el ectroni cal l y moni tors the motor posi ti on.
The front and rear of the seat are operated by two
separate verti cal adjustment motors. These motors
can be operated i ndependentl y of each other, ti l ti ng
the enti re seat assembl y forward or rearward; or,
they can be operated i n uni son by sel ecti ng the
proper power seat swi tch functi ons, whi ch wi l l rai se
or l ower the enti re seat assembl y. The thi rd motor i s
the hori zontal adjustment motor, whi ch moves the
seat track i n the forward and rearward di recti ons.
DIAGNOSIS AND TESTING - POWER SEAT
TRACK
hard wi red components and ci rcui ts of the power seat
system. However, i f the vehi cl e i s al so equi pped wi th
the opti onal memory system, these tests may not
prove concl usi ve i n the di agnosi s of the dri ver si de
power seat. I n order to obtai n concl usi ve testi ng of
the dri ver si de power seat wi th the memory system
opti on, the Programmabl e Communi cati ons I nterface
the memory system components must be checked.
di agnose the dri ver si de power seat wi th the memory
system opti on requi res the use of a DRB scan tool
and the proper Di agnosti c Procedures manual . The
DRB scan tool can provi de confi rmati on that the
PCI data bus i s functi onal , that al l of the el ectroni c
modul es are sendi ng and recei vi ng the proper mes-
sages on the PCI data bus, and that the memory sys-
tem i s recei vi ng the proper hard wi red i nputs and
rel ayi ng the proper hard wi red outputs to perform i ts
dri ver si de power seat functi ons.
Actuate the power seat swi tch to move al l three
power seat track adjusters i n each di recti on. The
power seat track adjusters shoul d move i n each of
the sel ected di recti ons. I f a power seat track adjuster
fai l s to operate i n onl y one di recti on, move the
adjuster a short di stance i n the opposi te di recti on
and test agai n to be certai n that the adjuster i s not
at i ts travel l i mi t. I f the power seat track adjuster
sti l l fai l s to operate i n onl y one di recti on, refer to
Power Seat Switch Diagnosis and Testing i n thi s
group. I f the power seat track adjuster fai l s to oper-
ate i n more than one di recti on, perform the fol l owi ng
tests. For compl ete ci rcui t di agrams, refer to Wiring
Diagrams.
nector from the power seat swi tch connector recepta-
cl e. Check for battery vol tage at the fused B(+)
ci rcui t cavi ty of the power seat wi re harness connec-
tor for the power seat swi tch. I f OK, go to Step 4. I f
not OK, repai r the open fused B(+) ci rcui t to the
power seat ci rcui t breaker i n the juncti on bl ock as
requi red.
for the power seat swi tch and a good ground. There
(5) Test the power seat swi tch. Refer to Power
I f the swi tch tests OK, test the ci rcui ts of the power
seat wi re harness between the i noperati ve power seat
track adjuster motor and the power seat swi tch for
shorts or opens. I f the ci rcui ts check OK, repl ace the
faul ty power seat track uni t. I f the ci rcui ts are not
OK, repai r the power seat wi re harness as requi red.
POWER SEAT TRACK (Continued)
POWER WINDOWS
TABLE OF CONTENTS
page page
POWER WINDOWS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
POWER WINDOW SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
WINDOW SWITCH . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
WINDOW MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - WINDOW
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
POWER WINDOWS
DESCRIPTION
Power operated dri ver si de and passenger si de
front and rear door wi ndows are standard factory-i n-
stal l ed equi pment on thi s model . The power wi ndow
system al l ows each of the door wi ndows to be rai sed
or l owered el ectri cal l y by operati ng a swi tch on the
tri m panel for that door. Addi ti onal l y, the master
swi tches on the dri ver si de front door tri m panel
al l ow al l of the wi ndows to be operated from the
dri ver seat posi ti on. A power wi ndow l ockout swi tch
on the dri ver si de front door tri m panel wi l l al l ow the
dri ver to di sabl e al l of the passenger door wi ndow
swi tches.
The power wi ndow system functi onal l y operates
when the i gni ti on swi tch i s i n the On posi ti on. How-
ever, a uni que feature of thi s system wi l l al l ow the
power wi ndows to be operated for up to forty-fi ve sec-
onds after the i gni ti on swi tch i s turned to the Off
posi ti on, or unti l a front door i s opened, whi chever
occurs fi rst.
An auto-down feature al l ows the dri ver si de front
door wi ndow to be l owered al l the way, even i f the
wi ndow swi tch i s rel eased. The dri ver si de front door
wi ndow swi tch must be depressed i n the down di rec-
ti on to a second detent to begi n an auto-down event.
Depressi ng the swi tch agai n i n any di recti on cancel
the auto-down event and begi n movement i n the
di recti on speci fi ed.
power wi ndow system:
Power wi ndow swi tches
Power wi ndow motors.
Certai n functi ons and features of the power wi n-
dow system rel y upon resources shared wi th other
el ectroni c modul es i n the vehi cl e over the Program-
work. The PCI data bus network al l ows the shari ng
of sensor i nformati on. Thi s hel ps to reduce wi re har-
ness compl exi ty, i nternal control l er hardware, and
component sensor current l oads. At the same ti me,
thi s system provi des i ncreased rel i abi l i ty, enhanced
modul es or of the PCI data bus network, the use of a
wi ndow system operati on are as fol l ows:
Driver Door Module (DDM) -(Refer to 8 -
Passenger Door Module (PDM) - (Refer to 8 -
Thi s group covers di agnosi s and servi ce of onl y the
el ectri cal components i n the power wi ndow system.
For servi ce of mechani cal components, such as the
regul ator, l i ft pl ate, wi ndow tracks, or gl ass refer to
Body. Refer to the appropri ate wi ri ng i nformati on.
wi re harness connectors, spl i ces and grounds. Fol l ow-
i ng are general descri pti ons of the major components
i n the power wi ndow system.
WJ POWER WINDOWS 8N - 33
OPERATION
The power wi ndow system i ncl udes the Dri ver
Door Modul e (DDM) and Passenger Door Modul e
(PDM), whi ch are mounted i n thei r respecti ve front
door, the rear door power wi ndow swi tches mounted
on the rear doors, and the power wi ndow motors
mounted to the wi ndow regul ator i n each door. The
DDM houses four master power wi ndow swi tches, the
power wi ndow l ockout swi tch and the control l ogi c for
the dri ver si de front and rear door power wi ndows.
The PDM houses the passenger si de front door power
wi ndow swi tch and the control l ogi c for the passenger
si de front and rear door power wi ndows.
When a master power wi ndow swi tch on the DDM
i s used to operate a passenger si de power wi ndow,
the DDM sends the wi ndow swi tch actuati on mes-
sage to the PDM over the Programmabl e Communi -
cati ons I nterface (PCI ) data bus. The PDM responds
to these messages by sendi ng control outputs to move
the passenger si de power wi ndow motors. I n addi -
ti on, when the power wi ndow l ockout swi tch i n the
DDM i s actuated to di sabl e power wi ndow operati on,
a l ockout message i s sent to the PDM over the PCI
data bus.
The Body Control Modul e (BCM) al so supports and
control s certai n features of the power wi ndow sys-
tem. The BCM recei ves a hard wi red i nput from the
i gni ti on swi tch. The programmi ng i n the BCM al l ows
i t to process the i nformati on from thi s i nput and
send i gni ti on swi tch status messages to the DDM
and the PDM over the PCI data bus. The DDM and
PDM use thi s i nformati on and hard wi red i nputs
from the front door ajar swi tches to control the l i ght-
i ng of the power wi ndow swi tch l amps, and to control
the operati on of the power wi ndow after i gni ti on-off
feature.
of the power wi ndow system.
WINDOWS
hard wi red components and ci rcui ts of the power
wi ndow system. However, these tests may not prove
concl usi ve i n the di agnosi s of thi s system. I n order to
obtai n concl usi ve testi ng of the power wi ndow sys-
tem, the Programmabl e Communi cati ons I nterface
the power wi ndow system components must be
checked.
di agnose the power wi ndow system requi res the use
of a DRB scan tool and the proper Di agnosti c Proce-
the power wi ndow motors are bei ng sent the proper
hard wi red outputs by the door modul es for them to
perform thei r power wi ndow system functi ons.
ALL WINDOWS INOPERATIVE
on the dri ver si de front door. I f al l of the doors l ock
and unl ock, but none of the power wi ndows operate,
use a DRB scan tool and the proper Di agnosti c Pro-
cedures manual to check the Body Control Modul e
(BCM), the Dri ver Door Modul e (DDM) and the PCI
data bus for proper operati on. I f not OK, go to Step
2.
on the passenger si de front door. I f the passenger
doors l ock and unl ock, but the dri ver si de front door
does not, go to Step 5. I f al l of the power l ocks and
power wi ndows are i noperati ve from both front doors,
go to Step 3.
buti on Center (PDC). I f OK, go to Step 4. I f not OK,
repai r the shorted ci rcui t or component as requi red
and repl ace the faul ty fuse.
i n the PDC. I f OK, go to Step 5. I f not OK, repai r the
open fused B(+) ci rcui t to the battery as requi red.
cabl e. Remove the tri m panel from the dri ver si de
front door. Di sconnect the 15-way door wi re harness
connector from the DDM connector receptacl e. Check
for conti nui ty between the ground ci rcui t cavi ty of
the 15-way door wi re harness connector for the DDM
15-way door wi re harness connector for the DDM. I f
OK, repl ace the faul ty DDM. I f not OK, repai r the
open fused B(+) ci rcui t to the fuse i n the PDC as
requi red.
8N - 34 POWER WINDOWS WJ
POWER WINDOWS (Continued)
PASSENGER SIDE FRONT AND REAR WINDOWS
INOPERATIVE
I f the dri ver si de front and rear power wi ndows
operate, but the passenger si de front and rear do not,
cedures manual to check the PCI data bus for proper
operati on.
ONE WINDOW INOPERATIVE
The wi ndow gl ass and regul ator mechani sm must
be free to sl i de up and down for the power wi ndow
motor to functi on properl y. I f the wi ndow gl ass and
regul ator i s not free to move up and down, the motor
wi l l overl oad and tri p the i ntegral ci rcui t breaker. To
determi ne i f the wi ndow gl ass and regul ator are free,
di sconnect the regul ator pl ate from the gl ass. Then
sl i de the wi ndow up and down by hand.
There i s an al ternate method to check i f the wi n-
dow gl ass and regul ator mechani sm i s free. Posi ti on
the gl ass between the up and down stops. Then,
shake the gl ass i n the door. Check that the gl ass can
be moved sl i ghtl y from si de to si de, front to rear, and
up and down. Then check that the gl ass i s not bound
ti ght i n the tracks.
I f the wi ndow gl ass and regul ator mechani sm i s
free, refer to Door Module i n El ectri cal , Power Wi n-
dows. I f the gl ass i s not free, i nspect the wi ndow
gl ass mounti ng and operati ng hardware for damage
or i mproperl y i nstal l ed components. Refer to Body to
check for proper i nstal l ati on or damage of the wi n-
dow gl ass mounti ng and operati ng hardware.
DOOR MODULE
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this component. The most
reliable, efficient, and accurate means to diagnose
this component requires the use of a DRB scan tool
and the proper Diagnostic Procedures manual.
I f the probl em bei ng di agnosed i s a rear door wi n-
dow that does not operate from the rear door swi tch,
but does operate from the master swi tch on the
dri ver si de front door, (Refer to 8 - ELECTRI CAL/
POWER WI NDOWS/POWER WI NDOW SWI TCH -
DI AGNOSI S AND TESTI NG). I f the probl em i s a
passenger si de front or rear wi ndow that operates
from the swi tch on that door, but does not operate
from the master swi tch on the dri ver si de front door,
cedures manual to di agnose the ci rcui try of both door
modul es and the PCI data bus. For compl ete ci rcui t
di agrams, refer to the appropri ate wi ri ng i nforma-
detai l s of wi re harness routi ng and retenti on, connec-
tor pi n-out i nformati on and l ocati on vi ews for the
cabl e. Remove the tri m panel from the front door, but
do not di sconnect the door wi re harness connectors
from the door modul e. Go to Step 2.
(2) Check the 15-way door wi re harness connector
for the door modul e to see that i t i s ful l y seated i n
the door modul e connector receptacl e. I f OK, go to
Step 3. I f not OK, properl y connect the 15-way door
wi re harness connector for the door modul e to the
door modul e connector receptacl e.
i ty of the 15-way door wi re harness connector for the
door modul e and a good ground. There shoul d be con-
ti nui ty. I f OK, go to Step 4. I f not OK, repai r the
open ground ci rcui t to ground as requi red.
15-way door wi re harness connector for the door
modul e. I f OK, go to Step 5. I f not OK, repai r the
open fused B(+) ci rcui t to the fuse i n the Power Di s-
tri buti on Center (PDC) as requi red.
(5) I f the i noperati ve wi ndow i s on a front door, go
to Step 6. I f the i noperati ve wi ndow i s on a rear door
go to Step 9.
cabl e. Di sconnect the door wi re harness connector
from the i noperati ve power wi ndow motor wi re har-
ness connector. Check for conti nui ty between the
front wi ndow dri ver up ci rcui t cavi ty of the 15-way
door wi re harness connector for the door modul e and
a good ground. Repeat the check for the front wi ndow
dri ver down ci rcui t. I n each case there shoul d be no
shorted front wi ndow dri ver up or down ci rcui t as
requi red.
(7) Check for conti nui ty between the front wi ndow
dri ver up ci rcui t cavi ti es of the 15-way door wi re har-
ness connector for the door modul e and the door wi re
harness connector for the power wi ndow motor.
Repeat the check for the front wi ndow dri ver down
ci rcui t. I n each case there shoul d be conti nui ty. I f
OK, go to Step 8. I f not OK, repai r the open front
wi ndow dri ver up or down ci rcui t as requi red.
(8) Reconnect the 15-way door wi re harness con-
nector back i nto the door modul e connector recepta-
cl e. Connect the battery negati ve cabl e. Connect the
probes of a reversi bl e DC di gi tal vol tmeter to the
door wi re harness connector for the power wi ndow
motor. Observe the vol tmeter whi l e actuati ng the
swi tch for that wi ndow i n the up and down di rec-
ti ons. There shoul d be battery vol tage for as l ong as
the swi tch i s hel d i n both the up and down posi ti ons,
and no vol tage i n the neutral posi ti on. I f OK,(Refer
to 8 - ELECTRI CAL/POWER WI NDOWS/WI NDOW
MOTOR - DI AGNOSI S AND TESTI NG). I f not OK,
repl ace the faul ty door modul e.
(9) Check the rear door power wi ndow swi tch con-
ti nui ty. (Refer to 8 - ELECTRI CAL/POWER WI N-
DOWS/POWER WI NDOW SWI TCH - DI AGNOSI S
AND TESTI NG). I f OK, go to Step 10. I f not OK,
repl ace the faul ty rear door power wi ndow swi tch.
cabl e. Reconnect the door wi re harness connector to
the rear door power wi ndow swi tch. Di sconnect the
door wi re harness connector from the i noperati ve
power wi ndow motor wi re harness connector. Check
for conti nui ty between the rear wi ndow dri ver up ci r-
cui t cavi ty of the 15-way door wi re harness connector
for the door modul e and a good ground. Repeat the
check for the rear wi ndow dri ver down ci rcui t. I n
each case there shoul d be no conti nui ty. I f OK, go to
Step 11. I f not OK, repai r the shorted rear wi ndow
dri ver up or down ci rcui t as requi red.
(11) Check for conti nui ty between the rear wi ndow
dri ver up ci rcui t cavi ti es of the 15-way door wi re har-
ness connector for the door modul e and the power
wi ndow motor wi re harness connector. Repeat the
check for the rear wi ndow dri ver down ci rcui t. I n
each case there shoul d be conti nui ty. I f OK, go to
Step 12. I f not OK, repai r the open rear wi ndow
dri ver up or down ci rcui t as requi red.
NOTE: The door module feeds battery current to
both terminals of the rear door power window
motors when the power window lockout switch is in
the Unlock position, until the master window switch
on the driver side front door is actuated. The door
module feeds ground to both terminals of the rear
door power window motor when the power window
lockout switch is in the Lock position, until the
master window switch on the driver side front door
is actuated.
(12) Reconnect the 15-way door wi re harness con-
nector for the door modul e to the door modul e con-
nector receptacl e. Connect the battery negati ve cabl e.
Check for battery vol tage at each cavi ty i n the door
wi re harness connector for the power wi ndow motor.
Each cavi ty shoul d have battery vol tage when the
power wi ndow swi tch i s i n the neutral posi ti on. Each
cavi ty shoul d al so have battery vol tage i n one other
swi tch posi ti on, ei ther up or down, and zero vol ts
wi th the swi tch i n the opposi te posi ti on. I f OK, (Refer
to 8 - ELECTRI CAL/POWER WI NDOWS/WI NDOW
repl ace the faul ty door modul e.
POWER WINDOW SWITCH
DESCRIPTION
The power wi ndow motors are control l ed by a two-
way momentary swi tch mounted on the tri m panel of
each passenger door, and four two-way momentary
swi tches on the dri ver si de front door tri m panel . The
dri ver si de front door tri m panel al so has a two-posi -
ti on power wi ndow l ockout swi tch. Each power wi n-
dow swi tch, except the l ockout swi tch, i s i l l umi nated
by a Li ght-Emi tti ng Di ode (LED) that i s i ntegral to
the swi tch paddl e.
The front door power wi ndow swi tches and the
power wi ndow l ockout swi tch are i ntegral to the
Dri ver Door Modul e (DDM) and Passenger Door
Modul e (PDM). The front door power wi ndow
swi tches and thei r l amps cannot be adjusted or
repai red and, i f faul ty or damaged, the enti re DDM
or PDM uni t must be repl aced. The rear door power
wi ndow swi tches and thei r l amps cannot be adjusted
or repai red but, i f faul ty or damaged, onl y the
affected rear door power wi ndow swi tch must be
repl aced. (Refer to 8 - ELECTRI CAL/ELECTRONI C
CONTROL MODULES/DRI VER DOOR MODULE -
REMOVAL).
OPERATION
The front door power wi ndow swi tches provi de an
up or down (or l ock and unl ock si gnal i n the case of
the l ockout swi tch) to the door modul e ci rcui try. The
Dri ver Door Modul e (DDM) ci rcui try control s the out-
put to the dri ver si de front and rear door power wi n-
dow motors, and suppl i es el ectri cal current as
requi red for the stand-al one operati on of the dri ver
si de rear door power wi ndow swi tch. The Passenger
Door Modul e (PDM) ci rcui try control s the output to
the passenger si de front and rear door power wi ndow
motors, and suppl i es el ectri cal current as requi red
for the stand-al one operati on of the passenger si de
rear door power wi ndow swi tch.
When a DDM-i ntegrated master power wi ndow
swi tch for a passenger si de wi ndow i s actuated, or
when the power wi ndow l ockout swi tch i s actuated to
di sabl e the passenger door power wi ndows, the DDM
ci rcui try sends a message to the PDM over the Pro-
to control the output to that power wi ndow motor(s).
The power wi ndow swi tch for the dri ver si de front
door power wi ndow has two detent posi ti ons i n the
Down di recti on. The fi rst detent provi des normal
power wi ndow down operati on. I f thi s swi tch i s
depressed to the second detent, the Auto Down ci r-
cui try of the DDM i s acti vated. The Auto-Down ci r-
cui try wi l l automati cal l y move the dri ver si de front
door wi ndow to i ts ful l y l owered posi ti on, even i f the
power wi ndow swi tch i s rel eased. The Auto-Down
event wi l l be automati cal l y cancel l ed and the wi ndow
movement wi l l be stopped i f the DDM ci rcui try
detects a second i nput from the dri ver si de front door
power wi ndow swi tch, i n ei ther di recti on.
Each power wi ndow swi tch, except the l ockout
swi tch, i s i l l umi nated by a Li ght-Emi tti ng Di ode
(LED) when the i gni ti on swi tch i s turned to the On
posi ti on. However, when the l ockout swi tch i s pl aced
i n the Lock posi ti on, the LED for the l ocked-out front
and rear passenger door power wi ndow swi tches i s
turned off.
of the power wi ndow swi tches.
DIAGNOSIS AND TESTING - POWER WINDOW
SWITCH
The di agnosi s found here appl i es onl y to the rear
door power wi ndow swi tches. I f the probl em bei ng
di agnosed i s an i noperati ve power wi ndow swi tch
i l l umi nati on l amp, but the power wi ndow swi tch
operates as desi gned, repl ace the faul ty rear door
power wi ndow swi tch (verify the power lockout
switch is not actuated). For compl ete ci rcui t di a-
grams, refer to the appropri ate wi ri ng i nformati on.
cabl e.
(2) Remove the power wi ndow swi tch from the
rear door tri m panel . (Refer to 8 - ELECTRI CAL/
POWER WI NDOWS/POWER WI NDOW SWI TCH -
REMOVAL).
(3) Check the rear door power wi ndow swi tch con-
ti nui ty as shown i n the Rear Door Power Wi ndow
Swi tch Conti nui ty chart (Fi g. 1). I f OK, (Refer to 8 -
ELECTRI CAL/POWER WI NDOWS/WI NDOW
repl ace the faul ty rear door power wi ndow swi tch.
REMOVAL
cabl e.
(2) Remove the tri m panel from the rear door.
(3) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the si des of the swi tch
receptacl e on the back of the rear door tri m panel
away from the peri meter of the power wi ndow swi tch
to rel ease the swi tch from the receptacl e (Fi g. 2).
(4) Remove the power wi ndow swi tch from the
rear door tri m panel swi tch receptacl e.
Fig. 1 Rear Door Power Window Switch Continuity
SWITCH POSITION CONTINUITY BETWEEN
LED 3 AND 6
OFF 1 AND 2
OFF 4 AND 5
FORWARD 1 AND 2
FORWARD 5 AND 6
REARWARD 2 AND 6
REARWARD 4 AND 5
Fig. 2 Rear Door Power Window Switch Remove/
Install
1 - REAR DOOR TRIM PANEL
2 - TRIM PANEL RECEPTACLE
3 - POWER WINDOW SWITCH
POWER WINDOW SWITCH (Continued)
INSTALLATION
(1) Posi ti on the power wi ndow swi tch to the rear
door tri m panel swi tch receptacl e.
(2) Press fi rml y and evenl y on the back of the
power wi ndow swi tch unti l i t snaps i nto rear door
tri m panel swi tch receptacl e.
(3) I nstal l the tri m panel onto the rear door. (Refer
to 23 - BODY/DOORS - REAR/TRI M PANEL -
WINDOW MOTOR
DESCRIPTION
Power operated front and rear door wi ndows are
standard equi pment on thi s model . Each door has a
permanent magnet reversi bl e el ectri c motor wi th an
i ntegral ri ght angl e gearbox mechani sm that oper-
ates the wi ndow regul ator. I n addi ti on, each power
wi ndow motor i s equi pped wi th an i ntegral sel f-reset-
ti ng ci rcui t breaker to protect the motor from over-
l oads.
The power wi ndow motor gearbox housi ng i s
secured to the wi ndow regul ator drum housi ng wi th
screws. The wi ndow regul ators used i n al l four doors
are si ngl e verti cal post cabl e-and-drum type. A
mol ded pl asti c sl i der gui ded by the post i s dri ven by
the regul ator cabl es. The sl i der rai ses and l owers the
wi ndow gl ass through a steel l i ft pl ate attachment.
Front and rear gl ass channel s wi thi n each door gui de
and stabi l i ze each end of the gl ass.
The power wi ndow motor and gearbox assembl y
cannot be repai red and, i f faul ty or damaged, the
enti re power wi ndow motor and gearbox uni t must be
repl aced. The wi ndow regul ators are avai l abl e for
servi ce. (Refer to 23 - BODY/DOOR - FRONT/WI N-
DOW REGULATOR - REMOVAL) or (Refer to 23 -
BODY/DOORS - REAR/WI NDOW REGULATOR -
REMOVAL) for the regul ator servi ce procedures.
OPERATION
A posi ti ve and negati ve battery connecti on to the
two motor termi nal s wi l l cause the power wi ndow
motor to rotate i n one di recti on. Reversi ng the cur-
rent through these same two connecti ons wi l l cause
the motor to rotate i n the opposi te di recti on.
When the power wi ndow motor operates, i t rotates
the regul ator cabl e drum through i ts gearbox. The
wi ndow regul ator cabl e drum i s connected through
two cabl es to the pl asti c sl i der on the verti cal post.
As the cabl e drum rotates, i t l ets cabl e out on one
si de of the drum, and takes cabl e i n on the other si de
of the drum. The changes i n cabl e l ength move the
sl i der up or down the verti cal post, rai si ng or l ower-
i ng the wi ndow gl ass.
I f the wi ndow regul ator or wi ndow gl ass bi nd,
encounter obstructi ons, or reach thei r travel l i mi ts i t
overl oads the power wi ndow motor. The overl oadi ng
condi ti on causes the power wi ndow motor sel f-reset-
ti ng ci rcui t breaker to open, whi ch stops the motor
from runni ng.
DIAGNOSIS AND TESTING - WINDOW MOTOR
Before you proceed wi th thi s di agnosi s, confi rm
proper swi tch operati on. (Refer to 8 - ELECTRI CAL/
ELECTRONI C CONTROL MODULES/DRI VER
DOOR MODULE - OPERATI ON) or (Refer to 8 -
ELECTRI CAL/POWER WI NDOWS/POWER WI N-
DOW SWI TCH - OPERATI ON). For compl ete ci rcui t
di agrams, refer to the appropri ate wi ri ng i nforma-
detai l s of wi re harness routi ng and retenti on, connec-
tor pi n-out i nformati on and l ocati on vi ews for the
(1) Remove the tri m panel from the door wi th the
i noperati ve power wi ndow. (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - REMOVAL) or
from the power wi ndow motor wi re harness connec-
tor. Appl y battery current to one cavi ty of the power
wi ndow motor wi re harness connector, and appl y
ground to the other cavi ty of the connector. The
power wi ndow motor shoul d operate i n one di recti on.
Remember, i f the wi ndow i s i n the ful l up or ful l
down posi ti on, the motor wi l l not operate i n that
di recti on by desi gn. I f OK, go to Step 3. I f not OK,
repl ace the faul ty power wi ndow motor.
(3) Reverse the battery and ground connecti ons to
the two cavi ti es of the power wi ndow motor wi re har-
ness connector. The power wi ndow motor shoul d now
operate i n the other di recti on. Remember, i f the wi n-
dow i s i n the ful l up or ful l down posi ti on, the motor
wi l l not operate i n that di recti on by desi gn. I f OK, go
to Step 4. I f not OK, repl ace the faul ty power wi ndow
motor.
(4) I f the power wi ndow motor operates i n both
di recti ons, check the operati on of the wi ndow gl ass
and regul ator mechani sm through i ts compl ete up
and down travel . There shoul d be no bi ndi ng or sti ck-
i ng of the wi ndow gl ass or regul ator mechani sm
through the enti re travel range. I f not OK, (Refer to
23 - BODY/DOOR - FRONT/WI NDOW REGULATOR
- REMOVAL) or (Refer to 23 - BODY/DOORS -
REAR/WI NDOW REGULATOR - REMOVAL) to
check for proper i nstal l ati on or damage of the wi n-
dow gl ass mounti ng and operati ng hardware.
POWER WINDOW SWITCH (Continued)
REMOVAL
cabl e.
(2) Remove the wi ndow regul ator from the door.
(Refer to 23 - BODY/DOOR - FRONT/WI NDOW
REGULATOR - REMOVAL) or (Refer to 23 - BODY/
DOORS - REAR/WI NDOW REGULATOR -
(3) Pl ace the wi ndow regul ator on a sui tabl e work
surface and remove the screws that secure the power
wi ndow motor to the wi ndow regul ator.
(4) Remove the power wi ndow motor from the wi n-
dow regul ator.
INSTALLATION
(1) Posi ti on the power wi ndow motor onto the wi n-
dow regul ator.
power wi ndow motor to the wi ndow regul ator.
Ti ghten the screws to 9 Nm (80 i n. l bs.).
(3) I nstal l the wi ndow regul ator onto the door.
(Refer to 23 - BODY/DOOR - FRONT/WI NDOW
REGULATOR - I NSTALLATI ON) or(Refer to 23 -
BODY/DOORS - REAR/WI NDOW REGULATOR -
WINDOW MOTOR (Continued)
RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WARNING - RESTRAINT SYSTEM . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . 5
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 6
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT. . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - VERIFICATION
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AIRBAG CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
CHILD TETHER ANCHOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
CLOCKSPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STANDARD PROCEDURE - CLOCKSPRING
CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
DRIVER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 20
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
FRONT IMPACT SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
FRONT IMPACT SENSOR & BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
FRONT SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
PASSENGER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
REAR CENTER SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REAR OUTBOARD SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
REAR SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
SEAT BELT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SEAT BELT TURNING LOOP ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
SIDE CURTAIN AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
SIDE IMPACT SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
RESTRAINTS
DESCRIPTION
An occupant restrai nt system i s standard factory-
i nstal l ed safety equi pment on thi s model . Avai l abl e
occupant restrai nts for thi s model i ncl ude both acti ve
and passi ve types. Acti ve restrai nts are those whi ch
requi re the vehi cl e occupants to take some acti on to
empl oy, such as fasteni ng a seat bel t; whi l e passi ve
restrai nts requi re no acti on by the vehi cl e occupants
to be empl oyed (Fi g. 1).
WJ RESTRAINTS 8O - 1
Fig. 1 Supplemental Restraints
1 - FRONT IMPACT SENSOR (2)
2 - PASSENGER AIRBAG
3 - DRIVER AIRBAG
4 - AIRBAG CONTROL MODULE
5 - SIDE IMPACT SENSOR (2)
6 - SIDE CURTAIN AIRBAG (2)
8O - 2 RESTRAINTS WJ
RESTRAINTS (Continued)
ACTIVE RESTRAINTS
The acti ve restrai nts for thi s model i ncl ude:
Front Seat Belts - Both front seati ng posi ti ons
are equi pped wi th three-poi nt seat bel t systems
empl oyi ng a l ower B-pi l l ar mounted i nerti a l atch-
type retractor, hei ght-adjustabl e upper B-pi l l ar
mounted turni ng l oops, a fi xed l ower seat bel t anchor
secured to the l ower B-pi l l ar, and a fi xed end-rel ease
seat bel t buckl e secured to the si de of the fl oor panel
transmi ssi on tunnel . Both front seat bel t buckl es
i ncl ude an i ntegral Hal l -effect seat bel t swi tch that
detects whether i ts respecti ve seat bel t has been fas-
tened.
Rear Seat Belts - Both outboard rear seati ng
posi ti ons are equi pped wi th three-poi nt seat bel t sys-
tems. The outboard seati ng posi ti on bel ts empl oy a
l ower C-pi l l ar mounted i nerti a l atch-type retractor,
hei ght-adjustabl e upper C-pi l l ar mounted turni ng
l oops, and a fi xed l ower seat bel t anchor secured to
the fl oor panel . The center rear seati ng posi ti on of
vehi cl es manufactured for sal e i n North Ameri ca has
a l ap bel t that i s anchored to the rear fl oor panel
wi th the ri ght outboard seat bel t buckl e. Vehi cl es
manufactured for sal e outsi de of North Ameri ca are
equi pped wi th a three-poi nt seat bel t i n the rear seat
center seati ng posi ti on. Thi s seat bel t has an i nerti a
l atch-type retractor that i s i ntegral to the rear seat
back panel , and the l ower bel t anchor i s secured to
the rear fl oor panel wi th the ri ght outboard seat bel t
buckl e. A cabl e from the seat back l atch l ocks the
center bel t retractor spool unl ess the seat back i s
ful l y l atched. Al l three rear seat bel ts have fi xed end-
rel ease seat bel t buckl es secured to the rear fl oor
panel , a si ngl e buckl e uni t on the ri ght si de and a
doubl e buckl e uni t on the l eft si de.
Child Seat Tether Anchors - Al l vehi cl es are
equi pped wi th three, fi xed-posi ti on, chi l d seat upper
tether anchors and two l ower anchors. Two upper
anchors are i ntegral to the back of the ri ght rear seat
back panel , and one i s i ntegral to the l eft rear seat
back panel . The two l ower anchors are i ntegral to the
outboard rear seat back brackets.
PASSIVE RESTRAINTS
The passi ve restrai nts avai l abl e for thi s model
Dual Front Airbags - Mul ti stage dri ver and
front passenger ai rbags are avai l abl e for thi s model .
Thi s ai rbag system i s a passi ve, i nfl atabl e, Suppl e-
mental Restrai nt System (SRS) and vehi cl es wi th
thi s equi pment can be readi l y i denti fi ed by the SRS
- AI RBAG l ogo mol ded i nto the dri ver ai rbag tri m
cover i n the center of the steeri ng wheel and al so
i nto the passenger ai rbag door area of the i nstru-
ment panel top pad above the gl ove box (Fi g. 2).
Vehi cl es wi th the ai rbag system can al so be i denti fi ed
by the ai rbag i ndi cator, whi ch wi l l i l l umi nate i n the
i nstrument cl uster for about seven seconds as a bul b
test each ti me the i gni ti on swi tch i s turned to the On
posi ti on.
Side Curtain Airbags - Opti onal si de curtai n
ai rbags are avai l abl e for thi s model when i t i s al so
equi pped wi th dual front ai rbags. Thi s ai rbag system
i s a passi ve, i nfl atabl e, Suppl emental Restrai nt Sys-
tem (SRS) and vehi cl es wi th thi s equi pment can be
readi l y i denti fi ed by a mol ded i denti fi cati on tri m but-
ton wi th the SRS - AI RBAG l ogo l ocated on the
headl i ner above each B-pi l l ar (Fi g. 2).
The suppl emental restrai nt system i ncl udes the
fol l owi ng major components, whi ch are descri bed i n
further detai l el sewhere i n thi s servi ce i nformati on:
Airbag Control Module - The Ai rbag Control
Modul e (ACM) i s al so someti mes referred to as the
Occupant Restrai nt Control l er (ORC). The ACM i s
l ocated on a mount on the fl oor panel transmi ssi on
tunnel near the park brake rel ease mechani sm,
under the center fl oor consol e.
Airbag Indicator - The ai rbag i ndi cator i s i nte-
gral to the El ectroMechani cal I nstrument Cl uster
(EMI C), whi ch i s l ocated on the i nstrument panel i n
front of the dri ver.
Clockspring - The cl ockspri ng i s l ocated near
the top of the steeri ng col umn, di rectl y beneath the
steeri ng wheel .
Driver Airbag - The dri ver ai rbag i s l ocated i n
the center of the steeri ng wheel , beneath the dri ver
ai rbag tri m cover.
Driver Knee Blocker - The dri ver knee bl ocker
i s a structural uni t secured to the back si de of and
i ntegral to the i nstrument panel steeri ng col umn
openi ng cover.
Front Impact Sensor - Two front i mpact sen-
sors are used on vehi cl es equi pped wi th dual front
ai rbags, one l eft si de and one ri ght si de. One sensor
i s l ocated on a bracket on the l ower i nboard si de of
each verti cal member of the radi ator support.
Fig. 2 SRS Logo
Passenger Airbag - The passenger ai rbag i s
l ocated on the i nstrument panel , beneath the i nstru-
ment panel top pad and above the gl ove box on the
passenger si de of the vehi cl e.
Passenger Knee Blocker - The passenger knee
bl ocker i s a structural rei nforcement that i s i ntegral
to and conceal ed wi thi n the gl ove box door.
Side Impact Sensor - Two si de i mpact sensors
are used on vehi cl es wi th the opti onal si de curtai n
ai rbags, one l eft si de and one ri ght si de. One sensor
i s l ocated behi nd the B-pi l l ar tri m near the base of
each B-pi l l ar.
Side Curtain Airbag - I n vehi cl es equi pped
wi th thi s opti on, a si de curtai n ai rbag i s l ocated on
each i nsi de roof si de rai l above the headl i ner, and
extends from the A-pi l l ar to just beyond the C-pi l l ar.
The ACM and the EMI C each contai n a central
processi ng uni t and programmi ng that al l ow them to
communi cate wi th each other usi ng the Programma-
bl e Communi cati on I nterface (PCI ) data bus network.
Thi s method of communi cati on i s used by the ACM
for control of the ai rbag i ndi cator on al l model s
equi pped wi th dual front ai rbags. (Refer to 8 - ELEC-
COMMUNI CATI ON - DESCRI PTI ON).
Hard wi red ci rcui try connects the suppl emental
restrai nt system components to each other through
the el ectri cal system of the vehi cl e. These hard wi red
ci rcui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system,
and to the suppl emental restrai nt system compo-
nents through the use of a combi nati on of sol dered
OPERATION
ACTIVE RESTRAINTS
The pri mary passenger restrai nts i n thi s or any
other vehi cl e are the standard equi pment factory-i n-
stal l ed seat bel ts. Seat bel ts are referred to as an
acti ve restrai nt because the vehi cl e occupants are
requi red to physi cal l y fasten and properl y adjust
these restrai nts i n order to benefi t from them. See
the owners manual i n the vehi cl e gl ove box for more
i nformati on on the features, use and operati on of al l
of the factory-i nstal l ed acti ve restrai nts.
PASSIVE RESTRAINTS
The passi ve restrai nts system i s referred to as a
suppl emental restrai nt system because they were
desi gned and are i ntended to enhance the protecti on
for the vehi cl e occupants of the vehi cl e only when
used i n conjuncti on wi th the seat bel ts. They are
referred to as passi ve systems because the vehi cl e
occupants are not requi red to do anythi ng to make
them operate; however, the vehi cl e occupants must
be weari ng thei r seat bel ts i n order to obtai n the
maxi mum safety benefi t from the factory-i nstal l ed
suppl emental restrai nt systems.
The suppl emental restrai nt system el ectri cal ci r-
cui ts are conti nuousl y moni tored and control l ed by a
mi croprocessor and software contai ned wi thi n the
Ai rbag Control Modul e (ACM). An ai rbag i ndi cator i n
the El ectroMechani cal I nstrument Cl uster (EMI C)
i l l umi nates for about seven seconds as a bul b test
each ti me the i gni ti on swi tch i s turned to the On or
Start posi ti ons. Fol l owi ng the bul b test, the ai rbag
i ndi cator i s turned on or off by the ACM to i ndi cate
the status of the suppl emental restrai nt system. I f
the ai rbag i ndi cator comes on at any ti me other than
duri ng the bul b test, i t i ndi cates that there i s a prob-
l em i n the suppl emental restrai nt system el ectri cal
ci rcui ts. Such a probl em may cause ai rbags not to
depl oy when requi red, or to depl oy when not
requi red.
Depl oyment of the suppl emental restrai nts
depends upon the angl e and severi ty of an i mpact.
Depl oyment i s not based upon vehi cl e speed; rather,
depl oyment i s based upon the rate of decel erati on as
measured by the forces of gravi ty (G force) upon the
i mpact sensors. When an i mpact i s severe enough,
the mi croprocessor i n the ACM si gnal s the i nfl ator
uni t of the ai rbag modul e to depl oy the ai rbag. Dur-
i ng a frontal vehi cl e i mpact, the knee bl ockers work
i n concert wi th properl y fastened and adjusted seat
bel ts to restrai n both the dri ver and the front seat
passenger i n the proper posi ti on for an ai rbag depl oy-
ment. The knee bl ockers al so absorb and di stri bute
the crash energy from the dri ver and the front seat
passenger to the structure of the i nstrument panel .
Typi cal l y, the vehi cl e occupants recal l more about
the events precedi ng and fol l owi ng a col l i si on than
they have of an ai rbag depl oyment i tsel f. Thi s i s
because the ai rbag depl oyment and defl ati on occur so
rapi dl y. I n a typi cal 48 ki l ometer-per-hour (30 mi l e-
per-hour) barri er i mpact, from the moment of i mpact
unti l the ai rbags are ful l y i nfl ated takes about 40
mi l l i seconds. Wi thi n one to two seconds from the
moment of i mpact, the ai rbags are al most enti rel y
defl ated. The ti mes ci ted for these events are approx-
i mati ons, whi ch appl y onl y to a barri er i mpact at the
gi ven speed. Actual ti mes wi l l vary somewhat,
dependi ng upon the vehi cl e speed, i mpact angl e,
severi ty of the i mpact, and the type of col l i si on.
When the ACM moni tors a probl em i n any of the
ai rbag system ci rcui ts or components, i t stores a
faul t code or Di agnosti c Troubl e Code (DTC) i n i ts
memory ci rcui t and sends an el ectroni c message to
the EMI C to turn on the ai rbag i ndi cator. Proper
testi ng of the ai rbag system components, the Pro-
grammabl e Communi cati on I nterface (PCI ) data bus,
the data bus message i nputs to and outputs from the
EMI C or the ACM, as wel l as the retri eval or erasure
of a DTC from the ACM or EMI C requi res the use of
a DRBI I I scan tool . Refer to the appropri ate di ag-
of al l of the factory-i nstal l ed passi ve restrai nts.
WARNING - RESTRAINT SYSTEM
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS
CATALOG.
PASSENGER AIRBAG, FRONT IMPACT SENSOR,
SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE SUPPLEMENTAL
PERSONAL INJURY.
WARNING: AN AIRBAG INFLATOR UNIT MAY CON-
TAIN SODIUM AZIDE AND POTASSIUM NITRATE.
THESE MATERIALS ARE POISONOUS AND
EXTREMELY FLAMMABLE. CONTACT WITH ACID,
WATER, OR HEAVY METALS MAY PRODUCE HARM-
FUL AND IRRITATING GASES (SODIUM HYDROXIDE
IS FORMED IN THE PRESENCE OF MOISTURE) OR
COMBUSTIBLE COMPOUNDS. AN AIRBAG INFLA-
TOR UNIT MAY ALSO CONTAIN A GAS CANISTER
PRESSURIZED TO OVER 2500 PSI. DO NOT
ATTEMPT TO DISMANTLE AN AIRBAG UNIT OR
TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE,
INCINERATE, OR BRING INTO CONTACT WITH
ELECTRICITY. DO NOT STORE AT TEMPERATURES
EXCEEDING 93 C (200 F).
WARNING: REPLACE ALL RESTRAINT SYSTEM
COMPONENTS ONLY WITH PARTS SPECIFIED IN
THE DAIMLERCHRYSLER MOPAR PARTS CATA-
LOG. SUBSTITUTE PARTS MAY APPEAR INTER-
CHANGEABLE, BUT INTERNAL DIFFERENCES MAY
RESULT IN INFERIOR OCCUPANT PROTECTION.
WARNING: THE FASTENERS, SCREWS, AND
BOLTS ORIGINALLY USED FOR THE RESTRAINT
SYSTEM COMPONENTS HAVE SPECIAL COATINGS
AND ARE SPECIFICALLY DESIGNED FOR THE
RESTRAINT SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANY TIME A
NEW FASTENER IS NEEDED, REPLACE IT WITH
THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
WARNING: WHEN A STEERING COLUMN HAS AN
AIRBAG UNIT ATTACHED, NEVER PLACE THE COL-
UMN ON THE FLOOR OR ANY OTHER SURFACE
WITH THE STEERING WHEEL OR AIRBAG UNIT
FACE DOWN.
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM
Proper di agnosi s and testi ng of the suppl emental
restrai nt system components, the PCI data bus, the
data bus message i nputs to and outputs from the
El ectroMechani cal I nstrument Cl uster (EMI C) or the
Ai rbag Control Modul e (ACM), as wel l as the
retri eval or erasure of a Di agnosti c Troubl e Code
(DTC) from the ACM requi res the use of a DRBI I I
mati on.
PERSONAL INJURY.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL RESTRAINTS
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of a non-de-
pl oyed ai rbag. When carryi ng a non-depl oyed ai rbag,
the tri m cover or ai rbag cushi on si de of the uni t
shoul d be poi nted away from the body to mi ni mi ze
i njury i n the event of an acci dental depl oyment. I f
the ai rbag uni t i s pl aced on a bench or any other sur-
face, the tri m cover or ai rbag cushi on si de of the uni t
shoul d be face up to mi ni mi ze movement i n the event
of an acci dental depl oyment. I n addi ti on, the suppl e-
mental restrai nt system shoul d be di sarmed when-
ever any steeri ng wheel , steeri ng col umn, dri ver
ai rbag, passenger ai rbag, front i mpact sensor, si de
i mpact sensor, si de curtai n ai rbag, or i nstrument
panel components requi re di agnosi s or servi ce. Fai l -
ure to observe thi s warni ng coul d resul t i n acci dental
ai rbag depl oyment and possi bl e personal i njury.
Al l damaged, faul ty or non-depl oyed ai rbags whi ch
are repl aced on vehi cl es are to be handl ed and di s-
posed of properl y. I f an ai rbag uni t i s faul ty or dam-
aged and non-depl oyed, refer to the Hazardous
Substance Control System for proper di sposal . Di s-
pose of al l non-depl oyed and depl oyed ai rbags i n a
manner consi stent wi th state, provi nci al , l ocal and
federal regul ati ons.
SUPPLEMENTAL RESTRAINT STORAGE
Ai rbags must be stored i n thei r ori gi nal , speci al
contai ner unti l they are used for servi ce. Al so, they
must be stored i n a cl ean, dry envi ronment; away
from sources of extreme heat, sparks, and hi gh el ec-
tri cal energy. Al ways pl ace or store any ai rbag on a
surface wi th i ts tri m cover or ai rbag cushi on si de fac-
i ng up, to mi ni mi ze movement i n case of an acci den-
tal depl oyment.
STANDARD PROCEDURE - SERVICE AFTER A
SUPPLEMENTAL RESTRAINT DEPLOYMENT
Any vehi cl e whi ch i s to be returned to use fol l ow-
i ng a suppl emental restrai nt depl oyment, must have
the depl oyed restrai nts repl aced. I n addi ti on, i f the
dri ver ai rbag has been depl oyed, the cl ockspri ng
must be repl aced. I f the passenger ai rbag i s
depl oyed, the i nstrument panel top pad must be
repl aced. I f a si de curtai n ai rbag has been depl oyed,
the compl ete ai rbag uni t, the headl i ner, as wel l as
the upper A, B, C and D-pi l l ar tri m must be repl aced.
These components are not i ntended for reuse and
wi l l be damaged or weakened as a resul t of a suppl e-
mental restrai nt depl oyment, whi ch may or may not
be obvi ous duri ng a vi sual i nspecti on.
The passenger ai rbag mounti ng poi nts on the
i nstrument panel structural duct must be cl osel y
i nspected for damage, and the i nstrument panel
assembl y repl aced i f structural duct damage i s evi -
dent. On vehi cl es wi th an opti onal sunroof, the sun-
roof drai n tubes and hoses must be cl osel y i nspected
fol l owi ng a si de curtai n ai rbag depl oyment. I t i s al so
cri ti cal that the mounti ng surfaces and/or mounti ng
brackets for the front and si de i mpact sensors be
cl osel y i nspected and restored to thei r ori gi nal condi -
ti ons fol l owi ng any vehi cl e i mpact damage. Because
the ACM and each i mpact sensor are used by the
suppl emental restrai nt system to moni tor or confi rm
the di recti on and severi ty of a vehi cl e i mpact,
i mproper ori entati on or i nsecure fasteni ng of these
components may cause ai rbags not to depl oy when
requi red, or to depl oy when not requi red.
Al l other vehi cl e components shoul d be cl osel y
i nspected fol l owi ng any suppl emental restrai nt
depl oyment, but are to be repl aced onl y as requi red
by the extent of the vi si bl e damage i ncurred.
AIRBAG SQUIB STATUS
Mul ti stage ai rbags wi th mul ti pl e i ni ti ators (squi bs)
must be checked to determi ne that al l squi bs were
used duri ng the depl oyment event. The dri ver and
passenger ai rbags i n thi s model are depl oyed by el ec-
tri cal si gnal s generated by the Ai rbag Control Mod-
ul e (ACM) through the dri ver or passenger squi b 1
and squi b 2 ci rcui ts to the two i ni ti ators i n the ai r-
bag i nfl ators. Typi cal l y, both i ni ti ators are used and
al l potenti al l y hazardous chemi cal s are burned dur-
i ng an ai rbag depl oyment event. However, i t i s possi -
bl e for onl y one i ni ti ator to be used due to an ai rbag
system faul t; therefore, i t i s al ways necessary to con-
fi rm that both i ni ti ators have been used i n order to
avoi d the i mproper handl i ng or di sposal of poten-
ti al l y l i ve pyrotechni c or hazardous materi al s. The
fol l owi ng procedure shoul d be performed usi ng a
DRBI I I scan tool to veri fy the status of both ai rbag
squi bs before ei ther depl oyed ai rbag i s removed from
the vehi cl e for di sposal .
CAUTION: Deployed front airbags having two initia-
tors (squibs) in the airbag inflator may or may not
have live pyrotechnic material within the inflator. Do
not dispose of these airbags unless you are sure of
complete deployment. Refer to the Hazardous Sub-
stance Control System for proper disposal proce-
dures. Dispose of all non-deployed and deployed
airbags in a manner consistent with state, provin-
cial, local, and federal regulations.
(1) Be certai n that the DRBI I I scan tool contai ns
the l atest versi on of the proper DRBI I I software.
Connect the DRBI I I to the 16-way Data Li nk Con-
nector (DLC). The DLC i s l ocated on the dri ver si de
l ower edge of the i nstrument panel , outboard of the
steeri ng col umn.
(3) Usi ng the DRBI I I , read and record the acti ve
(current) Di agnosti c Troubl e Code (DTC) data.
Usi ng the acti ve DTC i nformati on, refer to the Air-
bag Squib Status tabl e to determi ne the status of
both dri ver and/or passenger ai rbag squi bs.
AIRBAG SQUIB STATUS
IF the Active DTC is: Conditions Squib Status
Driver or Passenger Squib 1
open
AND the stored DTC mi nutes for both Dri ver
or Passenger squi bs are wi thi n 15 mi nutes of
each other
Both Squib 1 and 2 were
used.
open
open
AND the stored DTC mi nutes for Dri ver or
Passenger Squi b 2 open i s GREATER than the
stored DTC mi nutes for Dri ver or Passenger
Squi b 1 by 15 mi nutes or more
Squib 1 was used; Squib 2 is
live.
open
open
AND the stored DTC mi nutes for Dri ver or
Passenger Squi b 1 open i s GREATER than the
stored DTC mi nutes for Dri ver or Passenger
Squi b 2 by 15 mi nutes or more
Squib 1 is live; Squib 2 was
used.
open
open
AND Dri ver or Passenger Squi b 2 open i s NOT
an acti ve code
Squib 1 was used; Squib 2 is
live.
open
AND Dri ver or Passenger Squi b 1 open i s NOT
an acti ve code
Squib 1 is live; Squib 2 was
used.
If none of the Dri ver or Passenger Squi b 1 or 2
open are acti ve codes, the status of the ai rbag squi bs
i s unknown. I n thi s case the ai rbag shoul d be han-
dl ed and di sposed of as i f the squi bs were both l i ve.
CLEANUP PROCEDURE
Fol l owi ng a suppl emental restrai nt depl oyment,
the vehi cl e i nteri or wi l l contai n a powdery resi due.
Thi s resi due consi sts pri mari l y of harml ess parti cu-
l ate by-products of the smal l pyrotechni c charge that
i ni ti ates the propel l ant used to depl oy a suppl emen-
tal restrai nt. However, thi s resi due may al so contai n
traces of sodi um hydroxi de powder, a chemi cal
by-product of the propel l ant materi al that i s used to
generate the i nert gas that i nfl ates the ai rbag. Si nce
sodi um hydroxi de powder can i rri tate the ski n, eyes,
nose, or throat, be sure to wear safety gl asses, rubber
gl oves, and a l ong-sl eeved shi rt duri ng cl eanup (Fi g.
3).
Fig. 3 Wear Safety Glasses and Rubber Gloves -
Typical
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE IRRITA-
TION OF THE NOSE OR THROAT, EXIT THE VEHICLE
FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF
IRRITATION CONTINUES, SEE A PHYSICIAN.
(1) Begi n the cl eanup by usi ng a vacuum cl eaner
to remove any resi dual powder from the vehi cl e i nte-
ri or. Cl ean from outsi de the vehi cl e and work your
way i nsi de, so that you avoi d kneel i ng or si tti ng on a
non-cl eaned area.
(2) Be certai n to vacuum the heater and ai r condi -
ti oni ng outl ets as wel l (Fi g. 4). Run the heater and
ai r condi ti oner bl ower on the l owest speed setti ng
and vacuum any powder expel l ed from the outl ets.
CAUTION: Deployed front airbags having two initia-
tors (squibs) in the airbag inflator may or may not
have live pyrotechnic material within the inflator. Do
not dispose of these airbags unless you are sure of
complete deployment. Refer to AIRBAG SQUIB STA-
TUS . Refer to the Hazardous Substance Control
System for proper disposal procedures. Dispose of
all non-deployed and deployed airbags in a manner
consistent with state, provincial, local, and federal
regulations.
(3) Next, remove the depl oyed suppl emental
restrai nts from the vehi cl e. Refer to the appropri ate
servi ce removal procedures.
(4) You may need to vacuum the i nteri or of the
vehi cl e a second ti me to recover al l of the powder.
STANDARD PROCEDURE - VERIFICATION TEST
The fol l owi ng procedure shoul d be performed usi ng
a DRBI I I scan tool to veri fy proper suppl emental
restrai nt system operati on fol l owi ng the servi ce or
repl acement of any suppl emental restrai nt system
component.
PERSONAL INJURY.
(1) Duri ng the fol l owi ng test, the battery negati ve
cabl e remai ns di sconnected and i sol ated, as i t was
duri ng the ai rbag component removal and i nstal l a-
ti on procedures.
(2) Be certai n that the DRBI I I scan tool contai ns
the l atest versi on of the proper DRBI I I software.
Connect the DRBI I I to the 16-way Data Li nk Con-
nector (DLC). The DLC i s l ocated on the dri ver si de
l ower edge of the i nstrument panel , outboard of the
(3) Turn the i gni ti on swi tch to the On posi ti on and
exi t the vehi cl e wi th the DRBI I I scan tool .
Fig. 4 Vacuum Heater and A/C Outlets - Typical
Fig. 5 16-Way Data Link Connector - Typical
1 - 16WAY DATA LINK CONNECTOR
2 - BOTTOM OF INSTRUMENT PANEL
(4) Check to be certai n that nobody i s i n the vehi -
cl e, then reconnect the battery negati ve cabl e.
(5) Usi ng the DRBI I I , read and record the acti ve
(current) Di agnosti c Troubl e Code (DTC) data.
(6) Next, use the DRBI I I to read and record any
stored (hi stori cal ) DTC data.
(7) I f any DTC i s found i n Step 5 or Step 6, refer
(8) Use the DRBI I I to erase the stored DTC data.
I f any probl ems remai n, the stored DTC data wi l l not
erase. Refer to the appropri ate di agnosti c i nforma-
ti on to di agnose any stored DTC that wi l l not erase.
I f the stored DTC i nformati on i s successful l y erased,
go to Step 9.
(9) Turn the i gni ti on swi tch to the Off posi ti on for
about fi fteen seconds, and then back to the On posi -
ti on. Observe the ai rbag i ndi cator i n the i nstrument
cl uster. I t shoul d l i ght for si x to ei ght seconds, and
then go out. Thi s i ndi cates that the suppl emental
restrai nt system i s functi oni ng normal l y and that the
repai rs are compl ete. I f the ai rbag i ndi cator fai l s to
l i ght, or l i ghts and stays on, there i s sti l l an acti ve
suppl emental restrai nt system faul t or mal functi on.
Refer to the appropri ate di agnosti c i nformati on to
di agnose the probl em.
AIRBAG CONTROL MODULE
DESCRIPTION
The Ai rbag Control Modul e (ACM) i s al so some-
ti mes referred to as the Occupant Restrai nt Control -
l er (ORC) (Fi g. 6). The ACM i s conceal ed underneath
the center fl oor consol e, where i t i s secured by four
screws to a stamped steel mounti ng bracket wel ded
onto the top of the fl oor panel transmi ssi on tunnel
just forward of the park brake mechani sm i n the pas-
senger compartment of the vehi cl e.
Conceal ed wi thi n a hol l ow i n the center of the di e
cast al umi num ACM housi ng i s the el ectroni c ci r-
cui try of the ACM whi ch i ncl udes a mi croprocessor,
an el ectroni c i mpact sensor, an el ectroni c safi ng sen-
sor, and an energy storage capaci tor. A stamped
metal cover pl ate i s secured to the bottom of the
ACM housi ng wi th four screws to encl ose and protect
the i nternal el ectroni c ci rcui try and components. A
pri nted l abel on the top of the ACM housi ng provi des
a vi sual veri fi cati on of the proper ori entati on of the
uni t, and shoul d al ways be poi nted toward the front
of the vehi cl e.
Two mol ded pl asti c el ectri cal connector receptacl es
exi t the forward si de of the ACM housi ng. These two
receptacl es connect the ACM to the vehi cl e el ectri cal
system through a dedi cated take out and connector of
the i nstrument panel wi re harness, and a dedi cated
take out and connector of the ai rbag overl ay wi re
harness. For vehi cl es equi pped wi th the opti onal si de
curtai n ai rbags, both ACM connector receptacl es are
bl ack i n col or and the ACM contai ns a second bi -di -
recti onal safi ng sensor for the si de ai rbags. For vehi -
cl es not equi pped wi th the opti onal si de curtai n
ai rbags, the ACM connector receptacl es are both
gray.
The i mpact sensor and safi ng sensor i nternal to
the ACM are cal i brated for the speci fi c vehi cl e, and
are onl y servi ced as a uni t wi th the ACM. The ACM
cannot be repai red or adjusted and, i f damaged or
faul ty, i t must be repl aced.
OPERATION
The mi croprocessor i n the Ai rbag Control Modul e
(ACM) contai ns the suppl emental restrai nt system
l ogi c ci rcui ts and control s al l of the suppl emental
restrai nt system components. The ACM uses
On-Board Di agnosti cs (OBD) and can communi cate
wi th other el ectroni c modul es i n the vehi cl e as wel l
as wi th the DRBI I I scan tool usi ng the Programma-
bl e Communi cati ons I nterface (PCI ) data bus net-
work. Thi s method of communi cati on i s used for
control of the ai rbag i ndi cator i n the El ectroMechani -
cal I nstrument Cl uster (EMI C) and for suppl emental
restrai nt system di agnosi s and testi ng through the
16-way data l i nk connector l ocated on the dri ver si de
l ower edge of the i nstrument panel . (Refer to 8 -
ULES/COMMUNI CATI ON - OPERATI ON).
Fig. 6 Airbag Control Module
2 - ORIENTATION ARROW
3 - LABEL
4 - MOUNTING HOLES (4)
5 - CONNECTOR RECEPTACLE (2)
The ACM mi croprocessor conti nuousl y moni tors al l
of the suppl emental restrai nt system el ectri cal ci r-
cui ts to determi ne the system readi ness. I f the ACM
detects a moni tored system faul t, i t sets an acti ve
and stored Di agnosti c Troubl e Code (DTC) and sends
el ectroni c messages to the EMI C over the PCI data
bus to turn on the ai rbag i ndi cator. An acti ve faul t
onl y remai ns for the durati on of the faul t or i n some
cases the durati on of the current i gni ti on swi tch
cycl e, whi l e a stored faul t causes a DTC to be stored
i n memory by the ACM. For some DTCs, i f a faul t
does not recur for a number of i gni ti on cycl es, the
ACM wi l l automati cal l y erase the stored DTC. For
other i nternal faul ts, the stored DTC i s l atched for-
ever.
The ACM recei ves battery current through two ci r-
cui ts, on a fused i gni ti on swi tch output (run) ci rcui t
through a fuse i n the Juncti on Bl ock (JB), and on a
fused i gni ti on swi tch output (start-run) ci rcui t
through a second fuse i n the JB. The ACM i s
grounded through a ground ci rcui t and take out of
the i nstrument panel fl oor wi re harness. Thi s take
out has a si ngl e eyel et termi nal connector secured by
a nut to a ground stud l ocated behi nd the ACM
mount on the fl oor panel transmi ssi on tunnel . These
connecti ons al l ow the ACM to be operati onal when-
ever the i gni ti on swi tch i s i n the Start or On posi -
ti ons. The ACM al so contai ns an energy-storage
capaci tor. When the i gni ti on swi tch i s i n the Start or
On posi ti ons, thi s capaci tor i s conti nual l y bei ng
charged wi th enough el ectri cal energy to depl oy the
ai rbags for up to one second fol l owi ng a battery di s-
connect or fai l ure. The purpose of the capaci tor i s to
provi de backup suppl emental restrai nt system pro-
tecti on i n case there i s a l oss of battery current sup-
pl y to the ACM duri ng an i mpact.
Two sensors are contai ned wi thi n the ACM, an
el ectroni c i mpact sensor and a safi ng sensor. The
ACM al so moni tors i nputs from two remote front
i mpact sensors l ocated on brackets on the i nboard
si des of the ri ght and l eft verti cal members of the
radi ator support near the front of the vehi cl e. The
el ectroni c i mpact sensors are accel erometers that
sense the rate of vehi cl e decel erati on, whi ch provi de
veri fi cati on of the di recti on and severi ty of an
i mpact. On model s equi pped wi th opti onal si de cur-
tai n ai rbags, the ACM al so moni tors i nputs from two
remote si de i mpact sensors l ocated near the base of
both the l eft and ri ght i nner B-pi l l ars to control the
depl oyment of the si de curtai n ai rbag uni ts.
The safi ng sensor i s an el ectroni c accel erometer
sensor wi thi n the ACM that provi des an addi ti onal
l ogi c i nput to the ACM mi croprocessor. The safi ng
sensor i s used to veri fy the need for an ai rbag
depl oyment by detecti ng i mpact energy of a l esser
magni tude than that of the pri mary el ectroni c i mpact
sensors, and must exceed a safi ng threshol d i n order
for the ai rbags to depl oy. The ACM al so moni tors a
Hal l effect-type seat bel t swi tch l ocated i n the buckl e
of each front seat bel t to determi ne whether the seat-
bel ts are buckl ed, and provi des an i nput to the EMI C
over the PCI data bus to control the seatbel t i ndi ca-
tor operati on based upon the status of the dri ver si de
front seat bel t swi tch. Vehi cl es wi th the opti onal si de
curtai n ai rbags feature a second safi ng sensor wi thi n
the ACM to provi de confi rmati on to the ACM of si de
i mpact forces. Thi s second safi ng sensor i s a bi -di rec-
ti onal uni t that detects i mpact forces from ei ther si de
of the vehi cl e.
Pre-programmed deci si on al gori thms i n the ACM
mi croprocessor determi ne when the decel erati on rate
as si gnal ed by the i mpact sensors and the safi ng sen-
sors i ndi cate an i mpact that i s severe enough to
requi re suppl emental restrai nt system protecti on.
The ACM al so determi nes the l evel of front ai rbag
depl oyment force requi red for each front seati ng posi -
ti on based upon the status of the two seat bel t swi tch
i nputs and the severi ty of the moni tored i mpact.
When the programmed condi ti ons are met, the ACM
sends the proper el ectri cal si gnal s to depl oy the mul -
ti stage dual front ai rbags at the programmed force
l evel s, and to depl oy ei ther si de curtai n ai rbag.
The hard wi red i nputs and outputs for the ACM
may be di agnosed and tested usi ng conventi onal
di agnosti c tool s and procedures. However, conven-
ti onal di agnosti c methods wi l l not prove concl usi ve i n
the di agnosi s of the ACM, the PCI data bus network,
or the el ectroni c message i nputs to and outputs from
the ACM. The most rel i abl e, effi ci ent, and accurate
means to di agnose the ACM, the PCI data bus net-
work, and the el ectroni c message i nputs to and out-
puts from the ACM requi res the use of a DRBI I I
mati on.
REMOVAL
Two di fferent Ai rbag Control Modul es (ACM) are
avai l abl e for thi s vehi cl e. For vehi cl es equi pped wi th
the opti onal si de curtai n ai rbags, both ACM connec-
tor receptacl es are bl ack i n col or and the ACM con-
tai ns a second bi -di recti onal safi ng sensor for the
si de ai rbags. For vehi cl es not equi pped wi th the
opti onal si de curtai n ai rbags, the ACM connector
receptacl es are gray.
AIRBAG CONTROL MODULE (Continued)
PERSONAL INJURY.
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE SUPPLEMENTAL
RESTRAINTS. NEVER STRIKE OR DROP THE AIR-
BAG CONTROL MODULE, AS IT CAN DAMAGE THE
IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF
AN AIRBAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
(2) Remove the center consol e from the top of the
fl oor panel transmi ssi on tunnel . (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - REMOVAL).
(3) Remove the two nuts that secure the center
consol e bracket to the studs on the fl oor panel trans-
mi ssi on tunnel just forward of the Ai rbag Control
Modul e (ACM) (Fi g. 7).
(4) Remove the center consol e bracket from the
two studs on the fl oor panel transmi ssi on tunnel .
(5) Di sconnect the ai rbag overl ay wi re harness
connector for the ACM from the ACM connector
receptacl e (Fi g. 8). To di sconnect the ai rbag overl ay
wi re harness connector from the ACM:
(a) Sl i de the red Connector Posi ti on Assurance
(CPA) l ock on the top of the connector toward the
front of the vehi cl e.
(b) Depress the forward edge of the CPA l ock to
rel ease the connector l atch tab and pul l the connec-
tor strai ght away from the ACM connector recepta-
cl e.
connector for the ACM from the ACM connector
receptacl e.
Fig. 7 Center Console Bracket Remove/Install
1 - SHIFTER
2 - NUT (2)
3 - BRACKET
4 - PARK BRAKE LEVER
6 - FLOOR PANEL TRANSMISSION TUNNEL
Fig. 8 Airbag Control Module Connector
2 - LATCH TAB
3 - CPA LOCK
4 - AIRBAG OVERLAY WIRE HARNESS CONNECTOR
(7) Remove the four screws that secure the ACM to
the mount that i s wel ded onto the top of the fl oor
panel transmi ssi on tunnel (Fi g. 9).
(8) Remove the ACM from the ACM mount on the
top of the fl oor panel transmi ssi on tunnel .
INSTALLATION
Two di fferent Ai rbag Control Modul es (ACM) are
avai l abl e for thi s vehi cl e. For vehi cl es equi pped wi th
the opti onal si de curtai n ai rbags, both ACM connec-
tor receptacl es are bl ack i n col or and the ACM con-
tai ns a second bi -di recti onal safi ng sensor for the
si de ai rbags. For vehi cl es not equi pped wi th the
opti onal si de curtai n ai rbags, the ACM connector
receptacl es are gray.
PERSONAL INJURY.
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE SUPPLEMENTAL
RESTRAINTS. NEVER STRIKE OR DROP THE AIR-
BAG CONTROL MODULE, AS IT CAN DAMAGE THE
IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF
AN AIRBAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.
(1) Careful l y posi ti on the Ai rbag Control Modul e
(ACM) to the mount that i s wel ded onto the top of
the fl oor panel transmi ssi on tunnel (Fi g. 9). The bot-
tom of the ACM housi ng i s keyed. When the ACM i s
correctl y posi ti oned, the bottom of the housi ng wi l l fi t
fl ush wi th the mount and the ori entati on arrow on
the l abel on top of the housi ng wi l l be poi nted for-
ward i n the vehi cl e.
the ACM to the mount that i s wel ded onto the top of
the fl oor panel transmi ssi on tunnel . Ti ghten the
screws to 11 Nm (95 i n. l bs.).
connector for the ACM to the ACM connector recep-
tacl e. Be certai n that the connector l atch and the red
CPA l ock are ful l y engaged (Fi g. 8).
(4) Reconnect the ai rbag overl ay wi re harness con-
nector for the ACM to the ACM connector receptacl e.
Be certai n that the connector l atch and the red CPA
l ock are ful l y engaged.
(5) Rei nstal l the center consol e bracket onto the
two studs on the fl oor panel transmi ssi on tunnel just
forward of the ACM (Fi g. 7).
the center consol e bracket to the studs on the fl oor
panel transmi ssi on tunnel . Ti ghten the nuts to 28
Nm (21 ft. l bs.).
(7) Rei nstal l the center consol e onto the top of the
(8) Do not reconnect the battery negati ve cabl e at
thi s ti me. The suppl emental restrai nt system veri fi -
cati on test procedure shoul d be performed fol l owi ng
servi ce of any suppl emental restrai nt system compo-
nent. (Refer to 8 - ELECTRI CAL/RESTRAI NTS -
STANDARD PROCEDURE - VERI FI CATI ON TEST).
Fig. 9 Airbag Control Module Remove/Install
1 - SCREW (4)
3 - FLOOR PANEL TRANSMISSION TUNNEL
4 - MOUNT
CHILD TETHER ANCHOR
DESCRIPTION
Al l vehi cl es are equi pped wi th fi xed-posi ti on, chi l d
seat tether anchors. Vehi cl es manufactured for sal e
i n North Ameri ca have two stamped steel chi l d
tether anchor brackets, one secured wi th a screw to
each outboard end of the i nner l i ftgate openi ng
header at the rear of the passenger compartment
(Fi g. 10). These chi l d tether anchors are conceal ed
behi nd a removabl e mol ded pl asti c cap that snaps
i nto a bezel l ocated i n the headl i ner over each anchor
bracket posi ti on. Vehi cl es manufactured for sal e i n
Rest-Of-Worl d (ROW) markets have two anchors that
are i ntegral to the back of the ri ght rear seat back
panel , and one that i s i ntegral to the l eft rear seat
back panel (Fi g. 11). The North Ameri can chi l d seat
tether anchor brackets are avai l abl e for separate ser-
vi ce repl acement. The ROW chi l d seat tether anchors
cannot be adjusted or repai red and, i f faul ty or dam-
aged, they must be repl aced as a uni t wi th the rear
seat back panel .
OPERATION
more i nformati on on the proper use of the factory-i n-
stal l ed chi l d seat tether anchors.
REMOVAL
The fol l owi ng servi ce procedure appl i es to vehi cl es
manufactured for sal e i n North Ameri ca, whi ch have
removabl e chi l d seat tether anchor brackets that are
l ocated on the i nner l i ftgate openi ng header. Vehi cl es
manufactured for sal e i n Rest-Of-Worl d (ROW) mar-
kets have chi l d tether anchors that are i ntegral to,
and are onl y servi ced wi th the rear seat back panel s.
(1) Remove the cover from the chi l d tether anchor
bezel i n the headl i ner near the l i ftgate openi ng
header.
(2) Remove the screw that secures the chi l d tether
anchor bracket to the i nner l i ftgate openi ng header
(Fi g. 12).
(3) Remove the chi l d tether anchor bracket from
the i nner l i ftgate openi ng header.
Fig. 10 Child Tether Anchors - North America
1 - CHILD TETHER ANCHOR (RIGHT)
2 - CARGO LAMP
3 - HEADLINER
4 - BEZEL
5 - CHILD TETHER ANCHOR BRACKET
6 - D-PILLAR
7 - CAP
Fig. 11 Child Tether Anchors - Rest-Of-World
1 - REAR SEAT BACK (LEFT)
2 - REAR SEAT BACK (RIGHT)
3 - CHILD TETHER ANCHOR (3)
Fig. 12 Child Tether Anchor Remove/Install
1 - INNER LIFTGATE OPENING HEADER
2 - CHILD TETHER ANCHOR BRACKET
3 - SCREW
INSTALLATION
The fol l owi ng servi ce procedure appl i es to vehi cl es
manufactured for sal e i n North Ameri ca, whi ch have
removabl e chi l d seat tether anchor brackets that are
l ocated on the i nner l i ftgate openi ng header. Vehi cl es
manufactured for sal e i n Rest-Of-Worl d (ROW) mar-
kets have chi l d tether anchors that are i ntegral to,
and are onl y servi ced wi th the rear seat back panel s.
(1) Posi ti on the chi l d tether anchor bracket onto
the i nner l i ftgate openi ng header (Fi g. 12).
chi l d tether anchor bracket to the i nner l i ftgate open-
i ng header. Ti ghten the screw to 11.8 Nm (105 i n.
l bs.).
(3) Rei nstal l the cover i nto the chi l d tether anchor
bezel i n the headl i ner near the l i ftgate openi ng
header.
CLOCKSPRING
DESCRIPTION
The cl ockspri ng assembl y i s secured wi th two
screws to the mul ti -functi on swi tch mounti ng hous-
i ng near the top of the steeri ng col umn behi nd the
steeri ng wheel (Fi g. 13). The cl ockspri ng consi sts of a
fl at, round mol ded pl asti c case wi th a stubby tai l
that hangs bel ow the steeri ng col umn and contai ns
two connector receptacl es that face toward the
i nstrument panel (Fi g. 14). Wi thi n the pl asti c hous-
i ng i s a spool -l i ke mol ded pl asti c rotor wi th a l arge
exposed hub. The upper surface of the rotor hub has
a l arge center hol e, two l arge fl ats, an i ndex hol e,
two short pi gtai l wi res wi th connectors, and two con-
nector receptacl es that face toward the steeri ng
wheel .
The l ower surface of the rotor hub has three pi ns,
two round and one obl ong. These pi ns i ndex the
cl ockspri ng to the turn si gnal cancel cam uni t i n the
mul ti -functi on swi tch mounti ng housi ng. Wi thi n the
pl asti c case and wound around the rotor spool i s a
l ong ri bbon-l i ke tape that consi sts of several thi n cop-
per wi re l eads sandwi ched between two thi n pl asti c
membranes. The outer end of the tape termi nates at
the connector receptacl es that face the i nstrument
panel , whi l e the i nner end of the tape termi nates at
the pi gtai l wi res and connector receptacl es on the
hub of the cl ockspri ng rotor that face the steeri ng
wheel .
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a mol ded pl asti c l ocki ng pi n
i nstal l ed. The l ocki ng pi n secures the centered cl ock-
spri ng rotor to the cl ockspri ng case duri ng shi pment
and handl i ng, but must be removed from the cl ock-
spri ng after i t and the mul ti -functi on swi tch mount-
i ng housi ng are i nstal l ed on the steeri ng col umn.
SPRI NG - STANDARD PROCEDURE - CLOCK-
SPRI NG CENTERI NG).
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the dri ver ai rbag has
been depl oyed, the cl ockspri ng must be repl aced.
Fig. 13 Clockspring (Upper View)
1 - MOUNTING EAR (2)
2 - LOCKING PIN
3 - UPPER CONNECTOR RECEPTACLE (2)
4 - LABEL
5 - OBLONG PIN
6 - ALIGNMENT ARROWS
7 - CASE
8 - PIGTAIL WIRE (2)
Fig. 14 Clockspring (Lower View)
1 - LOCKING PIN
2 - CASE
3 - OBLONG PIN
4 - ROUND PIN (2)
5 - LOWER CONNECTOR RECEPTACLE (2)
6 - ROTOR
CHILD TETHER ANCHOR (Continued)
OPERATION
The cl ockspri ng i s a mechani cal el ectri cal ci rcui t
component that i s used to provi de conti nuous el ectri -
cal conti nui ty between the fi xed i nstrument panel
wi re harness and the el ectri cal components mounted
on or i n the rotati ng steeri ng wheel . On thi s model
the rotati ng el ectri cal components i ncl ude the dri ver
ai rbag, the horn swi tch, the speed control swi tches,
and the remote radi o swi tches, i f the vehi cl e i s so
equi pped. The cl ockspri ng case i s posi ti oned and
secured to the mul ti -functi on swi tch mounti ng hous-
i ng on the upper steeri ng col umn housi ng by two
screws. The two connector receptacl es on the tai l of
the fi xed cl ockspri ng case connect the cl ockspri ng to
the vehi cl e el ectri cal system through two take outs
wi th connectors from the i nstrument panel wi re har-
ness. The cl ockspri ng rotor i s movabl e and i s keyed
to the hub of the steeri ng wheel by two l arge fl ats
that are mol ded i nto the rotor hub. The three pi ns
(two round and one obl ong) on the l ower surface of
the cl ockspri ng rotor hub engage and i ndex the cl ock-
spri ng rotor to the turn si gnal cancel cam. The turn
si gnal cancel cam i s i ntegral to the mul ti -functi on
swi tch mounti ng housi ng and i s keyed to the upper
steeri ng col umn shaft. Two short, yel l ow-sl eeved pi g-
tai l wi res on the upper surface of the cl ockspri ng
rotor connect the cl ockspri ng to the dri ver ai rbag,
whi l e a steeri ng wheel wi re harness connects the two
connector receptacl es on the upper surface of the
cl ockspri ng rotor to the horn swi tch, the two speed
control swi tches, and the remote radi o swi tches on
vehi cl es that are so equi pped.
Li ke the cl ockspri ng i n a ti mepi ece, the cl ockspri ng
tape has travel l i mi ts and can be damaged by bei ng
wound too ti ghtl y duri ng ful l stop-to-stop steeri ng
wheel rotati on. To prevent thi s from occurri ng, the
cl ockspri ng must be centered when i t i s i nstal l ed on
the steeri ng col umn. Centeri ng the cl ockspri ng
i ndexes the cl ockspri ng tape to the movabl e steeri ng
components so that the tape can operate wi thi n i ts
desi gned travel l i mi ts. However, i f the cl ockspri ng i s
removed from the steeri ng col umn or i f the steeri ng
shaft i s di sconnected from the steeri ng gear, the
cl ockspri ng spool can change posi ti on rel ati ve to the
movabl e steeri ng components and must be re-cen-
tered fol l owi ng compl eti on of the servi ce or the tape
may be damaged. Servi ce repl acement cl ockspri ngs
are shi pped pre-centered and wi th a l ocki ng pi n
i nstal l ed. Thi s l ocki ng pi n shoul d not be removed
unti l the cl ockspri ng has been i nstal l ed on the steer-
i ng col umn. I f the l ocki ng pi n i s removed before the
cl ockspri ng i s i nstal l ed on a steeri ng col umn, the
cl ockspri ng centeri ng procedure must be performed.
SPRI NG - STANDARD PROCEDURE - CLOCK-
SPRI NG CENTERI NG).
STANDARD PROCEDURE - CLOCKSPRING
CENTERING
The cl ockspri ng i s desi gned to wi nd and unwi nd
when the steeri ng wheel i s rotated, but i s onl y
desi gned to rotate the same number of turns (about
fi ve compl ete rotati ons) as the steeri ng wheel can be
turned from stop to stop. Centeri ng the cl ockspri ng
i ndexes the cl ockspri ng tape to other steeri ng compo-
nents so that i t can operate wi thi n i ts desi gned
travel l i mi ts. The rotor of a centered cl ockspri ng can
be rotated two and one-hal f turns i n ei ther di recti on
from the centered posi ti on, wi thout damagi ng the
cl ockspri ng tape.
However, i f the cl ockspri ng i s removed for servi ce
or i f the steeri ng col umn i s di sconnected from the
steeri ng gear, the cl ockspri ng tape can change posi -
ti on rel ati ve to the other steeri ng components. The
cl ockspri ng must then be re-centered fol l owi ng com-
pl eti on of such servi ce or the cl ockspri ng tape may be
damaged. Servi ce repl acement cl ockspri ngs are
shi pped pre-centered and wi th a mol ded pl asti c l ock-
i ng pi n i nstal l ed. Thi s l ocki ng pi n shoul d not be
removed unti l the cl ockspri ng has been i nstal l ed on
the steeri ng col umn. I f the l ocki ng pi n i s removed
before the cl ockspri ng i s i nstal l ed on a steeri ng col -
umn, the cl ockspri ng centeri ng procedure must be
performed.
PERSONAL INJURY.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the cl ockspri ng from the steeri ng col -
umn. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
CLOCKSPRI NG - REMOVAL).
CLOCKSPRING (Continued)
(3) Hol d the cl ockspri ng case i n one hand so that i t
i s ori ented as i t woul d be when i t i s i nstal l ed on the
(4) Use your other hand to rotate the cl ockspri ng
rotor cl ockwi se to the end of i ts travel . Do not apply
excessive torque.
(5) From the end of the cl ockwi se travel , rotate the
rotor about two and one-hal f turns countercl ockwi se,
unti l the arrows on the cl ockspri ng rotor l abel and
the cl ockspri ng case are al i gned. The uppermost pi n
on the l ower surface of the cl ockspri ng rotor shoul d
now be the obl ong pi n.
(6) The cl ockspri ng i s now centered. Secure the
cl ockspri ng rotor to the cl ockspri ng case to mai ntai n
cl ockspri ng centeri ng unti l i t i s rei nstal l ed on the
steeri ng col umn.
(7) The front wheel s shoul d sti l l be i n the strai ght-
ahead posi ti on. Rei nstal l the cl ockspri ng onto the
steeri ng col umn. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - I NSTALLATI ON).
REMOVAL
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
PERSONAL INJURY.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the dri ver ai rbag from the steeri ng
DRI VER AI RBAG - REMOVAL).
connectors from the upper cl ockspri ng connector
receptacl es.
(4) Remove the steeri ng wheel from the steeri ng
col umn. (Refer to 19 - STEERI NG/COLUMN/STEER-
I NG WHEEL - REMOVAL).
(5) From bel ow the steeri ng col umn, remove the
screw that secures the l ower ti l ti ng steeri ng col umn
shroud to the steeri ng col umn mul ti -functi on swi tch
mounti ng housi ng (Fi g. 16).
(6) Usi ng hand pressure, push gentl y i nward on
both si des of the upper shroud near the parti ng l i ne
between the upper and l ower shrouds to rel ease the
snap features that secure the two hal ves to each
other.
(7) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(8) Di sconnect the two i nstrument panel wi re har-
ness connectors for the cl ockspri ng from the two con-
nector receptacl es bel ow the steeri ng col umn on the
back of the cl ockspri ng case.
(9) Remove the two screws that secure the cl ock-
spri ng case to the mul ti -functi on swi tch mounti ng
(10) Remove the cl ockspri ng from the mul ti -func-
ti on swi tch mounti ng housi ng. The cl ockspri ng can-
not be repai red. I t must be repl aced i f faul ty or
damaged, or i f the dri ver ai rbag has been depl oyed.
(11) I f the removed cl ockspri ng i s to be reused, be
certai n to secure the cl ockspri ng rotor to the cl ock-
spri ng case to mai ntai n cl ockspri ng centeri ng unti l i t
i s rei nstal l ed on the steeri ng col umn. I f cl ockspri ng
centeri ng i s not mai ntai ned, the cl ockspri ng must be
centered agai n before i t i s rei nstal l ed. (Refer to 8 -
Fig. 15 Clockspring
1 - MOUNTING EAR (2)
2 - LOCKING PIN
3 - UPPER CONNECTOR RECEPTACLE (2)
4 - LABEL
5 - OBLONG PIN
6 - ALIGNMENT ARROWS
7 - CASE
8 - PIGTAIL WIRE (2)
ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
TERI NG).
INSTALLATION
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
I f the cl ockspri ng i s not properl y centered i n rel a-
ti on to the steeri ng wheel , steeri ng shaft and steer-
i ng gear, i t may be damaged. (Refer to 8 -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
TERI NG). Servi ce repl acement cl ockspri ngs are
shi pped pre-centered and wi th a l ocki ng pi n
i nstal l ed. Thi s l ocki ng pi n shoul d not be removed
unti l the cl ockspri ng has been i nstal l ed on the steer-
i ng col umn. I f the l ocki ng pi n i s removed before the
cl ockspri ng i s i nstal l ed on a steeri ng col umn, the
cl ockspri ng centeri ng procedure must be performed.
PERSONAL INJURY.
NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
position.
(1) Whi l e hol di ng the centered cl ockspri ng rotor
and case stati onary i n rel ati on to each other, care-
ful l y sl i de the cl ockspri ng down over the steeri ng col -
umn upper shaft.
(2) Al i gn and seat the three pi ns on the l ower sur-
face of the cl ockspri ng rotor hub wi th the three hol es
i n the hub of the turn si gnal cancel cam (Fi g. 17). I t
shoul d be noted that when the cl ockspri ng i s prop-
erl y centered the uppermost pi n on the cl ockspri ng
rotor hub i s the obl ong pi n, and i t wi l l onl y fi t i n the
obl ong hol e i n the hub of the turn si gnal cancel cam.
4 - SCREW
Fig. 17 Clockspring Remove/Install
1 - OBLONG HOLE
2 - TURN SIGNAL CANCEL CAM
4 - RIGHT MULTI-FUNCTION SWITCH
5 - SCREW (2)
6 - OBLONG PIN
7 - CLOCKSPRING
(3) Al i gn and seat the one pi n and the two mount-
i ng ears on the cl ockspri ng case to thei r respecti ve
hol es i n the mul ti -functi on swi tch mounti ng housi ng.
(4) I nstal l and ti ghten the two cl ockspri ng mount-
i ng screws. Ti ghten the screws to 2.5 Nm (22 i n.
l bs.).
(5) Reconnect the two i nstrument panel wi re har-
ness connectors for the cl ockspri ng to the two connec-
tor receptacl es bel ow the steeri ng col umn on the back
of the cl ockspri ng case.
shroud onto the steeri ng col umn (Fi g. 16).
l ower ti l ti ng steeri ng col umn shroud to the mul ti -
functi on swi tch mounti ng housi ng. Ti ghten the screw
to 2 Nm (17 i n. l bs.).
(8) Posi ti on the upper ti l ti ng col umn shroud onto
the steeri ng col umn wi th the hazard warni ng swi tch
button i nserted through the hol e i n the upper surface
of the shroud. Al i gn the upper ti l ti ng steeri ng col umn
shroud to the l ower shroud and snap the two shroud
hal ves together.
(9) Al i gn the snap features on the upper and l ower
shrouds and appl y hand pressure to snap them
together.
(10) Rei nstal l the steeri ng wheel onto the steeri ng
col umn. (Refer to 19 - STEERI NG/COLUMN/STEER-
I NG WHEEL - I NSTALLATI ON).
nectors to the upper cl ockspri ng connector receptacl es.
(12) Rei nstal l the dri ver ai rbag onto the steeri ng
DRI VER AI RBAG - I NSTALLATI ON).
DRIVER AIRBAG
DESCRIPTION
The i njecti on mol ded, thermopl asti c dri ver ai rbag
protecti ve tri m cover i s the most vi si bl e part of the
dri ver ai rbag (Fi g. 18). The dri ver ai rbag i s l ocated i n
the center of the steeri ng wheel , where i t i s secured
wi th two screws to the two hori zontal spokes of the
four-spoke steeri ng wheel armature. A stamped, sati n
pol i shed embl em wi th the Jeep l ogo i s appl i ed to the
center of the tri m cover. Conceal ed beneath the
dri ver ai rbag tri m cover are the horn swi tch, the
fol ded ai rbag cushi on, the ai rbag retai ner or housi ng,
the ai rbag i nfl ator, and the retai ners that secure the
i nfl ator to the ai rbag housi ng.
The ai rbag cushi on, housi ng, and i nfl ator are
secured wi thi n an i ntegral receptacl e mol ded i nto the
back of the tri m cover. The dri ver ai rbag tri m cover
has l ocki ng bl ocks mol ded i nto the back si de of i t
that engage a l i p formed around the peri meter of the
ai rbag housi ng. Two stamped metal retai ners then fi t
over the i nfl ator mounti ng studs on the back of the
ai rbag housi ng and are engaged i n sl ots wi thi n the
upper and l ower tri m cover l ocki ng bl ocks, securel y
l ocki ng the cover i nto pl ace.
The resi sti ve membrane-type horn swi tch i s
secured wi thi n a pl asti c tray that i s i nserted i n a
pocket or pouch sewn onto the ai rbag cushi on
retai ner strap, between the tri m cover and the fol ded
ai rbag cushi on. The horn swi tch ground pi gtai l wi re
has an eyel et termi nal connector that i s captured on
the upper ri ght i nfl ator mounti ng stud between the
i nfl ator and the upper tri m cover retai ner. The horn
swi tch feed pi gtai l wi re has a whi te, mol ded pl asti c
i nsul ator that i s secured by an i ntegral retai ner to a
mounti ng hol e l ocated i n the upper tri m cover
retai ner near the upper l eft corner on the back of the
ai rbag housi ng, and i s connected to the vehi cl e el ec-
tri cal system through a take out and connector of the
steeri ng wheel wi re harness.
The ai rbag used i n thi s model i s a mul ti stage, Next
Generati on-type that compl i es wi th revi sed federal ai r-
bag standards to depl oy wi th l ess force than those used
i n some pri or model s. A radi al depl oyi ng fabri c ai rbag
cushi on wi th tethers i s used. The ai rbag i nfl ator i s a
dual -i ni ti ator, non-azi de, pyrotechni c-type uni t wi th
four mounti ng studs and i s secured to the stamped
metal ai rbag housi ng usi ng four hex nuts wi th washers.
Two keyed and col or-coded connector receptacl es on the
dri ver ai rbag i nfl ator connect the two i nfl ator i ni ti ators
to the vehi cl e el ectri cal system through two yel l ow-
jacketed, two-wi re pi gtai l harnesses of the cl ockspri ng.
The dri ver ai rbag cannot be repai red, and must be
repl aced i f depl oyed or i n any way damaged. The dri ver
ai rbag tri m cover and the horn swi tch are avai l abl e
i ndi vi dual l y, and may be di sassembl ed from the dri ver
ai rbag for servi ce repl acement.
Fig. 18 Driver Airbag Trim Cover
1 - STEERING WHEEL
2 - TRIM COVER
OPERATION
The mul ti stage dri ver ai rbag i s depl oyed by el ectri -
cal si gnal s generated by the Ai rbag Control Modul e
(ACM) through the dri ver ai rbag squi b 1 and squi b 2
ci rcui ts to the two i ni ti ators i n the ai rbag i nfl ator. By
usi ng two i ni ti ators, the ai rbag can be depl oyed at
mul ti pl e l evel s of force. The force l evel i s control l ed
by the ACM to sui t the moni tored i mpact condi ti ons
by provi di ng one of four del ay i nterval s between the
el ectri cal si gnal s provi ded to the two i ni ti ators. The
l onger the del ay between these si gnal s, the l ess force-
ful l y the ai rbag wi l l depl oy. When the ACM sends the
proper el ectri cal si gnal s to each i ni ti ator, the el ectri -
cal energy generates enough heat to i ni ti ate a smal l
pyrotechni c charge whi ch, i n turn i gni tes chemi cal
pel l ets wi thi n the i nfl ator. Once i gni ted, these chem-
i cal pel l ets burn rapi dl y and produce a l arge quanti ty
of ni trogen gas. The i nfl ator i s seal ed to the back of
the ai rbag housi ng and a di ffuser i n the i nfl ator
di rects al l of the ni trogen gas i nto the ai rbag cush-
i on, causi ng the cushi on to i nfl ate. As the cushi on
i nfl ates, the dri ver ai rbag tri m cover wi l l spl i t at pre-
determi ned breakout l i nes, then fol d back out of the
way al ong wi th the horn swi tch and tray uni t. Fol -
l owi ng an ai rbag depl oyment, the ai rbag cushi on
qui ckl y defl ates by venti ng the ni trogen gas towards
the i nstrument panel through vent hol es wi thi n the
fabri c used to construct the back (steeri ng wheel
si de) panel of the ai rbag cushi on.
Some of the chemi cal s used to create the ni trogen
gas may be consi dered hazardous whi l e i n thei r sol i d
state before they are burned, but they are securel y
seal ed wi thi n the ai rbag i nfl ator. Typi cal l y, both i ni -
ti ators are used and al l potenti al l y hazardous chem-
i cal s are burned duri ng an ai rbag depl oyment event.
However, i t i s possi bl e for onl y one i ni ti ator to be
used duri ng a depl oyment due to an ai rbag system
faul t; therefore, i t i s necessary to al ways confi rm
that both i ni ti ators have been used i n order to avoi d
the i mproper di sposal of potenti al l y l i ve pyrotechni c
or hazardous materi al s. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - SER-
VI CE AFTER A SUPPLEMENTAL RESTRAI NT
DEPLOYMENT). The ni trogen gas that i s produced
when the chemi cal s are burned i s harml ess. How-
ever, a smal l amount of resi due from the burned
chemi cal s may cause some temporary di scomfort i f i t
contacts the ski n, eyes, or breathi ng passages. I f ski n
or eye i rri tati on i s noted, ri nse the affected area wi th
pl enty of cool , cl ean water. I f breathi ng passages are
i rri tated, move to another area where there i s pl enty
of cl ean, fresh ai r to breath. I f the i rri tati on i s not
al l evi ated by these acti ons, contact a physi ci an.
REMOVAL
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged dri ver ai rbag. I f the ai rbag i s
faul ty or damaged, but not depl oyed, revi ew the rec-
ommended procedures for handl i ng non-depl oyed
suppl emental restrai nts. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - HAN-
DLI NG NON-DEPLOYED SUPPLEMENTAL
RESTRAI NTS). I f the dri ver ai rbag has been
depl oyed, revi ew the recommended procedures for
servi ce after a suppl emental restrai nt depl oyment
before removi ng the ai rbag from the vehi cl e. (Refer to
8 - ELECTRI CAL/RESTRAI NTS - STANDARD PRO-
CEDURE - SERVI CE AFTER A SUPPLEMENTAL
RESTRAI NT DEPLOYMENT).
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG CUSHION AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(2) From the undersi de of the steeri ng wheel ,
remove the two screws that secure the dri ver ai rbag
to the steeri ng wheel armature (Fi g. 19).
(3) Pul l the dri ver ai rbag away from the steeri ng
wheel far enough to access the three el ectri cal con-
necti ons on the back of the ai rbag housi ng.
connector for the horn swi tch from the horn swi tch
feed pi gtai l wi re connector, whi ch i s l ocated on the
back of the dri ver ai rbag housi ng.
DRIVER AIRBAG (Continued)
CAUTION: Do not pull on the clockspring pigtail
wires or pry on the connector insulator to disen-
gage the connector from the driver airbag inflator
connector receptacle. Improper removal of these
pigtail wires and their connector insulators can
result in damage to the airbag circuits or connector
insulators.
(5) The cl ockspri ng dri ver ai rbag pi gtai l wi re con-
nectors are secured by an i ntegral l ock to the ai rbag
i nfl ator connector receptacl es, whi ch are l ocated at
the back of the dri ver ai rbag housi ng. Fi rml y grasp
and pul l the l ock strai ght out from the connector
i nsul ator, then pul l the i nsul ators strai ght out from
the ai rbag i nfl ator to di sconnect them from the con-
nector receptacl es.
wheel .
(7) I f the dri ver ai rbag has been depl oyed, the
cl ockspri ng must be repl aced. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/CLOCKSPRI NG - REMOVAL).
DISASSEMBLY
PERSONAL INJURY.
WARNING: THE HORN SWITCH IS INTEGRAL TO
THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT
SHOULD BE PERFORMED ONLY BY
DAIMLERCHRYSLER-TRAINED AND AUTHORIZED
DEALER SERVICE TECHNICIANS. FAILURE TO
TAKE THE PROPER PRECAUTIONS OR TO FOL-
LOW THE PROPER PROCEDURES COULD RESULT
IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIR-
BAG DEPLOYMENT AND POSSIBLE OCCUPANT
INJURIES.
DRI VER AI RBAG - REMOVAL).
(3) Remove the four nuts that secure the upper
and l ower tri m cover retai ners to the studs on the
back of the dri ver ai rbag housi ng (Fi g. 20).
(4) Remove the upper and l ower tri m cover retai n-
ers from the ai rbag housi ng studs (Fi g. 21).
Fig. 19 Driver Airbag Remove/Install
1 - DRIVER AIRBAG
2 - HORN SWITCH FEED WIRE CONNECTOR
3 - STEERING WHEEL WIRE HARNESS CONNECTOR
4 - SCREW (2)
5 - CLOCKSPRING PIGTAIL WIRE CONNECTOR (2)
Fig. 20 Driver Airbag Trim Cover Retainer Nuts
Remove/Install
1 - HORN SWITCH GROUND PIGTAIL WIRE
2 - NUTS
3 - HORN SWITCH FEED PIGTAIL WIRE
(5) Di sengage the horn swi tch feed pi gtai l wi re
connector retai ner from the mounti ng hol e i n the
upper tri m cover retai ner.
(6) Remove the horn swi tch ground pi gtai l wi re
eyel et termi nal from the upper ri ght ai rbag housi ng
stud.
(7) Di sengage the four tri m cover l ocki ng bl ocks
from the l i p around the outsi de edge of the dri ver
ai rbag housi ng and remove the housi ng from the
cover (Fi g. 22).
ASSEMBLY
PERSONAL INJURY.
WARNING: THE HORN SWITCH IS INTEGRAL TO
THE DRIVER AIRBAG UNIT. SERVICE OF THIS UNIT
SHOULD BE PERFORMED ONLY BY
DAIMLERCHRYSLER-TRAINED AND AUTHORIZED
DEALER SERVICE TECHNICIANS. FAILURE TO
TAKE THE PROPER PRECAUTIONS OR TO FOL-
LOW THE PROPER PROCEDURES COULD RESULT
IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIR-
BAG DEPLOYMENT AND POSSIBLE OCCUPANT
INJURIES.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
Fig. 21 Driver Airbag Trim Cover Retainers
1 - UPPER RETAINER
2 - AIRBAG HOUSING
3 - TRIM COVER
4 - NUT (4)
5 - LOWER RETAINER
6 - INFLATOR
7 - STUDS
Fig. 22 Driver Airbag Trim Cover Remove/Install
1 - RETAINER SLOTS
2 - LOCKING BLOCKS
3 - RETAINER SLOTS
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT TRIM
COVERS ARE SERVICED IN THE ORIGINAL COL-
ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
NOTE: If the horn switch and tray have been
removed from the sewn pouch in the airbag cush-
ion retaining strap, be certain that they are properly
reinstalled with the horn switch feed and ground
pigtail wires properly oriented before assembling
the trim cover onto the airbag housing. (Refer to 8 -
ELECTRICAL/HORN/HORN SWITCH - INSTALLA-
TION).
(1) Careful l y posi ti on the dri ver ai rbag i n the tri m
cover. Be certai n that the horn swi tch feed and
ground pi gtai l wi res are not pi nched between the ai r-
bag housi ng and the tri m cover l ocki ng bl ocks.
(2) Engage the upper and l ower tri m cover l ocki ng
bl ocks wi th the l i p of the dri ver ai rbag housi ng, then
engage the l ocki ng bl ocks on each si de of the tri m
cover wi th the l i p of the housi ng. Be certai n that
each of the l ocki ng bl ocks i s ful l y engaged on the l i p
of the ai rbag housi ng (Fi g. 23).
(3) Rei nstal l the horn swi tch ground pi gtai l wi re
eyel et termi nal over the ri ght upper ai rbag housi ng
stud.
(4) Rei nstal l the upper and l ower ai rbag tri m cover
retai ners over the ai rbag housi ng studs. Be certai n
that the tabs on each retai ner are engaged i n the
retai ner sl ots of the upper and l ower tri m cover l ock-
i ng bl ocks (Fi g. 22).
(5) I nstal l and ti ghten the nuts that secure the
tri m cover retai ners to the ai rbag housi ng studs.
(6) Engage the horn swi tch feed pi gtai l wi re con-
nector retai ner i n the mounti ng hol e i n the upper
tri m cover retai ner.
(7) Rei nstal l the dri ver ai rbag onto the steeri ng
DRI VER AI RBAG - I NSTALLATI ON).
INSTALLATION
faul ty or damaged dri ver ai rbag. I f the ai rbag i s
RESTRAI NTS). I f the dri ver ai rbag has been
PERSONAL INJURY.
Fig. 23 Driver Airbag Trim Cover Locking Blocks
Engaged
1 - LIP
2 - TRIM COVER
3 - HORN SWITCH
4 - AIRBAG HOUSING
5 - LOCKING BLOCK
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT AIR-
BAGS AND TRIM COVERS ARE SERVICED IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE TRIM COVER
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Assembl e the dri ver ai rbag tri m cover onto the
ai rbag housi ng. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - ASSEMBLY).
(2) Posi ti on the dri ver ai rbag cl ose enough to the
steeri ng wheel to reconnect al l three el ectri cal con-
necti ons on the back of the ai rbag housi ng.
(3) When i nstal l i ng the dri ver ai rbag, reconnect
the two cl ockspri ng dri ver ai rbag pi gtai l wi re connec-
tors to the ai rbag i nfl ator connector receptacl es by
pressi ng strai ght i n on the connectors (Fi g. 19), then
pushi ng the l ocks strai ght i nto the connectors. You
can be certai n that the connector i s ful l y engaged by
l i steni ng careful l y for a di sti nct, audi bl e cl i ck as the
connector l atches snap i nto pl ace.
nector for the horn swi tch to the horn swi tch feed
pi gtai l wi re connector, whi ch i s l ocated at the back of
the dri ver ai rbag housi ng.
(5) Careful l y posi ti on the dri ver ai rbag i n the
steeri ng wheel . Be certai n that the cl ockspri ng pi g-
tai l wi res and steeri ng wheel wi re harness i n the
steeri ng wheel hub area are not pi nched between the
dri ver ai rbag and the steeri ng wheel armature.
(6) From the undersi de of the steeri ng wheel ,
i nstal l and ti ghten the two screws that secure the
dri ver ai rbag to the steeri ng wheel armature.
FRONT IMPACT SENSOR
DESCRIPTION
Two front i mpact sensors are used on thi s model ,
one each for the l eft and ri ght si des of the vehi cl e
(Fi g. 24). These sensors are mounted remotel y from
the i mpact sensor that i s i nternal to the Ai rbag Con-
trol Modul e (ACM). The ri ght and l eft front and si de
i mpact sensors are i denti cal i n constructi on and cal -
i brati on wi th the excepti on of the ri ght-hand and
l eft-hand di e cast al umi num mounti ng brackets to
whi ch each front i mpact sensor i s secured wi th two
screws. The front i mpact sensor brackets are secured
wi th three screws to the front and i nboard si des of
the ri ght and l eft verti cal members of the radi ator
support wi thi n the engi ne compartment.
The i mpact sensor housi ng has an i ntegral connec-
tor receptacl e and two i ntegral mounti ng ears, each
wi th a metal sl eeve to provi de crush protecti on. A cav-
i ty i n the center of the mol ded bl ack pl asti c i mpact
sensor housi ng contai ns the el ectroni c ci rcui try of the
sensor whi ch i ncl udes an el ectroni c communi cati on
chi p and an el ectroni c i mpact sensor. Potti ng materi al
fi l l s the cavi ty to seal and protect the i nternal el ec-
troni c ci rcui try and components. The front i mpact sen-
sors are each connected to the vehi cl e el ectri cal
system through a dedi cated take out and connector of
the ri ght or l eft headl amp and dash wi re harnesses.
The front i mpact sensors cannot be repai red or
adjusted and, i f damaged or faul ty, they must be
repl aced. I f a front i mpact sensor i s faul ty, onl y the
sensor needs to be repl aced. I f the sensor or the sen-
sor mounti ng bracket i s damaged or faul ty, or i f
proper ti ghteni ng torque of the screws that secure
the sensor to the bracket cannot be achi eved, the
sensor and bracket uni t must be repl aced.
Fig. 24 Front Impact Sensor
1 - SENSOR
OPERATION
The front i mpact sensors are el ectroni c accel erom-
eters that sense the rate of vehi cl e decel erati on,
whi ch provi des veri fi cati on of the di recti on and sever-
i ty of an i mpact. Each sensor al so contai ns an el ec-
troni c communi cati on chi p that al l ows the uni t to
communi cate the sensor status as wel l as sensor
faul t i nformati on to the mi croprocessor i n the Ai rbag
Control Modul e (ACM). The ACM mi croprocessor con-
ti nuousl y moni tors al l of the passi ve restrai nt system
el ectri cal ci rcui ts to determi ne the system readi ness.
I f the ACM detects a moni tored system faul t, i t sets
a Di agnosti c Troubl e Code (DTC) and control s the
ai rbag i ndi cator operati on accordi ngl y.
The i mpact sensors each recei ve battery current
and ground through dedi cated l eft and ri ght sensor
pl us and mi nus ci rcui ts from the ACM. The i mpact
sensors and the ACM communi cate by modul ati ng
the vol tage i n the sensor pl us ci rcui t. The hard wi red
ci rcui ts between the front i mpact sensors and the
ACM may be di agnosed and tested usi ng conven-
ti onal di agnosti c tool s and procedures. However, con-
venti onal di agnosti c methods wi l l not prove
concl usi ve i n the di agnosi s of the ACM or the i mpact
sensors. The most rel i abl e, effi ci ent, and accurate
means to di agnose the i mpact sensors, the ACM, and
the el ectroni c message communi cati on between the
sensors and the ACM requi res the use of a DRBI I I
mati on.
REMOVAL
The front and si de i mpact sensors are i nterchange-
abl e except that the front i mpact sensors are servi ced
wi th a ri ght or l eft mounti ng bracket, whi l e the si de
i mpact sensors use no mounti ng bracket. I f a front
i mpact sensor i s faul ty, but not damaged, the sensor
may be removed from the sensor mounti ng bracket
and repl aced wi th a si de i mpact sensor. I f the front
i mpact sensor or the sensor mounti ng bracket are
damaged i n any way, or i f proper ti ghteni ng torque of
the screws that secure the sensor to the bracket can-
not be achi eved, the front i mpact sensor and bracket
must be repl aced as a uni t.
PERSONAL INJURY.
WARNING: THE FRONT IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE FRONT SUPPLE-
MENTAL RESTRAINTS. NEVER STRIKE OR DROP
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
DROPPED DURING SERVICE, THE SENSOR MUST
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
RIES.
(2) From the engi ne compartment, di sconnect the
ri ght or l eft headl amp and dash wi re harness connec-
tor for the front i mpact sensor from the sensor con-
nector receptacl e (Fi g. 25).
Fig. 25 Front Impact Sensor Remove/Install (Right
Side Shown, Left Side Similar)
1 - BRACKET
2 - IMPACT SENSOR
3 - RADIATOR SUPPORT
5 - SCREW (2)
FRONT IMPACT SENSOR (Continued)
(3) From the engi ne compartment, remove the two
screws that secure the ri ght or l eft front i mpact sen-
sor to the sensor mounti ng bracket on the ri ght or
l eft radi ator support verti cal member.
(4) Remove the front i mpact sensor from the sen-
sor mounti ng bracket.
INSTALLATION
PERSONAL INJURY.
RIES.
(1) Posi ti on the ri ght or l eft front i mpact sensor to
the sensor mounti ng bracket on the ri ght or l eft radi -
ator support verti cal member i n the engi ne compart-
ment (Fi g. 25).
the ri ght or l eft front i mpact sensor to the sensor
mounti ng bracket. Ti ghten the screws to 10 Nm (85
i n. l bs.).
(3) Reconnect the ri ght or l eft headl amp and dash
wi re harness connector for the front i mpact sensor to
the sensor connector receptacl e.
FRONT IMPACT SENSOR &
BRACKET
REMOVAL
PERSONAL INJURY.
FRONT IMPACT SENSOR (Continued)
RIES.
(2) Remove the headl amp mounti ng modul e from
the front of the vehi cl e. (Refer to 23 - BODY/EXTE-
RI OR/HEADLAMP MOUNTI NG MODULE -
REMOVAL).
(3) Di sconnect the ri ght or l eft headl amp and dash
wi re harness connector for the front i mpact sensor
from the sensor connector receptacl e.
(4) Remove the three screws that secure the ri ght
or l eft front i mpact sensor and bracket uni t to the
ri ght or l eft radi ator support verti cal member (Fi g.
26).
(5) Remove the ri ght or l eft front i mpact sensor
and bracket uni t from the front of the vehi cl e.
INSTALLATION
PERSONAL INJURY.
RIES.
(1) Posi ti on the ri ght or l eft front i mpact sensor
and bracket uni t to the front of the vehi cl e (Fi g. 26).
(2) Posi ti on the ri ght or l eft front i mpact sensor
and bracket uni t to the ri ght or l eft radi ator support
verti cal member.
(3) Loosel y i nstal l the three screws that secure the
ri ght or l eft front i mpact sensor and bracket uni t
ri ght or l eft radi ator support verti cal member.
Fig. 26 Front Impact Sensor & B Remove/Install
1 - RADIATOR SUPPORT
2 - SCREW (3)
3 - BRACKET
5 - IMPACT SENSOR
FRONT IMPACT SENSOR & BRACKET (Continued)
(4) For the ri ght i mpact sensor and bracket uni t,
the ti ghteni ng sequence for the three screws that
secure i t to the ri ght radi ator support verti cal mem-
ber i s from top to bottom. For the l eft i mpact sensor
and bracket uni t, the ti ghteni ng sequence for the
three screws that secure i t to the l eft radi ator sup-
port verti cal member i s from bottom to top. Ti ghten
the screws to 12 Nm (105 i n. l bs.).
(5) Reconnect the ri ght or l eft headl amp and dash
wi re harness connector for the front i mpact sensor to
the sensor connector receptacl e.
(6) Rei nstal l the headl amp mounti ng modul e to
the front of the vehi cl e. (Refer to 23 - BODY/EXTE-
RI OR/HEADLAMP MOUNTI NG MODULE -
I NSTALLATI ON).
FRONT SEAT BELT &
RETRACTOR
REMOVAL
LISTED IN THE MOPAR PARTS CATALOG.
(1) Adjust the front seat to i ts most forward posi -
ti on for easi est access to the front seat bel t l ower
anchor and the B-pi l l ar tri m.
cabl e.
(3) Li ft the front seat bel t l ower anchor cover far
enough to access the screw that secures i t to the
l ower B-pi l l ar (Fi g. 27).
(4) Remove the screw that secures the l ower
anchor to the B-pi l l ar.
fl at-bl aded tool , gentl y pry the top of the turni ng l oop
tri m cover to unsnap i t from the hei ght adjuster and
access the screw that secures the front seat bel t turn-
i ng l oop to the adjuster on the upper B-pi l l ar (Fi g.
28).
Fig. 27 Front Seat Belt & Retractor Remove/Install
1 - ADJUSTER
2 - TURNING LOOP
3 - SCREW
4 - LOWER ANCHOR
5 - SCREW
6 - RETRACTOR
Fig. 28 Turning Loop Cover Remove/Install
1 - PILLAR
2 - TRIM COVER
3 - ADJUSTER
FRONT IMPACT SENSOR & BRACKET (Continued)
(6) Remove the screw that secures the seat bel t
turni ng l oop to the hei ght adjuster on the upper
B-pi l l ar.
(7) Remove the seat bel t turni ng l oop from the
hei ght adjuster.
(8) Remove the tri m from the l ower B-pi l l ar. (Refer
to 23 - BODY/I NTERI OR/B-PI LLAR LOWER TRI M -
REMOVAL).
(9) Pul l the front seat bel t turni ng l oop and l ower
anchor through the access hol e i n the l ower B-pi l l ar
tri m.
(10) Remove the pl asti c push-i n fastener that
secures the retractor to the l ower B-pi l l ar (Fi g. 29).
(11) Di sengage the retractor l ocator tab from the
sl ot i n the B-pi l l ar.
(12) Remove the front seat bel t and retractor from
the B-pi l l ar as a uni t.
INSTALLATION
(1) Be certai n that the retractor shi el d i s properl y
i nstal l ed i n the l ower B-pi l l ar and i n good condi ti on
before rei nstal l i ng the retractor (Fi g. 29).
(2) Posi ti on the front seat bel t and retractor to the
B-pi l l ar as a uni t. Be certai n to engage the retractor
l ocator tab i n the sl ot i n the l ower B-pi l l ar.
(3) Usi ng hand pressure, i nstal l the pl asti c push-i n
fastener that secures the retractor to the l ower B-pi l l ar.
(4) Push the seat bel t l ower anchor and turni ng
l oop through the access hol e i n the l ower B-pi l l ar
tri m (Fi g. 27).
(5) Rei nstal l the tri m onto the l ower B-pi l l ar.
(Refer to 23 - BODY/I NTERI OR/B-PI LLAR LOWER
TRI M - I NSTALLATI ON).
(6) Posi ti on the seat bel t turni ng l oop onto the
hei ght adjuster on the upper B-pi l l ar.
seat bel t turni ng l oop to the hei ght adjuster. Ti ghten
(8) Usi ng hand pressure, press the top of the turn-
i ng l oop tri m cover to snap i t onto the hei ght
adjuster and cover the screw that secures the front
seat bel t turni ng l oop to the adjuster on the upper
B-pi l l ar (Fi g. 28).
(9) Posi ti on the front seat bel t l ower anchor to the
l ower B-pi l l ar.
seat bel t l ower anchor to the B-pi l l ar. Ti ghten the
screw to 37 Nm (27 ft. l bs.).
(11) Pul l down the cover over the front seat bel t
l ower anchor far enough to conceal the screw.
FRONT SEAT BELT BUCKLE
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM
STEERING COLUMN, DRIVER AIRBAG, PASSENGER
AIRBAG, FRONT IMPACT SENSOR, SIDE IMPACT SEN-
SOR, SIDE CURTAIN AIRBAG, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE. DIS-
CONNECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE SUP-
PLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
Fig. 29 Front Retractor
1 - SHIELD
2 - RETRACTOR
3 - PLASTIC FASTENER
4 - SLOT
5 - LOCATOR TAB
FRONT SEAT BELT & RETRACTOR (Continued)
(1) Move the front seat to i ts most forward posi ti on
for easi est access to the front seat bel t buckl e l ower
anchor screw.
(3) Di sconnect the seat bel t swi tch pi gtai l wi re
connector from the body wi re harness connector for
the seat bel t swi tch wi th manual seats, or from the
power seat wi re harness connector for the seat bel t
swi tch wi th power seats (Fi g. 30).
(4) Remove the screw that secures the front seat
bel t buckl e l ower anchor to the si de of the fl oor panel
transmi ssi on tunnel .
(5) Remove the front seat bel t buckl e from the
fl oor panel transmi ssi on tunnel .
INSTALLATION
WHEEL, STEERING COLUMN, DRIVER AIRBAG, PAS-
SENGER AIRBAG, FRONT IMPACT SENSOR, SIDE
IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR
WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRECAU-
TIONS COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Posi ti on the front seat bel t buckl e to the si de of
the fl oor panel transmi ssi on tunnel (Fi g. 30).
front seat bel t buckl e l ower anchor to the si de of the
fl oor panel transmi ssi on tunnel . Ti ghten the screw to
43 Nm (32 ft. l bs.).
(3) Reconnect the seat bel t swi tch pi gtai l wi re con-
nector to the body wi re harness connector for the
seat bel t swi tch wi th manual seats, or to the power
seat wi re harness connector for the seat bel t swi tch
wi th power seats.
Fig. 30 Front Seat Belt Buckle
1 - SEAT BELT BUCKLE
2 - SEAT BELT SWITCH PIGTAIL WIRE
3 - SCREW
FRONT SEAT BELT BUCKLE (Continued)
PASSENGER AIRBAG
DESCRIPTION
The rearward faci ng surface of the i nstrument
panel top pad above the gl ove box i s the most vi si bl e
part of the passenger ai rbag (Fi g. 31). The passenger
ai rbag i s l ocated above the gl ove box openi ng i n front
of the front seat passenger seati ng posi ti on wi thi n
the i nstrument panel . The stamped steel passenger
ai rbag door i s secured on the back of the i nstrument
panel top pad armature between the two passenger
si de panel outl ets. A stamped metal rei nforcement i s
secured to the i nstrument panel top pad armature
near the upper edge of the passenger ai rbag door
openi ng, and hel ps to defi ne a predetermi ned hi nge
l i ne beneath the decorati ve cover of the top pad. The
i nstrument panel passenger si de bezel i s secured to
the ai rbag door from behi nd wi th four screws.
Located behi nd the passenger ai rbag door wi thi n
the i nstrument panel i s the passenger ai rbag uni t.
The passenger ai rbag uni t used i n thi s model i s a
mul ti stage, Next Generati on-type that compl i es wi th
revi sed federal ai rbag standards to depl oy wi th l ess
force than those used i n some pri or model s. The pas-
senger ai rbag uni t consi sts of an extruded al umi num
housi ng, a mol ded pl asti c i nner ai rbag cushi on dust
cover, the ai rbag cushi on, and the ai rbag i nfl ator.
The ai rbag housi ng contai ns the ai rbag i nfl ator,
whi l e the i nner dust cover contai ns the fol ded ai rbag
cushi on. The dust cover compl etel y encl oses the ai r-
bag cushi on and i s permanentl y retai ned to the hous-
i ng. The passenger ai rbag uni t i s secured wi th four
screws to the i nstrument panel structural duct. Con-
ceal ed beneath the i nstrument panel top pad are the
passenger ai rbag door, the fol ded ai rbag cushi on, the
ai rbag retai ner or housi ng, and the ai rbag i nfl ator.
The ai rbag cushi on i s constructed of a coated nyl on
fabri c. The ai rbag i nfl ator i s a dual -i ni ti ator, hybri d-
type uni t that i s secured to and seal ed wi thi n the ai r-
bag housi ng. A short four-wi re pi gtai l harness wi th a
keyed, yel l ow connector i nsul ator connects the two
i nfl ator i ni ti ators to the vehi cl e el ectri cal system
through a dedi cated take out and connector of the
i nstrument panel wi re harness.
The passenger ai rbag cannot be repai red, and must
be repl aced i f depl oyed, faul ty, or i n any way dam-
aged. The passenger ai rbag cannot be repai red, and
must be repl aced i f faul ty or i n any way damaged.
The passenger ai rbag door i s servi ced onl y as a uni t
wi th the i nstrument panel top pad. Fol l owi ng a pas-
senger ai rbag depl oyment, the passenger ai rbag and
the i nstrument panel top pad must be repl aced. I f
i nspecti on reveal s that the passenger ai rbag mount-
i ng poi nts on the i nstrument panel structural duct
have been cracked or damaged, the i nstrument panel
structural duct assembl y must al so be repl aced.
OPERATION
The mul ti stage passenger ai rbag i s depl oyed by
el ectri cal si gnal s generated by the Ai rbag Control
Modul e (ACM) through the passenger ai rbag squi b 1
and squi b 2 ci rcui ts to the two i ni ti ators i n the ai r-
bag i nfl ator. By usi ng two i ni ti ators, the ai rbag can
be depl oyed at mul ti pl e l evel s of force. The force l evel
i s control l ed by the ACM to sui t the moni tored
i mpact condi ti ons by provi di ng one of four del ay
i nterval s between the el ectri cal si gnal s provi ded to
the two i ni ti ators. The l onger the del ay between
these si gnal s, the l ess forceful l y the ai rbag wi l l
depl oy.
The hybri d-type i nfl ator assembl y i ncl udes a smal l
cani ster of hi ghl y compressed gas. When the ACM
sends the proper el ectri cal si gnal to the ai rbag i nfl a-
tor, the i ni ti ator generates enough heat to i gni te
chemi cal pel l ets wi thi n the i nfl ator. Once i gni ted,
these chemi cal pel l ets burn rapi dl y and produce the
pressure necessary to rupture a contai nment di sk i n
the pressuri zed gas cani ster. The i nfl ator and gas
cani ster are seal ed to the ai rbag cushi on so that al l
of the rel eased i nert gas i s di rected i nto the ai rbag
cushi on, causi ng the cushi on to i nfl ate. As the cush-
i on i nfl ates, the passenger ai rbag door wi l l bend back
the i nstrument panel top pad at the predetermi ned
hi nge l i ne, then fol d back over the top of the i nstru-
ment panel and out of the way. Fol l owi ng an ai rbag
depl oyment, the ai rbag cushi on qui ckl y defl ates by
venti ng the i nert gas through vent hol es wi thi n the
fabri c used to construct the si des of the ai rbag cush-
i on.
Fig. 31 Passenger Airbag Door
1 - BEZEL
2 - TOP PAD
3 - PASSENGER AIRBAG DOOR
4 - GLOVE BOX DOOR
Typi cal l y, both i ni ti ators are used duri ng an ai rbag
depl oyment event. However, i t i s possi bl e for onl y one
i ni ti ator to be used duri ng a depl oyment due to an
ai rbag system faul t; therefore, i t i s necessary to
al ways confi rm that both i ni ti ators have been used i n
order to avoi d the i mproper di sposal of potenti al l y
l i ve pyrotechni c materi al s. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS - STANDARD PROCEDURE -
SERVI CE AFTER A SUPPLEMENTAL RESTRAI NT
DEPLOYMENT).
REMOVAL
faul ty or damaged passenger ai rbag. I f the ai rbag i s
RESTRAI NTS). I f the passenger ai rbag has been
PERSONAL INJURY.
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
SKIN AND EYES.
(2) Remove the top pad from the i nstrument panel .
STRUMENT PANEL TOP PAD - REMOVAL).
(3) Di sconnect the passenger ai rbag pi gtai l wi re
connector from the i nstrument panel wi re harness
connector for the ai rbag. Thi s connector i s secured to
the outsi de of the outboard ai rbag uni t end bracket.
To di sconnect the connector:
(a) Sl i de the red Connector Posi ti on Assurance
(CPA) l ock on the top of the connector toward the
si de of the connector.
(b) Depress the connector l atch tab and pul l the
two hal ves of the connector strai ght away from
each other.
(4) Remove the two screws that secure the two ai r-
bag end bracket front mounti ng tabs to the top of the
(5) Remove the two screws that secure the two ai r-
bag end bracket rear mounti ng tabs to the rear of the
structural duct, just above the i nstrument panel
upper gl ove box openi ng rei nforcement.
(6) Remove the passenger ai rbag from the i nstru-
ment panel structural duct as a uni t.
Fig. 32 Passenger Side Airbag Module Remove/
Install
1 - STRUCTURAL DUCT
2 - PASSENGER AIRBAG
4 - STRUCTURAL DUCT
5 - SCREWS
PASSENGER AIRBAG (Continued)
INSTALLATION
faul ty or damaged passenger ai rbag. I f the ai rbag i s
RESTRAI NTS). I f the passenger ai rbag has been
PERSONAL INJURY.
SKIN AND EYES.
FOREIGN MATERIAL FROM ENTERING THE PAS-
SENGER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE INSTRUMENT PANEL TOP PAD. FAILURE
TO OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
WARNING: THE INSTRUMENT PANEL TOP PAD
MUST NEVER BE PAINTED. REPLACEMENT TOP
PADS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TOP PAD RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Careful l y posi ti on the passenger ai rbag onto
the i nstrument panel structural duct (Fi g. 32).
the passenger ai rbag to the i nstrument panel struc-
tural duct. Ti ghten the screws to 11.8 Nm (105 i n.
l bs.).
connector for the passenger ai rbag to the passenger
ai rbag pi gtai l wi re connector. Thi s connector i s
secured to the outsi de of the outboard ai rbag uni t
end bracket. Be certai n that the l atch on the connec-
tor and the red Connector Posi ti on Assurance (CPA)
l ock are each ful l y engaged.
(4) Rei nstal l the top pad onto the i nstrument
I NSTRUMENT PANEL TOP PAD - I NSTALLA-
TI ON).
REAR CENTER SEAT BELT &
RETRACTOR
REMOVAL
PASSENGER AIRBAG (Continued)
(1) Unl atch and fol d the ri ght rear seat cushi on
forward.
(2) Remove the screw that secures the rear center
seat bel t l ower anchor to the ri ght rear seat bel t
buckl e uni t bracket on the rear fl oor panel (Fi g. 33).
(3) Unl atch and fol d the ri ght rear seat back for-
ward and separate the cargo area carpet from the
base of the seat back panel .
(4) Remove the ri ght rear seat back panel from the
vehi cl e. (Refer to 23 - BODY/SEATS/SEAT BACK -
REAR - REMOVAL).
(5) Remove the two screws that secure the bel t
web gui de to the top of the ri ght rear seat back
panel .
(6) Remove the tri m from the ri ght rear seat back.
(Refer to 23 - BODY/SEATS/SEAT BACK COVER -
REAR - REMOVAL).
(7) Route the rear seat bel t l ower anchor and bel t
web gui de through the top of the seat back panel .
(8) Di sengage the seat back l atch cabl e fi tti ng from
the cabl e support on the retractor, whi ch i s a l i ght
snap fi t (Fi g. 34).
(9) Remove the screw that secures the retractor to
the rear seat back panel (Fi g. 35).
(10) Remove the rear center seat bel t and retractor
uni t from the seat back panel .
Fig. 33 Rear Center Seat Belt Lower Anchor
Remove/Install
1 - REAR SEAT BACK
2 - REAR CENTER SEAT BELT & RETRACTOR
3 - RIGHT REAR SEAT BELT BUCKLE UNIT
4 - REAR FLOOR PANEL
5 - SCREW (1)
6 - LOWER ANCHOR
Fig. 34 Seat Back Latch Cable Disengage/Engage
1 - LEVER
2 - PLUNGER
3 - LATCH CABLE FITTING
4 - REAR CENTER RETRACTOR
5 - SUPPORT
Fig. 35 Rear Center Retractor Remove/Install
1 - REAR SEAT BACK PANEL
2 - SCREW (1)
REAR CENTER SEAT BELT & RETRACTOR (Continued)
INSTALLATION
(1) Posi ti on the rear center seat bel t and retractor
uni t onto the seat back panel .
retractor to the rear seat back panel (Fi g. 35).
Ti ghten the screw to 43 Nm (32 ft. l bs.).
(3) Posi ti on the seat back l atch cabl e pl unger
agai nst the retractor l atch l ever, then engage the
cabl e fi tti ng i nto the cabl e support on the retractor,
whi ch i s a l i ght snap fi t (Fi g. 34).
(4) Route the rear seat bel t l ower anchor and bel t
web gui de through the top of the seat back panel .
(5) Rei nstal l the tri m onto the ri ght rear seat
back. (Refer to 23 - BODY/SEATS/SEAT BACK
COVER - REAR - I NSTALLATI ON).
the bel t web gui de to the top of the ri ght rear seat
back panel . Ti ghten the screws to 2 Nm (20 i n. l bs.).
(7) Rei nstal l the ri ght rear seat back panel i nto
the vehi cl e. (Refer to 23 - BODY/SEATS/SEAT BACK
- REAR - I NSTALLATI ON).
(8) Restore the cargo area carpet to the base of the
seat back panel and unfol d the ri ght rear seat back
to i ts upri ght posi ti on.
(9) Posi ti on the rear center seat bel t l ower anchor
to the ri ght rear seat bel t buckl e uni t bracket on the
rear fl oor panel (Fi g. 33).
rear center seat bel t l ower anchor to the ri ght rear
seat bel t buckl e uni t bracket on the rear fl oor panel .
(11) Fol d and l atch the ri ght rear seat cushi on i n
i ts normal seati ng posi ti on.
REAR OUTBOARD SEAT BELT
& RETRACTOR
REMOVAL
(1) Di sengage the rear seat cushi on l atch by pul l -
i ng upward on the rel ease strap.
(2) Fol d the rear seat cushi on forward agai nst the
back of the front bucket seat.
(3) Remove the screw that secures the rear out-
board seat bel t l ower anchor to the rear fl oor panel
(Fi g. 36).
(4) Remove the l ower anchor from the rear fl oor
panel .
fl at-bl aded tool , gentl y pry the top of the turni ng l oop
tri m cover to unsnap i t from the hei ght adjuster and
access the screw that secures the rear outboard seat
bel t turni ng l oop to the adjuster on the upper C-pi l -
l ar (Fi g. 37).
(6) Remove the screw that secures the seat bel t
turni ng l oop to the hei ght adjuster on the upper
C-pi l l ar.
(7) Remove the seat bel t turni ng l oop from the
hei ght adjuster.
(8) Remove the tri m from the quarter i nner panel .
(Refer to 23 - BODY/I NTERI OR/QUARTER TRI M
PANEL - REMOVAL).
(9) Remove the screw that secures the retractor to
the mounti ng tab on the i nner and outer rear wheel -
house fl ange.
(10) Di sengage the retractor l ocator tab from the
sl ot i n the l ower C-pi l l ar (Fi g. 38).
(11) Remove the rear outboard seat bel t and
retractor from the C-pi l l ar as a uni t.
REAR CENTER SEAT BELT & RETRACTOR (Continued)
INSTALLATION
(1) Be certai n that the retractor shi el d i s properl y
i nstal l ed i n the C-pi l l ar and i n good condi ti on before
i nstal l i ng the retractor.
(2) Posi ti on the retractor i n the retractor shi el d
and be certai n that the retractor l ocator tab i s
engaged i n the sl ot i n the l ower C-pi l l ar bel ow the
retractor shi el d (Fi g. 38).
retractor bracket to the mounti ng tab on the i nner
and outer rear wheel house fl ange (Fi g. 36). Ti ghten
(4) Rei nstal l the tri m onto the quarter i nner panel .
(Refer to 23 - BODY/I NTERI OR/QUARTER TRI M
PANEL - I NSTALLATI ON).
(5) Posi ti on the seat bel t turni ng l oop to the hei ght
adjuster on the upper C-pi l l ar.
Fig. 36 Rear Outboard Seat Belt & Retractor
Remove/Install
1 - ADJUSTER
2 - TURNING LOOP
3 - SCREW
4 - QUARTER TRIM PANEL
5 - SCREW
6 - RETRACTOR
7 - LOWER ANCHOR
8 - SCREW
Fig. 37 Turning Loop Cover Remove/Install
1 - PILLAR
2 - TRIM COVER
3 - ADJUSTER
Fig. 38 Rear Outboard Retractor
1 - RETRACTOR
2 - SLOT/LOCATOR TAB
REAR OUTBOARD SEAT BELT & RETRACTOR (Continued)
seat bel t turni ng l oop to the hei ght adjuster. Ti ghten
(7) Usi ng hand pressure, press the top of the turn-
i ng l oop tri m cover to snap i t onto the hei ght
adjuster and cover the screw that secures the rear
outboard seat bel t turni ng l oop to the adjuster on the
upper C-pi l l ar (Fi g. 37).
(8) Posi ti on the rear outboard seat bel t l ower
anchor to the rear fl oor panel .
seat bel t l ower anchor to the rear fl oor panel .
(10) Fol d the rear seat cushi on back i nto the seat-
i ng posi ti on.
REAR SEAT BELT BUCKLE
REMOVAL
(1) Di sengage the rear seat cushi on l atch by pul l -
i ng upward on the rel ease strap.
(2) Fol d the rear seat cushi on forward agai nst the
back of the front bucket seat.
(3) Remove the screw that secures the anchor
pl ate of the rear seat l ap bel t/buckl e uni t (ri ght si de)
or buckl e/buckl e uni t (l eft si de) to the rear fl oor
panel (Fi g. 39).
NOTE: Vehicles equipped with a three-point center
seat belt have the center seat belt lower anchor
secured to the right buckle anchor plate with a
screw instead of the center lap belt. (Refer to 8 -
ELECTRICAL/RESTRAINTS/REAR CENTER SEAT
BELT & RETRACTOR - REMOVAL).
(4) Remove the rear seat l ap bel t/buckl e uni t (ri ght
si de) or buckl e/buckl e uni t (l eft si de) from the rear
fl oor panel .
INSTALLATION
(1) Posi ti on the rear seat l ap bel t/buckl e uni t
(ri ght si de) or buckl e/buckl e uni t (l eft si de) onto the
rear fl oor panel (Fi g. 39). Be certai n the l ocator tab
on the anchor pl ate i s i nstal l ed i n the l ocator hol e
near the mounti ng hol e i n the rear fl oor panel .
anchor pl ate of the rear seat l ap bel t/buckl e uni t
(ri ght si de) or buckl e/buckl e uni t (l eft si de) to the
rear fl oor panel . Ti ghten the screw to 43 Nm (32 ft.
l bs.).
Fig. 39 Rear Seat Lap Belt/Buckle
1 - REAR SEAT LAP BELT/BUCKLE UNIT
2 - REAR SEAT BUCKLE/BUCKLE UNIT
3 - REAR FLOOR PANEL
4 - SCREW
REAR OUTBOARD SEAT BELT & RETRACTOR (Continued)
NOTE: Vehicles equipped with a three-point center
seat belt have the center seat belt lower anchor
secured to the right buckle anchor plate with a
screw instead of the center lap belt. (Refer to 8 -
ELECTRICAL/RESTRAINTS/REAR CENTER SEAT
BELT & RETRACTOR - INSTALLATION).
(3) Fol d the rear seat cushi on back i nto the seat-
i ng posi ti on.
SEAT BELT SWITCH
DESCRIPTION
The seat bel t swi tch for thi s model i s actual l y a
Hal l Effect-type sensor. Thi s sensor consi sts of a
fi xed-posi ti on, Hal l Effect I ntegrated Ci rcui t (I C) chi p
and a smal l permanent magnet that are i ntegral to
each front seat bel t buckl e. The front seat bel t buck-
l es are each l ocated on a stamped steel stanchi on
wi thi n a mol ded pl asti c scabbard and secured wi th a
screw to the fl oor panel transmi ssi on tunnel on the
i nboard si de of each front seat cushi on (Fi g. 40). The
seat bel t swi tches are connected to the vehi cl e el ec-
tri cal system through a two-l ead pi gtai l wi re and
connector on the seat bel t buckl e-hal f, whi ch i s con-
nected to a wi re harness connector and take out of
the body wi re harness on vehi cl es wi th manual seat
adjusters, or to a connector and take out of the power
seat wi re harness on vehi cl es wi th power seat adjust-
ers. A radi o noi se suppressi on capaci tor i s connected
i n paral l el wi th the I C where the two pi gtai l wi re
l eads connect to the I C pi ns.
The seat bel t swi tch cannot be adjusted or repai red
and, i f faul ty or damaged, the enti re seat bel t buckl e-
hal f uni t must be repl aced.
OPERATION
The seat bel t swi tches are desi gned to provi de a
status si gnal to the seat bel t swi tch sense i nputs of
the Ai rbag Control Modul e (ACM) i ndi cati ng whether
the front seat bel ts are fastened. The ACM uses the
seat bel t swi tch i nputs as a factor i n determi ni ng
what l evel of force wi th whi ch i t shoul d depl oy the
mul ti stage dri ver and passenger ai rbags. I n addi ti on,
the ACM sends el ectroni c messages to the El ectroMe-
chani cal I nstrument Cl uster (EMI C) to control the
seat bel t i ndi cator based upon the status of the
dri ver si de front seat bel t swi tch. A spri ng-l oaded
sl i de wi th a smal l wi ndow-l i ke openi ng i s i ntegral to
the buckl e l atch mechani sm. When a seat bel t ti p-
hal f i s i nserted and l atched i nto the seat bel t buckl e,
the sl i de i s pushed downward and the wi ndow of the
sl i de exposes the Hal l Effect I ntegrated Ci rcui t (I C)
chi p wi thi n the buckl e to the fi el d of the permanent
magnet, whi ch i nduces a current wi thi n the chi p.
The chi p provi des thi s i nduced current as an output
to the ACM, whi ch moni tors the current to determi ne
the status of the front seat bel ts. When the seat bel t
i s unbuckl ed, the spri ng-l oaded sl i de moves upward
and shi el ds the I C from the fi el d of the permanent
magnet, causi ng the output current from the seat
bel t swi tch to be reduced.
The seat bel t swi tch recei ves a suppl y current from
the ACM, and the ACM senses the status of the front
seat bel ts through i ts pi gtai l wi re connecti on to the
ai rbag overl ay wi re harness. The ACM moni tors the
condi ti on of the seat bel t swi tch ci rcui ts and wi l l i l l u-
mi nate the ai rbag i ndi cator i n the EMI C then store a
Di agnosti c Troubl e Code (DTC) for any faul t that i s
detected i n ei ther seat bel t swi tch ci rcui t. For proper
di agnosi s of the seat bel t swi tches, a DRBI I I scan
i nformati on.
Fig. 40 Front Seat Belt Buckle
1 - SEAT BELT BUCKLE
2 - SEAT BELT SWITCH PIGTAIL WIRE
3 - SCREW
REAR SEAT BELT BUCKLE (Continued)
SEAT BELT TURNING LOOP
ADJ USTER
REMOVAL
(1) Remove the turni ng l oop from the front or rear
seat bel t turni ng l oop adjuster. (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS/FRONT SEAT BELT &
RETRACTOR - REMOVAL) or (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS/REAR OUTBOARD SEAT
BELT & RETRACTOR - REMOVAL).
(2) Remove the tri m from the upper B-pi l l ar (front
seat bel t adjuster) or upper C-pi l l ar (rear seat bel t
adjuster). (Refer to 23 - BODY/I NTERI OR/B-PI LLAR
UPPER TRI M - REMOVAL) or (Refer to 23 - BODY/
I NTERI OR/C-PI LLAR TRI M - REMOVAL).
(3) Remove the screw that secures the upper end
of the front or rear turni ng l oop adjuster to the pi l l ar
(Fi g. 41).
(4) Pul l the upper end of the turni ng l oop adjuster
away from the pi l l ar far enough to di sengage the
hooks on the l ower end of the adjuster from the sl ots
i n the pi l l ar.
(5) Remove the turni ng l oop adjuster from the
B-pi l l ar (front seat bel t) or C-pi l l ar (rear seat bel t).
INSTALLATION
(1) Posi ti on the turni ng l oop adjuster to the B-pi l -
l ar (front seat bel t) or C-pi l l ar (rear seat bel t).
(2) Engage the hooks on the l ower end of the
adjuster i nto the sl ots i n the pi l l ar (Fi g. 41).
(3) Ti l t the upper end of the turni ng l oop adjuster
i nto posi ti on agai nst the pi l l ar.
upper end of the front or rear hei ght adjuster to the
pi l l ar. Ti ghten the screw to 43 Nm (32 ft. l bs.).
(5) Rei nstal l the tri m onto the upper B-pi l l ar
(front seat bel t adjuster) or upper C-pi l l ar (rear seat
bel t adjuster). (Refer to 23 - BODY/I NTERI OR/B-
PI LLAR UPPER TRI M - I NSTALLATI ON) or (Refer
to 23 - BODY/I NTERI OR/C-PI LLAR TRI M -
I NSTALLATI ON).
(6) Rei nstal l the front or rear seat bel t turni ng
l oop to the adjuster. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/FRONT SEAT BELT & RETRACTOR -
I NSTALLATI ON) or (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/REAR OUTBOARD SEAT BELT &
RETRACTOR - I NSTALLATI ON).
Fig. 41 Seat Belt Turning Loop Adjuster - Typical
1 - SCREW (1)
2 - ADJUSTER
3 - LEVER
4 - SLOTS (2)
5 - HOOKS (2)
SIDE CURTAIN AIRBAG
DESCRIPTION
Opti onal si de curtai n ai rbags are avai l abl e for thi s
model when i t i s al so equi pped wi th dual front ai r-
bags. These ai rbags are passi ve, i nfl atabl e, Suppl e-
mental Restrai nt System (SRS) components, and
vehi cl es wi th thi s equi pment can be readi l y i denti fi ed
by a mol ded i denti fi cati on tri m button wi th the SRS
- AI RBAG l ogo l ocated on the headl i ner above each
B-pi l l ar (Fi g. 42). Thi s system i s desi gned to reduce
i njuri es to the vehi cl e occupants i n the event of a
si de i mpact col l i si on.
Vehi cl es equi pped wi th si de curtai n ai rbags have
two i ndi vi dual l y control l ed curtai n ai rbag uni ts.
These ai rbag uni ts are conceal ed and mounted above
the headl i ner where they are each secured to one of
the roof si de rai l s (Fi g. 43). Each fol ded ai rbag cush-
i on i s contai ned wi thi n a l ong extruded pl asti c chan-
nel that extends al ong the roof rai l from the A-pi l l ar
at the front of the vehi cl e to just behi nd the C-pi l l ar
at the rear of the vehi cl e. One tether extends down
the A-pi l l ar from the front of the ai rbag cushi on, and
a second tether extends to the roof rai l above the
D-pi l l ar. The ends of these tethers are secured to
sl ots i n the sheet metal wi th metal hooks retai ned by
pl asti c anchor cl i ps.
The hybri d-type i nfl ator for each ai rbag i s secured
to the roof rai l at the rear of the ai rbag uni t between
the C-pi l l ar and the D-pi l l ar, and i s connected to the
ai rbag cushi on by a l ong tubul ar mani fol d. The i nfl a-
tor bracket and the extruded ai rbag cushi on channel
are secured wi th both pl asti c push-i n fasteners and
screws to the roof rai l . A dedi cated two-wi re take out
and connector of the body wi re harness i s routed for-
ward from the D-pi l l ar to the ai rbag i nfl ator.
The si de curtai n ai rbag uni t cannot be adjusted or
repai red and must be repl aced i f depl oyed, faul ty, or
i n any way damaged. Once a si de curtai n ai rbag has
been depl oyed, the compl ete ai rbag uni t, the head-
l i ner, the upper A, B, and C-pi l l ar tri m, and al l other
vi si bl y damaged components must be repl aced.
OPERATION
Each si de curtai n ai rbag i s depl oyed i ndi vi dual l y
by an el ectri cal si gnal generated by the Ai rbag Con-
trol Modul e (ACM) to whi ch i t i s connected through
l eft or ri ght curtai n ai rbag l i ne 1 and l i ne 2 (or
squi b) ci rcui ts. The hybri d-type i nfl ator assembl y for
each ai rbag contai ns a smal l cani ster of hi ghl y com-
pressed gas. When the ACM sends the proper el ectri -
cal si gnal to the ai rbag i nfl ator, the el ectri cal energy
creates enough heat to i gni te chemi cal pel l ets wi thi n
the i nfl ator. Once i gni ted, these chemi cal s burn rap-
i dl y and produce the pressure necessary to rupture a
contai nment di sk i n the pressuri zed gas cani ster. The
i nfl ator and gas cani ster are seal ed and connected to
a tubul ar mani fol d so that al l of the rel eased i nert
gas i s di rected i nto the fol ded si de curtai n ai rbag
cushi on, causi ng the cushi on to i nfl ate.
As the ai rbag cushi on i nfl ates i t wi l l drop down
from the roof rai l between the edge of the headl i ner
and the si de gl ass/body pi l l ars to form a curtai n-l i ke
cushi on to protect the vehi cl e occupants duri ng a si de
i mpact col l i si on. The front and rear tethers keep the
si de curtai n bag taut, thus ensuri ng that the bag wi l l
depl oy i n the proper posi ti on. Fol l owi ng the ai rbag
depl oyment, the ai rbag cushi on qui ckl y defl ates by
venti ng the i nert gas through the l oose weave of the
cushi on fabri c, and the defl ated cushi on hangs down
l oosel y from the roof rai l .
REMOVAL
faul ty or damaged si de curtai n ai rbag. I f the ai rbag
i s faul ty or damaged, but not depl oyed, revi ew the
recommended procedures for handl i ng non-depl oyed
RESTRAI NTS). I f the si de curtai n ai rbag has been
Fig. 42 SRS Logo
PERSONAL INJURY.
SKIN AND EYES.
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
(2) Remove the headl i ner from the vehi cl e. (Refer
to 23 - BODY/I NTERI OR/HEADLI NER - REMOV-
AL).
(3) Di sconnect the body wi re harness connector for
the si de curtai n ai rbag i nfl ator from the i nfl ator con-
nector receptacl e (Fi g. 44).
(4) Di sengage the si de curtai n ai rbag rear tether
hook and pl asti c retai ner cl i p from the sl ot i n the
roof rai l near the D-pi l l ar.
(5) Di sengage the si de curtai n ai rbag front tether
hook and pl asti c retai ner cl i p from the sl ot i n the
l ower A-pi l l ar (Fi g. 45).
(6) Di sengage the si de curtai n ai rbag front tether
pl asti c retai ner from the hol e i n the upper A-pi l l ar.
Fig. 43 Side Curtain Airbag
1 - NUT (9)
2 - REAR TETHER
3 - SCREW (9)
4 - INFLATOR
5 - MANIFOLD
6 - PUSH-IN FASTENER (4)
7 - CHANNEL
8 - FRONT TETHER
SIDE CURTAIN AIRBAG (Continued)
(7) Remove the ni ne screws that secure the si de
curtai n ai rbag channel and i nfl ator mounti ng bracket
to the spri ng nuts i n the roof si de rai l .
(8) Grasp the extruded pl asti c channel of the si de
curtai n ai rbag fi rml y and pul l i t strai ght away from
the body far enough to di sengage al l three pl asti c
push-i n fasteners that secure i t to the l ocati ng hol es
i n the roof si de rai l .
(9) Grasp the i nfl ator of the si de curtai n ai rbag
fi rml y and pul l i t strai ght away from the body far
enough to di sengage the push-i n fastener that
secures i t to the l ocati ng hol e i n the roof si de rai l .
(10) Remove the si de curtai n ai rbag from the vehi -
cl e as a uni t.
Fig. 44 Side Curtain Airbag Inflator
1 - BODY WIRE HARNESS
2 - D-PILLAR
3 - REAR TETHER
4 - INFLATOR
Fig. 45 Side Curtain Airbag Remove/Install
1 - NUT (9)
2 - REAR TETHER
3 - SCREW (9)
4 - INFLATOR
5 - MANIFOLD
6 - PUSH-IN FASTENER (4)
7 - CHANNEL
8 - FRONT TETHER
INSTALLATION
faul ty or damaged si de curtai n ai rbag. I f the ai rbag
i s faul ty or damaged, but not depl oyed, revi ew the
recommended procedures for handl i ng non-depl oyed
RESTRAI NTS). I f the si de curtai n ai rbag has been
PERSONAL INJURY.
SKIN AND EYES.
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
(1) Posi ti on the si de curtai n ai rbag i nto the vehi cl e
as a uni t.
(2) Al i gn the push-i n fastener that secures the
i nfl ator of the si de curtai n ai rbag to the l ocati ng hol e
i n the roof si de rai l and, usi ng hand pressure, push
fi rml y on the retai ner unti l i t i s ful l y seated (Fi g. 45).
(3) Al i gn the three push-i n fasteners that secure
the extruded pl asti c channel of the si de curtai n ai r-
bag to the l ocati ng hol es i n the roof si de rai l and,
usi ng hand pressure, push fi rml y on each retai ner
unti l i t i s ful l y seated.
(4) I nstal l and ti ghten the ni ne screws that secure
the si de curtai n ai rbag channel and i nfl ator mount-
i ng bracket to the spri ng nuts i n the roof si de rai l .
(5) Al i gn the si de curtai n ai rbag front tether pl as-
ti c retai ner wi th the hol e i n the upper A-pi l l ar and,
usi ng hand pressure, push fi rml y on the retai ner
unti l i t i s ful l y seated.
(6) Engage the si de curtai n ai rbag front tether
hook and pl asti c retai ner cl i p i nto the sl ot i n the
l ower A-pi l l ar.
(7) Engage the si de curtai n ai rbag rear tether
hook and pl asti c retai ner cl i p i nto the sl ot i n the roof
rai l near the D-pi l l ar (Fi g. 44).
(8) Reconnect the body wi re harness connector for
the si de curtai n ai rbag i nfl ator to the i nfl ator connec-
tor receptacl e.
(9) Rei nstal l the headl i ner i nto the vehi cl e. (Refer
to 23 - BODY/I NTERI OR/HEADLI NER - I NSTALLA-
TI ON).
SIDE IMPACT SENSOR
DESCRIPTION
Two si de i mpact sensors are used on thi s model
when i t i s equi pped wi th the opti onal si de curtai n
ai rbags, one each for the l eft and ri ght si des of the
vehi cl e (Fi g. 46). These sensors are mounted
remotel y from the bi -di recti onal safi ng sensor that i s
i nternal to the Ai rbag Control Modul e (ACM). The
si de and front i mpact sensors are i denti cal i n con-
structi on and cal i brati on wi th the excepti on of the
ri ght-hand and l eft-hand di e cast al umi num mount-
i ng brackets to whi ch each front i mpact sensor i s
secured wi th two screws. The si de i mpact sensors are
secured wi th two screws to the base of the ri ght and
l eft B-pi l l ars just bel ow the front seat bel t retractors
and behi nd the l ower B-pi l l ar tri m wi thi n the pas-
senger compartment.
The i mpact sensor housi ng has an i ntegral connec-
tor receptacl e and two i ntegral mounti ng ears, each
wi th a metal sl eeve to provi de crush protecti on. A
cavi ty i n the center of the mol ded bl ack pl asti c
i mpact sensor housi ng contai ns the el ectroni c ci r-
cui try of the sensor whi ch i ncl udes an el ectroni c com-
muni cati on chi p and an el ectroni c i mpact sensor.
Potti ng materi al fi l l s the cavi ty to seal and protect
the i nternal el ectroni c ci rcui try and components. The
si de i mpact sensors are each connected to the vehi cl e
el ectri cal system through a dedi cated take out and
connector of the ai rbag overl ay wi re harness.
The si de i mpact sensors cannot be repai red or
adjusted and, i f damaged or faul ty, they must be
repl aced.
OPERATION
The si de i mpact sensors are el ectroni c accel erome-
ters that sense the rate of vehi cl e decel erati on, whi ch
provi des veri fi cati on of the di recti on and severi ty of
an i mpact. Each sensor al so contai ns an el ectroni c
communi cati on chi p that al l ows the uni t to commu-
ni cate the sensor status as wel l as sensor faul t i nfor-
mati on to the mi croprocessor i n the Ai rbag Control
Modul e (ACM). The ACM mi croprocessor conti nu-
ousl y moni tors al l of the passi ve restrai nt system
el ectri cal ci rcui ts to determi ne the system readi ness.
I f the ACM detects a moni tored system faul t, i t sets
a Di agnosti c Troubl e Code (DTC) and control s the
ai rbag i ndi cator operati on accordi ngl y.
The i mpact sensors each recei ve battery current and
ground through dedi cated l eft and ri ght sensor pl us
and mi nus ci rcui ts from the ACM. The i mpact sensors
and the ACM communi cate by modul ati ng the vol tage
i n the sensor pl us ci rcui t. The hard wi red ci rcui ts
between the si de i mpact sensors and the ACM may be
di agnosed and tested usi ng conventi onal di agnosti c
tool s and procedures. However, conventi onal di agnos-
ti c methods wi l l not prove concl usi ve i n the di agnosi s
of the ACM or the i mpact sensors. The most rel i abl e,
effi ci ent, and accurate means to di agnose the i mpact
sensors, the ACM, and the el ectroni c message commu-
ni cati on between the sensors and the ACM requi res
the use of a DRBI I I scan tool . Refer to the appropri -
REMOVAL
PERSONAL INJURY.
WARNING: THE SIDE IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIR-
BAG. NEVER STRIKE OR DROP THE SIDE IMPACT
SENSOR, AS IT CAN DAMAGE THE IMPACT SEN-
SOR OR AFFECT ITS CALIBRATION. IF AN IMPACT
SENSOR IS ACCIDENTALLY DROPPED DURING
SERVICE, THE SENSOR MUST BE SCRAPPED AND
REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SIDE CUR-
TAIN AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
(2) Remove the tri m from the l ower ri ght or l eft
B-pi l l ar. (Refer to 23 - BODY/I NTERI OR/B-PI LLAR
LOWER TRI M - REMOVAL).
(3) Di sconnect the ai rbag overl ay wi re harness
connector for the ri ght or l eft si de i mpact sensor from
the sensor connector receptacl e (Fi g. 47).
(4) Remove the two screws that secure the ri ght or
l eft si de i mpact sensor to the B-pi l l ar.
(5) Remove the si de i mpact sensor from the B-pi l -
l ar.
Fig. 46 Side Impact Sensor
1 - SENSOR
SIDE IMPACT SENSOR (Continued)
INSTALLATION
PERSONAL INJURY.
WARNING: THE SIDE IMPACT SENSOR ENABLES
THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIR-
BAG. NEVER STRIKE OR DROP THE SIDE IMPACT
SENSOR, AS IT CAN DAMAGE THE IMPACT SEN-
SOR OR AFFECT ITS CALIBRATION. IF AN IMPACT
SENSOR IS ACCIDENTALLY DROPPED DURING
SERVICE, THE SENSOR MUST BE SCRAPPED AND
REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SIDE CUR-
TAIN AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
(1) Posi ti on the ri ght or l eft si de i mpact sensor
onto the B-pi l l ar (Fi g. 47).
the ri ght or l eft si de i mpact sensor to the B-pi l l ar.
(3) Reconnect the ai rbag overl ay wi re harness con-
nector for the ri ght or l eft si de i mpact sensor to the
sensor connector receptacl e.
(4) Rei nstal l the tri m onto the l ower ri ght or l eft
B-pi l l ar. (Refer to 23 - BODY/I NTERI OR/B-PI LLAR
LOWER TRI M - I NSTALLATI ON).
Fig. 47 Side Impact Sensor Remove/Install
1 - B-PILLAR
2 - SIDE IMPACT SENSOR
3 - SCREW (2)
SIDE IMPACT SENSOR (Continued)
SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - ROAD TEST . . . . . 2
SPECIFICATIONS
TORQUE - SPEED CONTROL . . . . . . . . . . . . . 3
CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . 4
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . . 4
SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VACUUM RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - VACUUM
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPEED CONTROL
DESCRIPTION
The speed control system i s el ectroni cal l y con-
trol l ed and vacuum operated. El ectroni c control of
the speed control system i s i ntegrated i nto the Pow-
ertrai n Control Modul e (PCM). The control s consi st
of two steeri ng wheel mounted swi tches. The
swi tches are l abel ed: ON/OFF, RES/ACCEL, SET,
COAST, and CANCEL.
The system i s desi gned to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
When speed control i s sel ected by depressi ng the
ON swi tch, the PCM al l ows a set speed to be stored
i n PCM RAM for speed control . To store a set speed,
depress the SET swi tch whi l e the vehi cl e i s movi ng
at a speed between 35 and 85 mph. I n order for the
speed control to engage, the brakes cannot be
appl i ed, nor can the gear sel ector be i ndi cati ng the
transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
Depressi ng the cl utch pedal (i f equi pped).
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the PCM.
For added safety, the speed control system i s pro-
grammed to di sengage for any of the fol l owi ng condi -
ti ons:
An i ndi cati on of Park or Neutral
A rapi d i ncrease rpm (i ndi cates that the cl utch
has been di sengaged)
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
The speed si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the coeffi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
WJ SPEED CONTROL 8P - 1
The speed si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
Once the speed control has been di sengaged,
depressi ng the RES/ACCEL swi tch (when speed i s
greater than 30 mph) restores the vehi cl e to the tar-
get speed that was stored i n the PCM.
Whi l e the speed control i s engaged, the dri ver can
i ncrease the vehi cl e speed by depressi ng the RES/AC-
CEL swi tch. The new target speed i s stored i n the
PCM when the RES/ACCEL i s rel eased. The PCM
al so has a tap-up feature i n whi ch vehi cl e speed
i ncreases at a rate of approxi matel y 2 mph for each
momentary swi tch acti vati on of the RES/ACCEL
swi tch.
A tap down feature i s used to decel erate wi thout
di sengagi ng the speed control system. To decel erate
from an exi sti ng recorded target speed, momentari l y
depress the COAST swi tch. For each swi tch acti va-
ti on, speed wi l l be l owered approxi matel y 1 mph.
OVERSHOOT/UNDERSHOOT
I f the vehi cl e operator repeatedl y presses and
rel eases the SET button wi th thei r foot off of the
accel erator (referred to as a l i ft foot set), the vehi cl e
may accel erate and exceed the desi red set speed by
up to 5 mph (8 km/h). I t may al so decel erate to l ess
than the desi red set speed, before fi nal l y achi evi ng
the desi red set speed.
The Speed Control System has an adapti ve strat-
egy that compensates for vehi cl e-to-vehi cl e vari ati ons
i n speed control cabl e l engths. When the speed con-
trol i s set wi th the vehi cl e operators foot off of the
accel erator pedal , the speed control thi nks there i s
excessi ve speed control cabl e sl ack and adapts
accordi ngl y. I f the l i ft foot sets are conti nual l y used,
a speed control overshoot/undershoot condi ti on wi l l
devel op.
To unl earn the overshoot/undershoot condi ti on,
the vehi cl e operator has to press and rel ease the set
button whi l e mai ntai ni ng the desi red set speed usi ng
the accel erator pedal (not decel erati ng or accel erat-
i ng), and then turni ng the crui se control swi tch to
the OFF posi ti on (or press the CANCEL button i f
equi pped) after wai ti ng 10 seconds. Thi s procedure
must be performed approxi matel y 1015 ti mes to
compl etel y unl earn the overshoot/undershoot condi -
ti on.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d
be corrected before proceedi ng. Refer to Group 8J,
I nstrument Cl uster for speedometer di agnosi s.
I f a road test veri fi es a system probl em and the
speedometer operates properl y, check for:
A Di agnosti c Troubl e Code (DTC). I f a DTC
exi sts, conduct tests per the Powertrai n Di agnosti c
Procedures servi ce manual .
A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
Loose, damaged or corroded el ectri cal connec-
ti ons at the servo. Corrosi on shoul d be removed from
el ectri cal termi nal s and a l i ght coati ng of Mopar
Mul ti Purpose Grease, or equi val ent, appl i ed.
Leaki ng vacuum reservoi r.
Loose or l eaki ng vacuum hoses or connecti ons.
Defecti ve one-way vacuum check val ve.
Secure attachment of both ends of the speed con-
trol servo cabl e.
Smooth operati on of throttl e l i nkage and throttl e
body ai r val ve.
Fai l ed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity 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.
8P - 2 SPEED CONTROL WJ
SPEED CONTROL (Continued)
SPECIFICATIONS
TORQUE - SPEED CONTROL
Servo Mounting Bracket-to-
Servo Nuts
8.5 75
Servo Mounting Bracket-to-
Body Nuts
28 6 250 50
Switch Module Mounting
Screws
.6-1 6-9
Vacuum Reservoir Mounting
Bolts
3 25
CABLE
DESCRIPTION
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage.
OPERATION
Thi s cabl e causes the throttl e control l i nkage to
open or cl ose the throttl e val ve i n response to move-
ment of the vacuum servo di aphragm.
REMOVAL
REMOVAL - 4. 0L
(2) Remove ai r box housi ng from throttl e body.
(3) Usi ng fi nger pressure onl y, remove speed con-
trol cabl e connector at throttl e body bel l crank pi n by
pushi ng connector off bel l crank pi n towards dri vers
si de of vehi cl e (Fi g. 1). DO NOT try to pull con-
nector off perpendicular to the bellcrank pin.
Connector will be broken.
(4) Remove cabl e from cabl e gui de at top of val ve
cover.
(5) Squeeze 2 rel ease tabs (Fi g. 1) on si des of cabl e
at bracket and push cabl e out of bracket.
(6) Remove servo cabl e from servo. Refer to Speed
Control Servo Removal /I nstal l ati on.
REMOVAL - 4. 7L
(2) Remove ai r box housi ng from throttl e body.
The accel erator cabl e must be parti al l y removed to
gai n access to speed control cabl e.
(3) Usi ng fi nger pressure onl y, di sconnect accel era-
tor cabl e connector at throttl e body bel l crank pi n by
pushi ng connector off bel l crank pi n towards front of
vehi cl e (Fi g. 2). DO NOT try to pull connector off
perpendicular to the bellcrank pin. Connector
will be broken.
Fig. 1 Speed Control Cable at Bell Crank4.0L
Engine
1 - ACCELERATOR CABLE
2 - OFF
3 - OFF
4 - THROTTLE BODY BELLCRANK
5 - SPEED CONTROL CABLE
6 - RELEASE TABS
7 - BRACKET
SPEED CONTROL (Continued)
(4) Li ft accel erator cabl e from top of cabl e cam
(Fi g. 2).
(5) Press tab (Fi g. 3) to rel ease pl asti c cabl e mount
from bracket. Press on tab only enough to
release cable from bracket. If tab is pressed too
much, it will be broken. Sl i de pl asti c mount (Fi g.
3) towards passenger si de of vehi cl e to remove cabl e
from bracket.
(6) Usi ng fi nger pressure onl y, di sconnect speed
control cabl e connector at throttl e body bel l crank pi n
by pushi ng connector off bel l crank pi n towards front
of vehi cl e (Fi g. 2). DO NOT try to pull connector
off perpendicular to the bellcrank pin. Connec-
tor will be broken.
(7) Sl i de speed control cabl e pl asti c mount towards
passenger si de of vehi cl e to remove cabl e from
bracket (Fi g. 4).
(8) Remove servo cabl e from servo. Refer to Speed
Control Servo Removal /I nstal l ati on.
INSTALLATION
(1) I nstal l end of cabl e to speed control servo.
Refer to Speed Control Servo Removal /I nstal l ati on.
(2) I nstal l cabl e i nto mounti ng bracket (snaps i n).
(3) I nstal l speed control cabl e connector at throttl e
body bel l crank pi n (snaps on).
(4) Connect negati ve battery cabl e at battery.
(5) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
(1) I nstal l end of cabl e to speed control servo.
Refer to Speed Control Servo Removal /I nstal l ati on.
(2) Sl i de speed control cabl e pl asti c mount i nto
bracket.
(3) I nstal l speed control cabl e connector onto throt-
tl e body bel l crank pi n (snaps on).
(4) Sl i de accel erator cabl e pl asti c mount i nto
bracket. Conti nue sl i di ng unti l tab (Fi g. 3) i s al i gned
to hol e i n mounti ng bracket.
(5) Route accel erator cabl e over top of cabl e cam
(Fi g. 2).
(6) I nstal l accel erator cabl e connector onto throttl e
body bel l crank pi n (snaps on).
(7) I nstal l ai r box housi ng to throttl e body.
Fig. 2 Cable Connectors at Bell Crank4.7L V-8
Engine
1 - THROTTLE BODY
2 - SPEED CONTROL CABLE CONNECTOR
3 - OFF
4 - OFF
5 - ACCELERATOR CABLE CONNECTOR
6 - CABLE CAM
7 - BELLCRANK
Fig. 3 Accelerator Cable Release Tab4.7L V-8
Engine
2 - PLASTIC CABLE MOUNT
3 - PRESS TAB FOR REMOVAL
4 - CABLE BRACKET
5 - SLIDE FOR REMOVAL
CABLE (Continued)
(8) Connect negati ve battery cabl e at battery.
SERVO
DESCRIPTION
The servo uni t consi sts of a sol enoi d val ve body,
and a vacuum chamber. The sol enoi d val ve body con-
tai ns three sol enoi ds:
Vacuum
Vent
Dump
The vacuum chamber contai ns a di aphragm wi th a
cabl e attached to control the throttl e l i nkage.
OPERATION
The Powertrai n Control Modul e (PCM) control s the
sol enoi d val ve body. The sol enoi d val ve body control s
the appl i cati on and rel ease of vacuum to the di a-
phragm of the vacuum servo. The servo uni t cannot
be repai red and i s servi ced onl y as a compl ete assem-
bl y.
Power i s suppl i ed to the servos by the PCM
through the brake swi tch. The PCM control s the
ground path for the vacuum and vent sol enoi ds.
The dump sol enoi d i s energi zed anyti me i t recei ves
power. I f power to the dump sol enoi d i s i nterrupted,
the sol enoi d dumps vacuum i n the servo. Thi s pro-
vi des a safety backup to the vent and vacuum sol e-
noi ds.
The vacuum and vent sol enoi ds must be grounded
at the PCM to operate. When the PCM grounds the
vacuum servo sol enoi d, the sol enoi d al l ows vacuum
to enter the servo and pul l open the throttl e pl ate
usi ng the cabl e. When the PCM breaks the ground,
the sol enoi d cl oses and no more vacuum i s al l owed to
enter the servo. The PCM al so operates the vent sol e-
noi d vi a ground. The vent sol enoi d opens and cl oses a
passage to bl eed or hol d vacuum i n the servo as
requi red.
The PCM duty cycl es the vacuum and vent sol e-
noi ds to mai ntai n the set speed, or to accel erate and
decel erate the vehi cl e. To i ncrease throttl e openi ng,
the PCM grounds the vacuum and vent sol enoi ds. To
decrease throttl e openi ng, the PCM removes the
grounds from the vacuum and vent sol enoi ds. When
the brake i s rel eased, i f vehi cl e speed exceeds 30
mph to resume, 35 mph to set, and the RES/ACCEL
swi tch has been depressed, ground for the vent and
vacuum ci rcui ts i s restored.
REMOVAL
The speed control servo i s attached to a bracket.
The bracket and servo assembl y are l ocated bel ow
the battery tray.
(2) Di sconnect posi ti ve battery cabl e at battery.
(3) Remove ai r cl eaner housi ng at top of throttl e
body and di sconnect servo cabl e at throttl e body.
Refer to Servo Cabl e Removal /I nstal l ati on.
(4) Remove battery from battery tray.
(5) Di sconnect wi ri ng at battery tray.
(6) Di sconnect posi ti ve battery cabl e at Power Di s-
(7) Loosen PDC at battery tray.
(8) Remove 4 battery tray bol ts. One of these bol ts
attaches to speed control bracket fl ange that sup-
ports battery tray. Whi l e removi ng battery tray, di s-
connect battery temperature sensor el ectri cal
connector at sensor.
(9) Di sconnect vacuum l i ne at servo vacuum hose
fi tti ng (Fi g. 5) .
(10) Di sconnect el ectri cal connector at servo (Fi g.
5) .
I f servo and mounti ng bracket are bei ng removed
as one assembl y, remove two mounti ng nuts (Fi g. 5) .
These are l ocated above ri ght-front ti re. Remove
i nner fender cl i ps and pry i nner fender back sl i ghtl y
to gai n access to mounti ng nuts.
Fig. 4 Speed Control Cable at Bracket4.7L V-8
Engine
3 - BRACKET
CABLE (Continued)
(11) I f servo i s bei ng removed from i ts mounti ng
bracket, remove 2 mounti ng nuts hol di ng servo cabl e
sl eeve to bracket (Fi g. 6) .
(12) Pul l speed control cabl e sl eeve and servo away
from servo mounti ng bracket to expose cabl e retai n-
i ng cl i p (Fi g. 6) and remove cl i p. Note: The servo
mounti ng bracket di spl ayed i n (Fi g. 6) i s a typi cal
bracket and may/may not be appl i cabl e to thi s model
vehi cl e.
(13) Remove servo from mounti ng bracket or,
remove servo and mounti ng bracket as one assembl y.
INSTALLATION
(1) Posi ti on servo to mounti ng bracket.
(2) Al i gn hol e i n cabl e connector wi th hol e i n servo
pi n. I nstal l cabl e-to-servo retai ni ng cl i p.
(3) I nsert servo mounti ng studs through hol es i n
servo mounti ng bracket.
(4) I nstal l servo cabl e mounti ng nuts (Fi g. 6) and
ti ghten to 8.5 Nm (75 i n. l bs.) torque. I f servo and
bracket i s bei ng i nstal l ed as one assembl y, i nstal l 2
mounti ng nuts (Fi g. 5) and ti ghten to 28 Nm 6 Nm
(250 i n. l bs. 50 i n. l bs.) torque.
(5) Connect vacuum l i ne at servo.
(6) Connect el ectri cal connector at servo.
(7) Connect servo cabl e to throttl e body. Refer to
Servo Cabl e Removal /I nstal l ati on.
(8) I nstal l battery tray and battery temperature
sensor.
(9) Connect wi ri ng to battery tray.
(10) I nstal l battery to battery tray.
(11) Connect posi ti ve battery cabl e to Power Di stri -
buti on Center (PDC).
(12) Connect posi ti ve battery cabl e to battery.
Fig. 5 Speed Control
1 - VACUUM HOSE FITTING
2 - SPEED CONTROL SERVO
3 - SERVO CABLE
4 - RIGHT INNER FENDER
5 - SERVO MOUNTING NUTS (2)
6 - SERVO MOUNTING BRACKET
7 - ELEC. CONNECTOR
Fig. 6 Servo Cable Clip Remove/InstallTypical
1 - SERVO MOUNTING NUTS (2)
2 - SERVO
3 - CABLE RETAINING CLIP
4 - SERVO CABLE AND SLEEVE
SERVO (Continued)
SWITCH
DESCRIPTION
There are two separate swi tch pods that operate
the speed control system. The steeri ng-wheel -
mounted swi tches use mul ti pl exed ci rcui ts to provi de
i nputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owners manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures.
The i ndi vi dual swi tches cannot be repai red. I f one
swi tch fai l s, the enti re swi tch modul e must be
repl aced.
OPERATION
When speed control i s sel ected by depressi ng the
ON, OFF swi tch, the PCM al l ows a set speed to be
stored i n i ts RAM for speed control . To store a set
speed, depress the SET swi tch whi l e the vehi cl e i s
movi ng at a speed between approxi matel y 35 and 85
mph. I n order for the speed control to engage, the
brakes cannot be appl i ed, nor can the gear sel ector
be i ndi cati ng the transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
The speed control can be di sengaged al so by any of
the fol l owi ng condi ti ons:
An i ndi cati on of Park or Neutral
The VSS si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the co-effi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
Depressi ng the cl utch pedal .
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
The VSS si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
I f the actual speed i s not wi thi n 20 mph of the
set speed
The previ ous di sengagement condi ti ons are pro-
grammed for added safety.
Once the speed control has been di sengaged,
depressi ng the ACCEL swi tch restores the vehi cl e to
the target speed that was stored i n the PCMs RAM.
NOTE: Depressing the OFF switch will erase the set
speed stored in the PCMs RAM.
I f, whi l e the speed control i s engaged, the dri ver
wi shes to i ncrease vehi cl e speed, the PCM i s pro-
grammed for an accel erati on feature. Wi th the
ACCEL swi tch hel d cl osed, the vehi cl e accel erates
sl owl y to the desi red speed. The new target speed i s
stored i n the PCMs RAM when the ACCEL swi tch i s
rel eased. The PCM al so has a tap-up feature i n
whi ch vehi cl e speed i ncreases at a rate of approxi -
matel y 2 mph for each momentary swi tch acti vati on
of the ACCEL swi tch.
The PCM al so provi des a means to decel erate wi th-
out di sengagi ng speed control . To decel erate from an
exi sti ng recorded target speed, depress and hol d the
COAST swi tch unti l the desi red speed i s reached.
Then rel ease the swi tch. The ON, OFF swi tch oper-
ates two components: the PCMs ON, OFF i nput, and
the battery vol tage to the brake swi tch, whi ch powers
the speed control servo.
Multiplexing
The PCM sends out 5 vol ts through a fi xed resi stor
and moni tors the vol tage change between the fi xed
resi stor and the swi tches. I f none of the swi tches are
depressed, the PCM wi l l measure 5 vol ts at the sen-
sor poi nt (open ci rcui t). I f a swi tch wi th no resi stor i s
cl osed, the PCM wi l l measure 0 vol ts (grounded ci r-
cui t). Now, i f a resi stor i s added to a swi tch, then the
PCM wi l l measure some vol tage proporti onal to the
si ze of the resi stor. By addi ng a di fferent resi stor to
each swi tch, the PCM wi l l see a di fferent vol tage
dependi ng on whi ch swi tch i s pushed.
Another resi stor has been added to the at rest ci r-
cui t causi ng the PCM to never see 5 vol ts. Thi s was
done for di agnosti c purposes. I f the swi tch ci rcui t
shoul d open (bad connecti on), then the PCM wi l l see
the 5 vol ts and know the ci rcui t i s bad. The PCM wi l l
then set an open ci rcui t faul t.
REMOVAL
WARNING: BEFORE BEGINNING ANY AIRBAG SYS-
TEM COMPONENT REMOVAL OR INSTALLATION,
REMOVE AND ISOLATE THE NEGATIVE (-) CABLE
FROM THE BATTERY. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. THEN
WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO
DISCHARGE BEFORE FURTHER SYSTEM SERVICE.
FAILURE TO DO THIS COULD RESULT IN ACCIDEN-
TAL AIRBAG DEPLOYMENT AND POSSIBLE
INJURY.
(1) Di sconnect and i sol ate negati ve battery cabl e.
(2) Remove ai rbag modul e. Refer to Group 8M,
Passi ve Restrai nt Systems.
(3) Remove el ectri cal connector at swi tch.
(4) Remove swi tch-to-steeri ng wheel mounti ng
screw (Fi g. 7) .
(5) Remove swi tch.
INSTALLATION
(1) I nstal l swi tch and mounti ng screw.
(2) Ti ghten screw to 1.5 Nm (15 i n. l bs.) torque.
(3) I nstal l el ectri cal connector to swi tch.
(4) I nstal l ai rbag modul e. Refer to Group 8M, Pas-
si ve Restrai nt Systems.
(5) Connect negati ve battery cabl e.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s a pl asti c storage tank con-
nected to an engi ne vacuum source by vacuum l i nes.
OPERATION
The vacuum reservoi r i s used to suppl y the vac-
uum needed to mai ntai n proper speed control opera-
ti on when engi ne vacuum drops, such as i n cl i mbi ng
a grade whi l e dri vi ng. A one-way check val ve i s used
i n the vacuum l i ne between the reservoi r and the
vacuum source. Thi s check val ve i s used to trap
engi ne vacuum i n the reservoi r. On certai n vehi cl e
appl i cati ons, thi s reservoi r i s shared wi th the heat-
i ng/ai r-condi ti oni ng system. The vacuum reservoi r
cannot be repai red and must be repl aced i f faul ty.
RESERVOIR
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at vacuum reservoi r. To l ocate and gai n
access to reservoi r, refer to Vacuum Reservoi r Remov-
al /I nstal l ati on i n thi s group. Di sconnect vacuum l i ne
at reservoi r and connect a hand-operated vacuum
pump to reservoi r fi tti ng. Appl y vacuum. Reservoi r
vacuum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace reservoi r.
(5) Veri fy operati on of one-way check val ve and
check i t for l eaks.
(a) Locate one-way check val ve. The val ve i s
l ocated i n vacuum l i ne between vacuum reservoi r
and engi ne vacuum source. Di sconnect vacuum
hoses (l i nes) at each end of val ve.
(b) Connect a hand-operated vacuum pump to
reservoi r end of check val ve. Appl y vacuum. Vac-
uum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace one-way check val ve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check val ve. Appl y vacuum.
Vacuum shoul d fl ow through val ve. I f vacuum i s
not fl owi ng, repl ace one-way check val ve. Seal the
fi tti ng at opposi te end of val ve wi th a fi nger and
appl y vacuum. I f vacuum wi l l not hol d, di aphragm
wi thi n check val ve has ruptured. Repl ace val ve.
REMOVAL
The vacuum reservoi r i s l ocated i n the ri ght/front
corner of the vehi cl e behi nd the front bumper fasci a
(Fi g. 8).
(1) Remove front bumper and gri l l assembl y.
(2) Remove 1 support bol t near front of reservoi r
(Fi g. 8).
(3) Remove 2 reservoi r mounti ng bol ts.
(4) Remove reservoi r from vehi cl e to gai n access to
vacuum hose (Fi g. 9). Di sconnect vacuum hose from
reservoi r fi tti ng at rear of reservoi r.
Fig. 7 Speed Control Switches
1 - MOUNTING SCREW
2 - SPEED CONTROL SWITCHES
SWITCH (Continued)
INSTALLATION
The vacuum reservoi r i s l ocated i n the ri ght/front
corner of the vehi cl e behi nd the front bumper fasci a
(Fi g. 8).
(1) Connect vacuum hose to reservoi r.
(2) I nstal l reservoi r and ti ghten 2 bol ts to 3 Nm
(3) I nstal l front bumper and gri l l assembl y.
Fig. 8 Vacuum Reservoir Location
3 - BOLT
Fig. 9 Vacuum Reservoir Removal/Installation
1 - VACUUM HOSE
2 - RADIATOR
VACUUM RESERVOIR (Continued)
VEHICLE THEFT SECURITY
TABLE OF CONTENTS
page page
DESCRIPTION
DESCRIPTION - VEHICLE THEFT
SECURITY SYSTEM . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - SENTRY KEY
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . 2
OPERATION
OPERATION - VEHICLE THEFT SECURITY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION - SENTRY KEY IMMOBILIZER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - VEHICLE
THEFT SECURITY SYSTEM . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . 5
STANDARD PROCEDURE
STANDARD PROCEDURE - SKIS
INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING. . . . . . . . . . 6
DOOR CYLINDER LOCK SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - DOOR
CYLINDER LOCK SWITCH . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HOOD AJAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - HOOD AJAR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL
REMOVAL - HOOD AJAR SWITCH . . . . . . . . 10
REMOVAL - HOOD AJAR SWITCH
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL - HOOD AJAR SWITCH STRIKER . 10
INSTALLATION
INSTALLATION - HOOD AJAR SWITCH . . . . . 10
INSTALLATION - HOOD AJAR SWITCH
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STRIKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INTRUSION TRANSCEIVER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SIREN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
SKIS INDICATOR LAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRANSPONDER KEY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
VTSS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - VTSS
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION
DESCRIPTION - VEHICLE THEFT SECURITY
SYSTEM
The Vehi cl e Theft Securi ty System (VTSS) i s
desi gned to provi de peri meter protecti on agai nst
unauthori zed vehi cl e use or tamperi ng by moni tori ng
the vehi cl e doors, the l i ftgate, the l i ftgate fl i p-up
gl ass, the i gni ti on system and, onl y on vehi cl es bui l t
for sal e i n certai n i nternati onal markets where i t i s
requi red equi pment, the hood. I f unauthori zed vehi -
cl e use or tamperi ng i s detected, the system responds
by pul si ng the horn and fl ashi ng the exteri or l amps.
I n many markets the VTSS al so i ncl udes the Sentry
Key I mmobi l i zer System (SKI S), whi ch provi des pas-
si ve vehi cl e protecti on by preventi ng the engi ne from
operati ng unl ess a val i d el ectroni cal l y encoded key i s
detected i n the i gni ti on l ock cyl i nder. (Refer to 8 -
DESCRI PTI ON - SENTRY KEY I MMOBI LI ZER
SYSTEM).
The VTSS i ncl udes the fol l owi ng major compo-
nents, whi ch are descri bed i n further detai l el se-
where i n thi s servi ce manual :
Body Control Modul e (Refer to 8 - ELECTRI -
CAL/ELECTRONI C CONTROL MODULES/BODY
WJ VEHICLE THEFT SECURITY 8Q - 1
CONTROL/CENTRAL TI MER MODULE -
DESCRI PTI ON).
Combi nati on Fl asher (Refer to 8 - ELECTRI -
CAL/LAMPS/LI GHTI NG - EXTERI OR/COMBI NA-
TI ON FLASHER - DESCRI PTI ON).
Door Ajar Swi tch (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - I NTERI OR/DOOR AJAR
SWI TCH - DESCRI PTI ON - DOOR AJAR SWI TCH).
Dri ver Cyl i nder Lock Swi tch (Refer to 8 - ELEC-
TRI CAL/POWER LOCKS/DOOR CYLI NDER LOCK/
UNLOCK SWI TCH - DESCRI PTI ON).
Hood Ajar Swi tch(Refer to 8 - ELECTRI CAL/VE-
HI CLE THEFT SECURI TY/HOOD AJAR SWI TCH -
DESCRI PTI ON).
Horn Rel ay (Refer to 8 - ELECTRI CAL/HORN/
HORN RELAY - DESCRI PTI ON).
Li ftgate Ajar Swi tch (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - I NTERI OR/DOOR AJAR
SWI TCH - DESCRI PTI ON - LI FTGATE AJAR
SWI TCH).
Li ftgate Fl i p-Up Gl ass Ajar Swi tch(Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - I NTERI OR/
DOOR AJAR SWI TCH - DESCRI PTI ON - LI FTGATE
FLI P-UP GLASS AJAR SWI TCH).
Low Beam Headl amp Rel ay
VTSS I ndi cator (Refer to 8 - ELECTRI CAL/VE-
HI CLE THEFT SECURI TY/VTSS I NDI CATOR -
DESCRI PTI ON).
Certai n functi ons and features of the VTSS rel y
upon resources shared wi th or control l ed by other
other modul es that may affect VTSS operati on are:
Dri ver Door Modul e (Refer to 8 - ELECTRI CAL/
ELECTRONI C CONTROL MODULES/DOOR MOD-
Passenger Door Modul e (Refer to 8 - ELECTRI -
CAL/ELECTRONI C CONTROL MODULES/DOOR
MODULE - DESCRI PTI ON).
DESCRIPTION - SENTRY KEY IMMOBILIZER
SYSTEM
Vehi cl es equi pped wi th the Sentry Key I mmobi l i zer
System (SKI S) can be i denti fi ed by the presence of
an amber SKI S i ndi cator i n the i nstrument cl uster
that wi l l i l l umi nate for about three seconds each
ti me the i gni ti on swi tch i s turned to the On posi ti on,
or by a gray mol ded rubber cap on the head of the
i gni ti on key. Model s not equi pped wi th SKI S sti l l
have a SKI S i ndi cator i n the cl uster, but i t wi l l not
i l l umi nate. Al so, model s not equi pped wi th the SKI S
have a bl ack mol ded rubber cap on the head of the
i gni ti on key.
The SKI S i ncl udes the fol l owi ng major components,
whi ch are descri bed i n further detai l el sewhere i n
thi s servi ce manual :
Powertrai n Control Modul e
Sentry Key I mmobi l i zer Modul e
Sentry Key Transponder
SKI S I ndi cator
Except for the Sentry Key transponders, whi ch rel y
upon Radi o Frequency (RF) communi cati on, hard
wi red ci rcui try connects the SKI S components to the
el ectri cal system of the vehi cl e.Refer to the appropri -
ate wi ri ng i nformati on.
OPERATION
OPERATION - VEHICLE THEFT SECURITY
SYSTEM
The Vehi cl e Theft Securi ty System (VTSS) i s
di vi ded i nto two basi c subsystems: Vehi cl e Theft
Al arm (VTA) and Sentry Key I mmobi l i zer System
(SKI S). The fol l owi ng are paragraphs that bri efl y
descri be the operati on of each of those two sub-
systems.
A Body Control Modul e (BCM) i s used to control
and i ntegrate many of the functi ons and features
i ncl uded i n the Vehi cl e Theft Securi ty System
(VTSS). I n the VTSS, the BCM recei ves i nputs i ndi -
cati ng the status of the door ajar swi tches, the dri ver
cyl i nder l ock swi tch, the i gni ti on swi tch, the l i ftgate
ajar swi tches, the l i ftgate fl i p-up gl ass ajar swi tch,
the power l ock swi tches and, i n vehi cl es so equi pped,
the hood ajar swi tch. The programmi ng i n the BCM
al l ows i t to process the i nformati on from al l of these
i nputs and send control outputs to energi ze or de-en-
ergi ze the combi nati on fl asher, the horn rel ay (except
vehi cl es wi th the premi um versi on of the VTA), and
the VTSS i ndi cator. I n addi ti on, i n vehi cl es bui l t for
certai n markets where premi um versi ons of the VTA
i s requi red, the BCM al so exchanges messages wi th
the I ntrusi on Transcei ver Modul e (I TM) over the Pro-
buss network to provi de the features found i n thi s
versi on of the VTA. The control of these i nputs and
outputs are what consti tute al l of the features of the
VTSS. Fol l owi ng i s i nformati on on the operati on of
each of the VTSS features.
ENABLING
The BCM must have the VTSS functi on enabl ed i n
order for the VTSS to perform as desi gned. The l ogi c
i n the BCM keeps i ts VTSS functi on dormant unti l i t
i s enabl ed usi ng a DRBI I I scan tool . Refer to the
PRE-ARMING
The VTA has a pre-armi ng sequence. Pre-armi ng
occurs when a door, the tai l gate, or the fl i p-up gl ass
i s open when the vehi cl e i s l ocked usi ng a power l ock
8Q - 2 VEHICLE THEFT SECURITY WJ
VEHICLE THEFT SECURITY (Continued)
swi tch, or when the Lock button on the Remote
Keyl ess Entry (RKE) transmi tter i s depressed. The
powerl ock swi tch wi l l not i ni ti ate the pre-armi ng
sequence i f the key i s i n the i gni ti on swi tch. When
the VTA i s pre-armed, the armi ng sequence i s
del ayed unti l al l of the doors, the tai l gate and the
fl i p-up gl ass are cl osed.
ARMING
Passi ve armi ng of the VTSS occurs when the vehi -
cl e i s exi ted wi th the key removed from the i gni ti on
swi tch, the headl amps are turned off, and the doors
are l ocked whi l e they are open usi ng the power l ock
swi tch. The power l ock swi tch wi l l not functi on i f the
key i s i n the i gni ti on swi tch or the headl amps are
turned on wi th the dri ver si de front door open. The
VTSS wi l l not arm i f the dri ver si de front door i s
l ocked usi ng the key i n the l ock cyl i nder or usi ng the
mechani cal l ock button. Acti ve armi ng of the VTSS
occurs when the Lock button on the Remote Key-
l ess Entry (RKE) transmi tter i s depressed to l ock the
vehi cl e, even i f the doors and/or the l i ftgate are open
when the RKE transmi tter Lock button i s depressed.
However, the VTSS armi ng wi l l not be compl ete unti l
al l of the doors, the l i ftgate and the l i ftgate fl i p-up
gl ass are cl osed. On vehi cl es equi pped wi th the hood
ajar swi tch, VTSS armi ng wi l l compl ete i f the hood i s
open, but the underhood area wi l l not be protected
unl ess the hood i s cl osed when the VTSS i s armed.
Fol l owi ng successful passi ve or acti ve VTSS arm-
i ng, the VTSS i ndi cator on the top of the i nstrument
panel wi l l fl ash rapi dl y for about si xteen seconds
after the i l l umi nated entry system ti mes out. Thi s
i ndi cates that VTSS armi ng i s i n progress. Once the
si xteen second armi ng functi on i s successful l y com-
pl eted, the i ndi cator wi l l fl ash at a sl ower rate, i ndi -
cati ng that the VTSS i s armed.
DISARMING
Passi ve di sarmi ng of the VTSS occurs when the
vehi cl e i s unl ocked usi ng the key to unl ock the dri ver
si de front door. Acti ve di sarmi ng of the VTSS occurs
when the vehi cl e i s unl ocked by depressi ng the
Unl ock button of the Remote Keyl ess Entry (RKE)
transmi tter. Once the al arm has been acti vated,
ei ther di sarmi ng method wi l l al so deacti vate the
al arm. Depressi ng the Pani c button on the RKE
transmi tter wi l l al so di sarm the VTSS, but the horn
wi l l conti nue to pul se and the exteri or l amps wi l l
conti nue to fl ash for about three mi nutes as part of
the Pani c feature functi on. The Pani c feature i s over-
ri dden i f the Pani c button i s depressed a second
ti me, or i f a vehi cl e speed of about 24 ki l ometers-per-
hour (15 mi l es-per-hour) i s attai ned.
POWER-UP MODE
When the armed VTSS senses that the battery has
been di sconnected and reconnected, i t enters i ts pow-
er-up mode. I n the power-up mode the al arm system
remai ns armed fol l owi ng a battery fai l ure or di scon-
nect. I f the VTSS was armed pri or to a battery di s-
connect or fai l ure, the techni ci an or vehi cl e operator
wi l l have to acti vel y or passi vel y di sarm the al arm
system after the battery i s reconnected. The pow-
er-up mode wi l l al so appl y i f the battery goes dead
whi l e the system i s armed, and battery jump-starti ng
i s then attempted. The VTSS wi l l be armed unti l i t i s
acti vel y or passi vel y di sarmed. I f the VTSS i s i n the
di sarmed mode pri or to a battery di sconnect or fai l -
ure, i t wi l l remai n di sarmed after the battery i s
reconnected or repl aced, or i f jump-starti ng i s
attempted.
ALARM
The VTA al arm output vari es by the versi on of the
VTA wi th whi ch the vehi cl e i s equi pped. I n al l cases,
the al arm provi des both vi sual and audi bl e outputs;
however, the ti me i nterval s of these outputs vary by
the requi rements of the market for whi ch the vehi cl e
i s manufactured. I n al l cases, the vi sual output wi l l
be a fl ashi ng of the exteri or l amps. For vehi cl es
equi pped wi th North Ameri can or the base versi on of
the VTA, the audi bl e output wi l l be the pul si ng of the
horn. For vehi cl es wi th the premi um versi on of the
VTA, the audi bl e output wi l l be the cycl i ng of the
si ren. The i nputs that wi l l tri gger the al arm i ncl ude
the door ajar swi tch, the fl i p-up gl ass ajar swi tch,
and i n vehi cl es bui l t for certai n markets where they
are requi red, the hood ajar swi tch and the I ntrusi on
Transcei ver Modul e (I TM).
TAMPER ALERT
The VTSS tamper al ert feature wi l l sound the horn
(or the al arm si ren for the premi um versi on) three
ti mes upon VTA di sarmi ng, i f the al arm was tri g-
gered and has si nce ti med-out (about ei ghteen mi n-
utes). Thi s feature al erts the vehi cl e operator that
the VTA al arm was acti vated whi l e the vehi cl e was
unattended.
INTRUSION ALARM
The I ntrusi on Al arm i s an excl usi ve feature of the
premi um versi on of the VTA, whi ch i s onl y avai l abl e
i n certai n markets, where i t i s requi red. When the
VTA i s armed, a moti on sensor i n the I ntrusi on
Transcei ver Modul e (I TM) moni tors the i nteri or of
the vehi cl e for movement. I f moti on i s detected, the
I TM sends a message to the BCM over the PCI bus
to i nvoke the vi sual al arm feature, and sends a mes-
sage to the al arm si ren over a dedi cated seri al bus to
i nvoke the audi bl e al arm feature. The moti on detec-
ti on feature of the I TM can be di sabl ed by depressi ng
the Lock button on the RKE transmi tter three
ti mes or cycl i ng the key i n the dri ver door cyl i nder
from the center to l ock posi ti on wi thi n fi fteen seconds
duri ng VTA armi ng, whi l e the securi ty i ndi cator i s
sti l l fl ashi ng rapi dl y. The VTA provi des a si ngl e short
si ren chi rp as an audi bl e conformati on that the
moti on detect di sabl e request has been recei ved. The
I TM must be el ectroni cal l y enabl ed i n order for the
i ntrusi on al arm to perform as desi gned. The i ntru-
si on al arm functi on of the I TM i s enabl ed on vehi cl es
equi pped wi th thi s opti on at the factory, but a servi ce
repl acement I TM must be confi gured and enabl ed by
the deal er usi ng the DRBI I I scan tool . Refer to the
OPERATION - SENTRY KEY IMMOBILIZER
SYSTEM
The Sentry Key I mmobi l i zer System (SKI S) i s
desi gned to provi de passi ve protecti on agai nst unau-
thori zed vehi cl e use by di sabl i ng the engi ne after
about two seconds of runni ng, whenever any method
other than a val i d Sentry Key i s used to start the
vehi cl e. The SKI S i s consi dered a passi ve protecti on
system because i t i s al ways acti ve when the i gni ti on
system i s energi zed and does not requi re any cus-
tomer i nterventi on. The SKI S uses Radi o Frequency
(RF) communi cati on to obtai n confi rmati on that the
key i n the i gni ti on swi tch i s a val i d key for operati ng
the vehi cl e. The mi croprocessor-based SKI S hard-
ware and software al so uses messages to communi -
cate wi th other modul es i n the vehi cl e over the
bus. (Refer to 8 - ELECTRI CAL/ELECTRONI C CON-
TROL MODULES/COMMUNI CATI ON - OPERA-
TI ON).
Pre-programmed Sentry Key transponders are pro-
vi ded wi th the vehi cl e from the factory. Each Sentry
Key I mmobi l i zer Modul e (SKI M) wi l l recogni ze a
maxi mum of ei ght Sentry Keys. I f the customer
woul d l i ke addi ti onal keys other than those provi ded
wi th the vehi cl e, they may be purchased from any
authori zed deal er. These addi ti onal keys must be pro-
grammed to the SKI M i n the vehi cl e i n order for the
system to recogni ze them as val i d keys. Thi s can be
done by the deal er usi ng a DRBI I I scan tool or, i f
Customer Learn programmi ng i s an avai l abl e SKI S
feature i n the market where the vehi cl e was pur-
chased, the customer can program the addi ti onal
keys, as l ong as at l east two val i d Sentry Keys are
al ready avai l abl e. (Refer to 8 - ELECTRI CAL/VEHI -
CLE THEFT SECURI TY - STANDARD PROCE-
DURE - TRANSPONDER PROGRAMMI NG).
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store faul t i nformati on i n the form of Di agnosti c
Troubl e Codes (DTCs) i f a system mal functi on i s
detected. Refer to the appropri ate di agnosti c i nforma-
ti on.
DIAGNOSIS AND TESTING - VEHICLE THEFT
SECURITY SYSTEM
The VTSS-rel ated hard wi red i nputs to and out-
puts from the Body Control Modul e (BCM), the
Dri ver Door Modul e (DDM), or the Passenger Door
Modul e (PDM) may be di agnosed and tested usi ng
conventi onal di agnosti c tool s and procedures. Refer
to the appropri ate wi ri ng i nformati on.
However, conventi onal di agnosti c methods may not
prove concl usi ve i n the di agnosi s of the BCM, the
DDM, the PDM, or the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus network. I n order to
obtai n concl usi ve testi ng of the VTSS, the BCM, the
DDM, the PDM, and the PCI data bus network must
al so be checked. The most rel i abl e, effi ci ent, and
accurate means to di agnose the VTSS requi res the
use of a DRBI I I scan tool and the appropri ate di ag-
INJURY.
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM
INJURY.
SENTRY KEY IMMOBILIZER SYSTEM DIAGNOSIS
SKIS INDICATOR FAILS TO
LIGHT DURING BULB TEST
1. Bulb faulty. 1. Perform the instrument cluster actuator test.
(Refer to 8 - ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND TESTING -
ACTUATOR TEST). Replace the faulty bulb, if
required.
2. Fuse faulty. 2. Check the SKIM fused B(+) fuse and the fused
ignition switch output (st-run) fuse in the JB.
Replace fuses, if required.
3. Ground path faulty. 3. Check for continuity to ground at the connector
for the SKIM. Repair wiring, if required.
4. Battery feed faulty. 4. Check for battery current at the connector for
the SKIM. Repair wiring, if required.
5. Ignition feed faulty. 5. Check for battery current at the connector for
the SKIM with the ignition switch in the On
position. Repair wiring, if required.
SKIS INDICATOR FLASHES
FOLLOWING BULB TEST
1. Invalid key in ignition
switch lock cylinder.
1. Replace the key with a known valid key.
2. Key-related fault. 2. Use a DRBIII scan tool and the appropriate
diagnostic information for further diagnosis.
SKIS INDICATOR LIGHTS
SOLID FOLLOWING BULB
TEST
1. SKIS system malfunction/
fault detected.
1. Use a DRBIII scan tool and the appropriate
2. SKIS system inoperative. 2. Use a DRBIII scan tool and the appropriate
SKIS INDICATOR FAILS TO LIGHT DURING BULB TEST
I f the Sentry Key I mmobi l i zer System (SKI S) i ndi -
cator i n the i nstrument cl uster fai l s to i l l umi nate for
about three seconds after the i gni ti on swi tch i s
turned to the On posi ti on (bul b test), perform the
i nstrument cl uster actuator test. (Refer to 8 - ELEC-
AND TESTI NG - ACTUATOR TEST). I f the bul b
fai l s to operate duri ng the actuator test, repl ace the
bul b. I f the SKI S i ndi cator sti l l fai l s to l i ght duri ng
the bul b test, a wi ri ng probl em resul ti ng i n the l oss
of battery current or ground to the Sentry Key I mmo-
bi l i zer Modul e (SKI M) shoul d be suspected, and the
fol l owi ng procedure shoul d be used for di agnosi s.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Sentry Key Immobilizer System requires the use of
a DRBIII scan tool. Refer to the appropriate diag-
nostic information.
shorted ci rcui t or component and repl ace the faul ty
fuse.
open B(+) ci rcui t between the JB fuse and the Power
Di stri buti on Center (PDC).
(3) Check the fused i gni ti on swi tch output (st-run)
fuse i n the JB. I f OK, go to Step 4. I f not OK, repai r
the shorted ci rcui t or component and repl ace the
faul ty fuse.
output (st-run) fuse i n the JB. I f OK, go to Step 5. I f
not OK, repai r the open fused i gni ti on swi tch output
(st-run) ci rcui t between the JB fuse and the i gni ti on
swi tch as requi red.
connector for the Sentry Key I mmobi l i zer Modul e
(SKI M) from the SKI M connector. Check for conti nu-
i ty between the ground ci rcui t of the i nstrument
panel wi re harness connector for the SKI M and a
Step 6. I f not OK, repai r the open ground ci rcui t.
SKI M. I f OK, go to Step 7. I f not OK, repai r the open
fused B(+) ci rcui t between the SKI M and the JB
fuse.
output (st-run) ci rcui t of the i nstrument panel wi re
harness connector for the SKI M. I f OK, refer to the
appropri ate di agnosti c i nformati on and use a
DRBI I I scan tool to compl ete the di agnosi s of the
SKI S. I f not OK, repai r the open fused i gni ti on
swi tch output (st-run) ci rcui t between the SKI M and
the JB fuse.
SKIS INDICATOR FLASHES OR LIGHTS SOLID FOLLOWING
BULB TEST
A SKI S i ndi cator that fl ashes fol l owi ng a successful
bul b test i ndi cates that an i nval i d key has been
detected, or that a key-rel ated faul t has been set. A
SKI S i ndi cator that l i ghts sol i d fol l owi ng a successful
bul b test i ndi cates that the SKI M has detected a sys-
tem mal functi on or that the SKI S i s i noperati ve. I n
ei ther case, faul t i nformati on wi l l be stored i n the
SKI M memory. For retri eval of thi s faul t i nformati on
and further di agnosi s of the SKI S, the PCI data bus,
the SKI M message outputs to the i nstrument cl uster,
the SKI M message outputs to the Body Control Mod-
ul e (BCM), or the message i nputs and outputs
between the SKI M and the Powertrai n Control Mod-
ul e (PCM), a DRBI I I scan tool and the appropri ate
di agnosti c i nformati on are requi red. Fol l owi ng are
prel i mi nary troubl eshooti ng gui del i nes to be fol l owed
duri ng di agnosi s usi ng a DRBI I I scan tool :
(1) Usi ng the DRBI I I scan tool , read and record
the faul ts as they exi st i n the SKI M when you fi rst
begi n your di agnosi s of the vehi cl e. I t i s i mportant to
document these faul ts because the SKI M does not
di fferenti ate between hi stori cal and acti ve faul ts. I f
thi s probl em turns out to be an i ntermi ttent condi -
ti on, thi s i nformati on may become i nval uabl e to your
di agnosi s.
(2) Usi ng the DRBI I I scan tool , erase al l of the
faul ts from the SKI M.
(3) Cycl e the i gni ti on swi tch to the Off posi ti on,
then back to the On posi ti on.
(4) Usi ng the DRBI I I scan tool , read any faul ts
that are now present i n the SKI M. These are the
acti ve faul ts.
(5) Usi ng thi s acti ve faul t i nformati on, refer to the
proper procedure i n the appropri ate di agnosti c i nfor-
mati on for the addi ti onal speci fi c di agnosti c steps.
STANDARD PROCEDURE
STANDARD PROCEDURE - SKIS
INITIALIZATION
The Sentry Key I mmobi l i zer System (SKI S) must
be i ni ti al i zed fol l owi ng a Sentry Key I mmobi l i zer
Modul e (SKI M) repl acement. SKI S i ni ti al i zati on
requi res the use of a DRBI I I scan tool . I ni ti al i zati on
wi l l al so requi re that you have access to the uni que
four-di gi t PI N code that was assi gned to the ori gi nal
SKI M. The PI N code must be used to enter the
Secured Access Mode i n the SKI M. Thi s PI N number
may be obtai ned from the vehi cl e owner, from the
ori gi nal vehi cl e i nvoi ce, or from the Dai ml erChrysl er
Customer Center. (Refer to 8 - ELECTRI CAL/ELEC-
TRONI C CONTROL MODULES - STANDARD PRO-
CEDURE - PCM/SKI M PROGRAMMI NG).
NOTE: If a Powertrain Control Module (PCM) is
replaced on a vehicle equipped with the Sentry Key
Immobilizer System (SKIS), the unique Secret Key
data must be transferred from the Sentry Key
Immobilizer Module (SKIM) to the new PCM using
the PCM replacement procedure. This procedure
also requires the use of a DRBIII scan tool and the
unique four-digit PIN code to enter the Secured
Access Mode in the SKIM. Refer to the appropriate
diagnostic information for the proper PCM replace-
ment procedures.
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING
Al l Sentry Keys i ncl uded wi th the vehi cl e are pre-
programmed to work wi th the Sentry Key I mmobi -
l i zer System (SKI S) when i t i s shi pped from the
factory. The Sentry Key I mmobi l i zer Modul e (SKI M)
can be programmed to recogni ze up to a total of ei ght
Sentry Keys. When programmi ng a bl ank Sentry Key
transponder, the key must fi rst be cut to match the
i gni ti on swi tch l ock cyl i nde for whi ch i t wi l l be used.
Once the addi ti onal key has been cut, the SKI M
must be programmed to recogni ze i t as a val i d key.
There are two possi bl e methods to program the
SKI M to recogni ze a new or addi ti onal val i d key, the
Secured Access Method and the Customer Learn
Method. Fol l owi ng are the detai l s of these two pro-
grammi ng methods.
SECURED ACCESS METHOD
The Secured Access method appl i es to al l vehi cl es.
Thi s method requi res the use of a DRBI I I scan tool .
Thi s method wi l l al so requi re that you have access to
the uni que four-di gi t PI N code that was assi gned to
the ori gi nal SKI M. The PI N code must be used to
enter the Secured Access Mode i n the SKI M. Thi s
PI N number may be obtai ned from the vehi cl e owner,
from the ori gi nal vehi cl e i nvoi ce, or from the
Dai ml erChrysl er Customer Center. Refer to the
appropri ate di agnosti c i nformati on for the proper
Secured Access method programmi ng procedures.
CUSTOMER LEARN METHOD
The Customer Learn feature i s onl y avai l abl e on
domesti c vehi cl es, or those vehi cl es whi ch have a
U.S. country code desi gnator. Thi s programmi ng
method al so requi res access to at l east two val i d Sen-
try Keys. I f two val i d Sentry Keys are not avai l abl e,
or i f the vehi cl e does not have a U.S. country code
desi gnator, the Secured Access Method must be used
to program new or addi ti onal val i d keys to the SKI M.
The Customer Learn programmi ng method proce-
dures are as fol l ows:
(1) Obtai n the bl ank Sentry Key(s) that are to be
programmed as val i d keys for the vehi cl e. Cut the
bl ank key(s) to match the i gni ti on swi tch l ock cyl i n-
der mechani cal key codes.
(2) I nsert one of the two val i d Sentry Keys i nto the
i gni ti on swi tch and turn the i gni ti on swi tch to the
On posi ti on.
(3) After the i gni ti on swi tch has been i n the On
posi ti on for l onger than three seconds, but no more
than fi fteen seconds, cycl e the i gni ti on swi tch back to
the Off posi ti on. Repl ace the fi rst val i d Sentry Key i n
the i gni ti on swi tch l ock cyl i nder wi th the second
val i d Sentry Key and turn the i gni ti on swi tch back to
the On posi ti on. The second val i d Sentry Key must
be i nserted i n the l ock cyl i nder wi thi n fi fteen seconds
of removi ng the fi rst val i d key.
(4) About ten seconds after the compl eti on of Step
3, the SKI S i ndi cator i n the i nstrument cl uster wi l l
start to fl ash and a si ngl e audi bl e chi me tone wi l l
sound to i ndi cate that the system has entered the
Customer Learn programmi ng mode.
(5) Wi thi n si xty seconds of enteri ng the Customer
Learn programmi ng mode, turn the i gni ti on swi tch to
the Off posi ti on, repl ace the val i d Sentry Key wi th a
bl ank Sentry Key transponder, and turn the i gni ti on
swi tch back to the On posi ti on.
(6) About ten seconds after the compl eti on of Step
5, a si ngl e audi bl e chi me tone wi l l sound and the
SKI S i ndi cator wi l l stop fl ashi ng, stay on sol i d for
three seconds, then turn off to i ndi cate that the
bl ank Sentry Key has been successful l y programmed.
The SKI S wi l l i mmedi atel y exi t the Customer Learn
programmi ng mode and the vehi cl e may now be
started usi ng the newl y programmed val i d Sentry
Key.
Each of these steps must be repeated and com-
pl eted i n thei r enti rety for each addi ti onal Sentry
Key that i s to be programmed. I f the above steps are
not compl eted i n the gi ven sequence, or wi thi n the
al l otted ti me, the SKI S wi l l exi t the Customer Learn
programmi ng mode and the programmi ng wi l l be
unsuccessful . The SKI S wi l l al so automati cal l y exi t
the Customer Learn programmi ng mode i f i t sees a
non-bl ank Sentry Key transponder when i t shoul d
see a bl ank, i f i t has al ready programmed ei ght (8)
val i d Sentry Keys, or i f the i gni ti on swi tch i s turned
to the Off posi ti on for more than about fi fty seconds.
NOTE: If an attempt is made to start the vehicle
while in the Customer Learn mode (SKIS indicator
flashing), the SKIS will respond as though the vehi-
cle were being started with an invalid key. In other
words, the engine will stall after about two seconds
of operation. No faults will be set.
NOTE: Once a Sentry Key has been programmed as
a valid key to a vehicle, it cannot be programmed
as a valid key for use on any other vehicle.
DOOR CYLINDER LOCK
SWITCH
DESCRIPTION
Vehi cl es manufactured for North Ameri can mar-
kets that are equi pped wi th the opti onal Vehi cl e
Theft Securi ty System (VTSS) have a door cyl i nder
l ock swi tch secured to the back of the key l ock cyl i n-
der i nsi de the dri vers front door (Fi g. 1). The door
cyl i nder l ock swi tch i s a resi stor mul ti pl exed momen-
tary swi tch that i s hard wi red i n seri es between the
door l ock swi tch ground and ri ght or l eft cyl i nder
l ock swi tch mux ci rcui ts of the Dri vers Door Modul e
(DDM) through the front door wi re harness. The door
cyl i nder l ock swi tches are dri ven by the key l ock cyl -
i nders and contai n two i nternal resi stors. One resi s-
tor val ue i s used for the Lock posi ti on, and one for
the Unl ock posi ti on.
The door cyl i nder l ock swi tches cannot be adjusted
or repai red and, i f faul ty or damaged, they must be
repl aced.
OPERATION
The door cyl i nder l ock swi tches are actuated by the
key l ock cyl i nder when the key i s i nserted i n the l ock
cyl i nder and turned to the l ock or unl ock posi ti ons.
The door cyl i nder l ock swi tch cl ose a ci rcui t between
the door l ock swi tch ground ci rcui t and the l eft or
ri ght cyl i nder l ock swi tch mux ci rcui ts through one of
two i nternal resi stors for the Dri ver Door Modul e
(DDM) when ei ther front door key l ock cyl i nder i s i n
the Lock, or Unl ock posi ti ons. The DDM reads the
swi tch status through an i nternal pul l -up, then uses
thi s i nformati on as an i nput for the Vehi cl e Theft
Securi ty System (VTSS) operati on.
The door cyl i nder l ock swi tches and ci rcui ts can be
methods.
DIAGNOSIS AND TESTING - DOOR CYLINDER
LOCK SWITCH
wi re and connector repai r procedures, further detai l s
on wi re harness routi ng and retenti on, as wel l as
pi n-out and l ocati on vi ews for the vari ous wi re har-
ness connectors, spl i ces and grounds.
(1) Di sconnect the door cyl i nder l ock swi tch pi gtai l
wi re connector from the door wi re harness connector.
(2) Usi ng a ohmmeter, check the swi tch resi stance
checks between the two termi nal s i n the door cyl i n-
der l ock swi tch pi gtai l wi re connector. Actuate the
swi tch by rotati ng the key i n the door l ock cyl i nder
to test for the proper resi stance val ues i n each of the
two swi tch posi ti ons, as shown i n the Door Cyl i nder
Lock Swi tch Test tabl e.
DOOR CYLINDER LOCK SWITCH TEST
Switch Position Resistance
(10%)
Left Side Right Side
Lock (Clockwise) Unlock
(Counterclockwise)
473 Ohms
Unlock
(Counterclockwise)
Lock (Clockwise) 1.994
Kilohms
(3) I f a door cyl i nder l ock swi tch fai l s ei ther of the
resi stance tests, repl ace the faul ty swi tch.
REMOVAL
cabl e.
(2) Remove the outsi de door handl e uni t from the
outer door panel . (Refer to 23 - BODY/DOOR -
FRONT/EXTERI OR HANDLE - REMOVAL).
(3) Remove the retai ner cl i p from the pi n on the
back of the door l ock cyl i nder (Fi g. 2).
(4) Remove the l ock l ever from the pi n on the back
of the door l ock cyl i nder.
Fig. 1 DOOR CYLINDER LOCK SWITCH
1 - SWITCH
2 - OUTSIDE DOOR HANDLE
3 - DOOR LOCK CYLINDER
Fig. 2 LOCK CYLINDER LEVER RETAINER RE
1 - LEVER
2 - RETAINER
3 - LOCK CYLINDER
4 - SWITCH
5 - PLIERS
DOOR CYLINDER LOCK SWITCH (Continued)
(5) Remove the door cyl i nder l ock swi tch from the
back of the l ock cyl i nder.
INSTALLATION
(1) Posi ti on the door cyl i nder l ock swi tch onto the
back of the l ock cyl i nder wi th i ts pi gtai l wi re harness
ori ented toward the bottom (Fi g. 2).
(2) Posi ti on the l ock l ever onto the pi n on the back
of the door l ock cyl i nder wi th the l ever ori ented
toward the rear.
(3) I nstal l the retai ner cl i p onto the pi n on the
back of the door l ock cyl i nder. Be certai n that the
center tab of the retai ner i s engaged i n the retenti on
hol e on the l ock l ever.
(4) Rei nstal l the outsi de door handl e uni t onto the
outer door panel . (Refer to 23 - BODY/DOOR -
FRONT/EXTERI OR HANDLE - I NSTALLATI ON).
HOOD AJ AR SWITCH
DESCRIPTION
The hood ajar swi tch i s a sel f-adjusti ng, normal l y
cl osed, si ngl e pol e, doubl e throw momentary swi tch
that i s used onl y on vehi cl es bui l t for sal e i n certai n
i nternati onal markets where i t i s requi red equi pment
(Fi g. 3). The mounti ng bracket i s fastened to the l eft
i nner fender. A mol ded pl asti c stri ker wi th three i nte-
gral retai ners i s secured to the undersi de of the hood
panel i nner rei nforcement to actuate the swi tch
pl unger as the hood panel i s cl osed.The swi tch
recei ves a path to ground through the l eft i nner
fender shi el d i n the engi ne compartment.
The hood ajar swi tch adjusts i tsel f as the stri ker
pushes the swi tch body down through the swi tch
when the hood panel i s cl osed after the i ni ti al i nstal -
l ati on. Thi s sel f-adjustment feature i s onl y functi onal
the fi rst ti me the hood i s cl osed fol l owi ng i nstal l a-
ti on. I f the swi tch requi res adjustment fol l owi ng the
i ni ti al i nstal l ati on, the swi tch must be repl aced.
OPERATION
The normal l y cl osed hood ajar swi tch i s normal l y
hel d open when the hood panel i s cl osed and l atched.
When the hood i s opened, the swi tch pl unger extends
from the swi tch body and the swi tch contacts are
cl osed. The hood ajar swi tch i s connected i n seri es
between ground and the hood ajar swi tch sense i nput
of the Body Control Modul e (BCM). The BCM uses
an i nternal resi stor pul l up to moni tor the state of
the hood ajar swi tch contacts. The hood ajar swi tch
can be di agnosed usi ng conventi onal di agnosti c tool s
and methods.
DIAGNOSIS AND TESTING - HOOD AJAR
SWITCH
hood ajar swi tch. I f the probl em bei ng di agnosed i s
rel ated to hood ajar swi tch accuracy, be certai n to
confi rm that the probl em i s not an i mproperl y
adjusted hood ajar swi tch. I f no hood ajar swi tch
adjustment probl em i s found, the fol l owi ng procedure
wi l l hel p to l ocate a short or open i n the hood ajar
swi tch ci rcui t. Refer to the appropri ate wi ri ng i nfor-
mati on.
INJURY.
cabl e. Di sconnect the hood ajar swi tch. Check for
conti nui ty between the harness ground ci rcui t a good
2. I f not OK, repai r the open ground ci rcui t to
ground.
Fig. 3 Hood Ajar Switch
1 - SWITCH
2 - STUD (2)
3 - BRACKET
4 - FENDER
5 - CONNECTOR
6 - NUT (2)
DOOR CYLINDER LOCK SWITCH (Continued)
(2) Check for conti nui ty between the two termi nal s
of the hood ajar swi tch. There shoul d be conti nui ty
wi th the swi tch pl unger extended, and no conti nui ty
wi th the swi tch pl unger depressed. I f OK, go to Step
3. I f not OK, repl ace the faul ty hood ajar swi tch.
connector from the Body Control Modul e (BCM).
Check for conti nui ty between the hood ajar swi tch
sense ci rcui t of the hood ajar swi tch and a good
Step 4. I f not OK, repai r the shorted hood ajar swi tch
sense ci rcui t between the hood ajar swi tch and the
BCM.
(4) Check for conti nui ty between the hood ajar
swi tch sense ci rcui t and the i nstrument panel wi re
ti nui ty. I f OK, proceed to di agnosi s of the Vehi cl e
Theft Securi ty System (VTSS). (Refer to 8 - ELEC-
TRI CAL/VEHI CLE THEFT SECURI TY - DI AGNO-
SI S AND TESTI NG). I f not OK, repai r the open hood
ajar swi tch sense ci rcui t between the hood ajar
swi tch and the BCM.
REMOVAL
REMOVAL - HOOD AJAR SWITCH
(1) Open the hood.
cabl e.
(3) Squeeze the two swi tch l atch tabs together and
pul l the swi tch upward (Fi g. 3)
(4) Di sconnect the wi ri ng harness connector.
(5) Remove the hood ajar swi tch from the mount-
i ng bracket.
REMOVAL - HOOD AJAR SWITCH BRACKET
(1) Remove the hood ajar swi tch from the mount-
i ng bracket. (Refer to 8 - ELECTRI CAL/VEHI CLE
THEFT SECURI TY/HOOD AJAR SWI TCH -
REMOVAL).
(2) Remove the two nuts that secure the hood ajar
swi tch bracket to the l eft i nner fender (Fi g. 3)
(3) Remove the hood ajar swi tch bracket from the
studs on the l eft i nner fender.
REMOVAL - HOOD AJAR SWITCH STRIKER
(1) Open the hood.
fl at-bl ade tool , gentl y rai se the hood ajar swi tch
stri ker away from the i nner hood panel rei nforce-
ment, and remove. (Fi g. 4).
INSTALLATION
(1) Posi ti on the hood ajar swi tch i nto the hol e i n
the mounti ng bracket (Fi g. 3)
(2) Reconnect the wi ri ng harness connector.
(3) Press the swi tch downward i nto the mounti ng
bracket unti l the l atch tabs l ock i t i nto pl ace.
(5) Cl ose and l atch the hood.
BRACKET
(1) Posi ti on the hood ajar swi tch bracket onto the
studs on the l eft i nner fender (Fi g. 3)
(2) I nstal l and ti ghten the two nuts. Ti ghten the
nuts to 11.8 Nm (105 i n. l bs.).
(3) Rei nstal l the hood ajar swi tch i nto the mount-
i ng bracket. (Refer to 8 - ELECTRI CAL/VEHI CLE
THEFT SECURI TY/HOOD AJAR SWI TCH -
I NSTALLATI ON).
Fig. 4 Hood Ajar Switch Striker
1 - REINFORCEMENT
2 - STRIKER
3 - HOOD
HOOD AJ AR SWITCH (Continued)
STRIKER
(1) Al i gn the three i ntegral retai ners of the hood
ajar swi tch stri ker wi th thei r mounti ng hol es i n the
i nner hood panel rei nforcement (Fi g. 4).
(2) Usi ng hand pressure, fi rml y press the hood
ajar swi tch stri ker agai nst the i nner hood panel rei n-
forcement unti l al l of the stri ker retai ners are ful l y
engaged i n thei r mounti ng hol es.
INTRUSION TRANSCEIVER
MODULE
DESCRIPTION
An I ntrusi on Transcei ver Modul e (I TM) i s part of
the premi um versi on of the Vehi cl e Theft Al arm
(VTA) i n the Vehi cl e Theft Securi ty System (VTSS)
(Fi g. 5). The premi um versi on of the VTA i s onl y
avai l abl e i n vehi cl es bui l t for certai n markets, where
the addi ti onal features offered by thi s system are
requi red. The I TM i s l ocated i n the passenger com-
partment. Thi s uni t i s desi gned to provi de i nteri or
moti on detecti on, and serve as an i nterface between
the Body Control Modul e (BCM) and the al arm si ren
modul e.
The I TM i s conceal ed beneath a dedi cated mol ded
pl asti c tri m cover that approxi mates the si ze and
shape of a typi cal dome l amp housi ng. However,
rather than a l ens, the I TM features three sets of
l ouvered openi ngs. One set of l ouvered openi ngs i s
l ocated at each outboard end of the center ri b, whi l e
the thi rd set i s centered. Each of the l ouvered open-
i ngs i s covered on the i nsi de by a si ght shi el d that
extends the l ength of the center ri b. The modul e i s
secured to a mounti ng bracket above the headl i ner
(Fi g. 6).
Conceal ed wi thi n the housi ng i s the ci rcui try of the
I TM whi ch i ncl udes a mi croprocessor, and an ul tra-
soni c recei ve transducer. Both the transmi t trans-
ducer on the ri ght si de of the modul e and the recei ve
transducer on the I TM ci rcui t board are ai med
through two smal l round hol es i n the si ght shi el d of
the tri m cover. The I TM i s connected to the vehi cl e
el ectri cal system by a take out and connector of the
overhead wi re harness that i s i ntegral to the head-
l i ner.
The I TM uni t cannot be adjusted or repai red and,
i f faul ty or damaged, i t must be repl aced. The I TM i s
servi ced as a uni t wi th the tri m cover.
OPERATION
The mi croprocessor i n the I ntrusi on Transcei ver
Modul e (I TM) contai ns the moti on sensor l ogi c ci r-
cui ts and control s al l of the features of the premi um
versi on of the Vehi cl e Theft Al arm (VTA). The I TM
uses On-Board Di agnosti cs (OBD) and can communi -
cate wi th other modul es i n the vehi cl e as wel l as
wi th the DRBI I I scan tool usi ng the Programmabl e
Thi s method of communi cati on i s used by the I TM to
communi cate wi th the Body Control Modul e (BCM)
and for di agnosi s and testi ng. The I TM al so commu-
ni cates wi th the al arm si ren over a dedi cated seri al
bus ci rcui t.
Fig. 5 INTRUSION TRANSCEIVER MODULE
1 - ITM
2 - HEADLINER
1 - TRIM COVER
3 - HOUSING
4 - SCREW (4)
5 - SERVICE HOLE (2)
6 - LATCH FEATURE (4)
HOOD AJ AR SWITCH (Continued)
The I TM mi croprocessor conti nuousl y moni tors
i nputs from i ts on-board moti on sensor as wel l as
i nputs from the BCM and the al arm si ren modul e.
The I TM moti on sensor transmi ts ul trasoni c si gnal s
i nto the vehi cl e cabi n through a transmi t transducer,
then l i stens to the returni ng si gnal s as the bounce off
of objects i n the vehi cl e i nteri or. I f an object i s mov-
i ng i n the i nteri or, a detecti on ci rcui t i n the I TM
senses thi s movement through the modul ati on of the
returni ng ul trasoni c si gnal s that occurs due to the
Doppl er effect. The moti on detect functi on of the I TM
can be di sabl ed by depressi ng the Lock button on
the Remote Keyl ess Entry (RKE) transmi tter three
ti mes wi thi n fi fteen seconds, whi l e the securi ty i ndi -
cator i s sti l l fl ashi ng rapi dl y or by cycl i ng the key i n
the dri ver door cyl i nder from the center to the l ock
posi ti on. The I TM wi l l si gnal the al arm si ren modul e
to provi de a si ngl e si ren chi rp as an audi bl e confi r-
mati on that the moti on sensor functi on has been di s-
abl ed.
I f movement i s detected, the I TM sends an mes-
sage to the BCM over the PCI data bus to fl ash the
exteri or l i ghti ng and send a message to the al arm
si ren modul e over a dedi cated seri al bus l i ne to
sound the si ren. When the BCM detects a breach i n
the peri meter protecti on through a door, tai l gate,
fl i p-up gl ass, or hood ajar swi tch i nput, i t sends an
message to the I TM and the I TM sends an message
to the BCM over the PCI data bus to fl ash the exte-
ri or l i ghti ng and send a message to the al arm si ren
modul e over a dedi cated seri al bus l i ne to sound the
si ren. The I TM al so moni tors i nputs from the al arm
si ren modul e for si ren battery or si ren i nput/output
ci rcui t tamper al erts, and si ren battery condi ti on
al erts, then sets acti ve and stored Di agnosti c Troubl e
Codes (DTC) for any moni tored system faul ts i t
detects. An acti ve faul t onl y remai ns for the current
i gni ti on swi tch cycl e, whi l e a stored faul t causes a
DTC to be stored i n memory by the I TM. I f a faul t
does not reoccur for fi fty i gni ti on cycl es, the I TM wi l l
automati cal l y erase the stored DTC.
The I TM i s connected to the vehi cl e el ectri cal sys-
tem through the overhead wi re harness. The I TM
recei ves battery vol tage on a B(+) ci rcui t through a
fuse i n the Juncti on Bl ock (JB), and i s grounded to
the chassi s at G303. These connecti ons al l ow the
I TM to remai n operati onal , regardl ess of the i gni ti on
swi tch posi ti on. The hard wi red i nputs and outputs
for the I TM may be di agnosed and tested usi ng con-
venti onal di agnosti c tool s and procedures. However,
conventi onal di agnosti c methods wi l l not prove con-
cl usi ve i n the di agnosi s of the I TM, the PCI data bus
network, or the el ectroni c message i nputs to and out-
puts from the I TM. The most rel i abl e, effi ci ent, and
accurate means to di agnose the I TM, the PCI data
bus network, and the message i nputs to and outputs
from the I TM requi res the use of a DRBI I I scan
REMOVAL
cabl e.
(2) Whi l e pul l i ng downward l i ghtl y on the rear cor-
ner of the I ntrusi on Transcei ver Modul e (I TM) tri m
cover, i nsert a smal l thi n-bl aded screwdri ver through
each of the servi ce hol es on the rear edge of the tri m
cover to rel ease the two i ntegral rear l atch features
of the modul e from the mounti ng bracket above the
headl i ner (Fi g. 7).
(3) Pul l the I TM tri m cover rearward far enough
to di sengage the two front l atch features of the mod-
ul e from the mounti ng bracket above the headl i ner.
(4) Pul l the I TM and tri m cover down from the
headl i ner far enough to access and di sconnect the
overhead wi re harness connector for the I TM from
the modul e connector.
(5) Remove the I TM from the headl i ner.
INSTALLATION
(1) Posi ti on the I ntrusi on Transcei ver Modul e
(I TM) to the headl i ner.
(2) Reconnect the overhead wi re harness connector
for the I TM to the modul e connector.
(3) Al i gn the two front l atch features of the I TM
wi th the two front l atch receptacl es of the mounti ng
bracket above the headl i ner (Fi g. 8).
(4) Push the I TM tri m cover forward far enough to
i nsert the two rear l atch features of the modul e i nto
REMOVE
1 - SMALL SCREWDRIVER
2 - HEADLINER
3 - SERVICE HOLES
4 - ITM
INTRUSION TRANSCEIVER MODULE (Continued)
the two rear l atch receptacl es of the mounti ng
bracket above the headl i ner.
(5) Push upward fi rml y and evenl y on the rear
edge of the I TM tri m cover unti l the two rear l atch
features of the modul e are engaged and l atched i n
the mounti ng bracket above the headl i ner.
NOTE: If the Intrusion Transceiver Module (ITM) has
been replaced with a new unit, the new ITM MUST
be initialized before the Vehicle Theft Security Sys-
tem can operate as designed. The use of a DRBIII
scan tool is required to initialize the ITM. Refer to
the appropriate diagnostic information.
SIREN
DESCRIPTION
An al arm si ren modul e i s part of the premi um ver-
si on of the Vehi cl e Theft Al arm (VTA) i n the Vehi cl e
Theft Securi ty System (VTSS) (Fi g. 9). The premi um
versi on of the VTA i s onl y avai l abl e i n vehi cl es bui l t
for certai n markets, where the addi ti onal features
offered by thi s system are requi red. The al arm si ren
modul e i s l ocated i n the ri ght front frame rai l . Thi s
uni t i s desi gned to provi de the audi bl e al ert requi re-
ments for the premi um VTA.
The al arm si ren modul e consi sts of mi croprocessor,
the si ren, and a ni ckel metal hydri de backup battery.
Al l of the al arm modul e components are protected
and seal ed wi thi n the housi ng.
The al arm si ren modul e cannot be repai red or
adjusted and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
The mi croprocessor wi thi n the al arm si ren modul e
provi des the si ren uni t features and functi ons based
upon i nternal programmi ng and arm and di sarm
messages recei ved from the I ntrusi on Transcei ver
Modul e (I TM) over a dedi cated seri al bus communi -
cati on ci rcui t. The al arm si ren modul e wi l l sel f-detect
probl ems wi th i ts i nternal and external power suppl y
and communi cati on ci rcui ts, then send messages
i ndi cati ng the probl em to the I TM upon recei vi ng a
request from the I TM. The I TM wi l l store a Di agnos-
ti c Troubl e Code (DTC) for a detected al arm si ren
modul e faul t that can be retri eved wi th the DRBI I I
scan tool over the Programmabl e Communi cati ons
I nterface (PCI ) data bus.
When the premi um versi on of the Vehi cl e Theft
Al arm (VTA) i s armed, the al arm si ren modul e con-
ti nuousl y moni tors i nputs from the I TM for messages
to sound i ts si ren and enters i ts auto-detect mode.
Whi l e i n the auto-detect mode, i f the al arm si ren
modul e detects that i ts power suppl y or communi ca-
ti on ci rcui ts are bei ng tampered wi th or have been
sabotaged, i t wi l l sound an al arm and conti nue to
operate through i ts on-board backup battery. I f the
arm si ren modul e i s i n i ts di sarmed mode when i ts
power suppl y or communi cati on ci rcui ts are i nter-
rupted, the si ren wi l l not sound. The al arm modul e
wi l l al so noti fy the I TM when the backup battery
requi res chargi ng, and the I TM wi l l send a message
that wi l l al l ow the backup battery to be charged
through the battery vol tage and ground ci rcui ts to
the al arm modul e onl y when the i gni ti on swi tch i s i n
the On posi ti on and the engi ne i s runni ng. Thi s wi l l
prevent the chargi ng of the al arm backup battery
from depl eti ng the charge i n the mai n vehi cl e battery
whi l e the vehi cl e i s not bei ng operated.
The al arm si ren modul e recei ves battery vol tage
(PDC), and i s grounded to the chassi s. These connec-
ti ons al l ow the al arm si ren modul e to remai n opera-
ti onal , regardl ess of the i gni ti on swi tch posi ti on. The
hard wi red i nputs and outputs for the al arm si ren
modul e may be di agnosed and tested usi ng conven-
ti onal di agnosti c tool s and procedures. However, con-
venti onal di agnosti c methods wi l l not prove
concl usi ve i n the di agnosi s of the i nternal ci rcui try or
the backup battery of the al arm si ren modul e, the
I TM, the seri al bus communi cati on l i ne, or the mes-
sage i nputs to and outputs from the al arm si ren
modul e. The most rel i abl e, effi ci ent, and accurate
means to di agnose the al arm si ren modul e, the I TM,
the seri al bus communi cati on l i ne, and the el ectroni c
RETAINER RING
1 - STAMPED NUT (2)
2 - MOUNTING BRACKET
3 - HEADLINER
4 - LATCH RECEPTACLES (4)
INTRUSION TRANSCEIVER MODULE (Continued)
message i nputs to and outputs from the al arm si ren
modul e requi res the use of a DRBI I I scan tool .
REMOVAL
cabl e.
(2) Di sconnect the al arm si ren modul e wi ri ng har-
ness connector. (Fi g. 9).
(3) Remove the screws that secure the al arm si ren
modul e to the l eft frame rai l .
(4) Remove the al arm si ren modul e.
INSTALLATION
(1) Posi ti on the al arm si ren modul e on to the l eft
frame rai l . (Fi g. 9).
al arm si ren modul eto the frame rai l . Ti ghten the
(3) Reconnect the al arm si ren modul e wi ri ng har-
ness connector.
NOTE: If the alarm siren module has been replaced
with a new unit, the new unit MUST be configured
in the Intrusion Transceiver Module (ITM) before the
Vehicle Theft Security System can operate as
designed. The use of a DRBIII scan tool is required
to configure the alarm siren module settings in the
ITM. Refer to the appropriate diagnostic informa-
tion.
SKIS INDICATOR LAMP
DESCRIPTION
A Sentry Key I mmobi l i zer System (SKI S) i ndi cator
l amp i s standard equi pment on al l i nstrument cl us-
ters, but i s onl y functi onal on vehi cl es equi pped wi th
the opti onal SKI S. The amber SKI S i ndi cator l amp i s
l ocated to the ri ght of the oi l pressure gauge.
OPERATION
The Sentry Key I mmobi l i zer System (SKI S) i ndi ca-
tor l amp gi ves an i ndi cati on to the vehi cl e operator of
the status of the SKI S. Thi s l amp i s control l ed by a
based upon messages recei ved by the cl uster from
the Sentry Key I mmobi l i zer Modul e (SKI M) over the
bus. The SKI S i ndi cator l amp bul b recei ves battery
current on the i nstrument cl uster ci rcui t board
through the fused i gni ti on swi tch output (st-run) ci r-
cui t whenever the i gni ti on swi tch i s i n the On or
Start posi ti ons. The l amp bul b onl y i l l umi nates when
i t i s provi ded a path to ground by the i nstrument
cl uster transi stor. The i nstrument cl uster wi l l turn
on the SKI S i ndi cator l amp for the fol l owi ng reasons:
turned to the On posi ti on, the SKI M tel l s the cl uster
to i l l umi nate the l amp for about three seconds.
SKIS Lamp-On Message - Each ti me the cl us-
ter recei ves a SKI S l amp-on message from the SKI M,
the l amp wi l l be i l l umi nated. The l amp can be
fl ashed on and off, or i l l umi nated sol i d, as di ctated
by the message from the SKI M. For more i nforma-
ti on on the SKI S and the SKI S l amp control param-
eters, (Refer to 8 - ELECTRI CAL/VEHI CLE THEFT
SECURI TY - OPERATI ON - SENTRY KEY I MMO-
BI LI ZER SYSTEM). The l amp remai ns i l l umi nated
unti l the cl uster recei ves a l amp-off message from
the SKI M or unti l the i gni ti on swi tch i s turned to the
through the actuator test, the l amp wi l l be turned on
for the durati on of the test to confi rm the functi onal -
i ty of the l amp and the cl uster.
The SKI M performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on to deci de
whether the system i s i n good operati ng condi ti on.
The SKI M then sends a message to the i nstrument
cl uster. I f the SKI S i ndi cator l amp fai l s to l i ght dur-
i ng the bul b test, repl ace the bul b. For further di ag-
nosi s of the SKI S i ndi cator l amp or the i nstrument
Fig. 9 Siren Remove/Install
1 - SIREN
2 - FRAME
SIREN (Continued)
cl uster ci rcui try that control s the l amp, (Refer to 8 -
SI S AND TESTI NG). I f the i nstrument cl uster turns
on the SKI S i ndi cator l amp after the bul b test, ei ther
sol i d or fl ashi ng, i t i ndi cates that a SKI S mal functi on
has occurred or that the SKI S i s i noperati ve. For
proper di agnosi s of the SKI S, the PCI data bus, or
the message i nputs to the i nstrument cl uster that
control the SKI S i ndi cator l amp, a DRBI I I scan tool
and the appropri ate di agnosti c i nformati on are
requi red.
TRANSPONDER KEY
DESCRIPTION
Each i gni ti on key used i n the Sentry Key I mmobi -
l i zer System (SKI S) has an i ntegral transponder chi p
(Fi g. 10). I gni ti on keys wi th thi s feature can be
readi l y i denti fi ed by a gray rubber cap mol ded onto
the head of the key, whi l e conventi onal i gni ti on keys
have a bl ack mol ded rubber cap. The transponder
chi p i s conceal ed beneath the mol ded rubber cap,
where i t i s mol ded i nto the head of the metal key.
Each new Sentry Key has a uni que transponder i den-
ti fi cati on code permanentl y programmed i nto i t by
the manufacturer. The Sentry Key transponder i f
faul ty or damaged, must be repl aced.
OPERATION
When the i gni ti on swi tch i s turned to the On posi -
ti on, the Sentry Key I mmobi l i zer Modul e (SKI M)
communi cates through i ts antenna wi th the Sentry
Key transponder usi ng a Radi o Frequency (RF) si g-
nal . The SKI M then wai ts for a RF response from the
transponder through the same antenna. The Sentry
Key transponder chi p i s wi thi n the range of the
SKI M transcei ver antenna ri ng when i t i s i nserted
i nto the i gni ti on l ock cyl i nder. The SKI M determi nes
whether a val i d key i s present i n the i gni ti on l ock
cyl i nder based upon the response from the transpon-
der. I f a val i d key i s detected, that fact i s communi -
cated by the SKI M to the Powertrai n Control Modul e
I nterface (PCI ) data bus, and the PCM al l ows the
engi ne to conti nue runni ng. I f the PCM recei ves an
i nval i d key message, or recei ves no message from the
SKI M over the PCI data bus, the engi ne wi l l be di s-
abl ed after about two seconds of operati on. The El ec-
troMechani cal I nstrument Cl uster (EMI C) wi l l al so
respond to the i nval i d key message on the PCI data
bus by fl ashi ng the SKI S i ndi cator on and off.
Each Sentry Key has a uni que transponder i denti -
fi cati on code permanentl y programmed i nto i t by the
manufacturer. Li kewi se, the SKI M has a uni que
Secret Key code programmed i nto i t by the manufac-
turer. When a Sentry Key i s programmed i nto the
memory of the SKI M, the SKI M stores the transpon-
der i denti fi cati on code from the Sentry Key, and the
Sentry Key l earns the Secret Key code from the
SKI M. Once the Sentry Key l earns the Secret Key
code of the SKI M, i t i s permanentl y stored i n the
memory of the transponder. Therefore, once a Sentry
Key has been programmed to a parti cul ar vehi cl e, i t
cannot be used on any other vehi cl e. (Refer to 8 -
STANDARD PROCEDURE - TRANSPONDER PRO-
GRAMMI NG).
VTSS INDICATOR
DESCRIPTION
The Vehi cl e Theft Securi ty System (VTSS) i ndi ca-
tor consi sts of a red Li ght-Emi tti ng Di ode that i s
mounted and i ntegral to the automati c headl amp
l i ght sensor photo di ode uni t, whi ch i s l ocated on the
top of the i nstrument panel . The remai nder of the
housi ng i ncl udi ng the mount and the el ectri cal con-
necti on are conceal ed beneath the i nstrument panel
top cover.
The VTSS i ndi cator cannot be adjusted or repai red
the enti re automati c headl amp l i ght sensor/VTSS
i ndi cator must be repl aced. (Refer to 8 - ELECTRI -
CAL/LAMPS/LI GHTI NG - EXTERI OR/AUTO HEAD-
LAMP SENSOR - REMOVAL).
Fig. 10 Sentry Key Immobilizer Transponder
1 - MOLDED CAP
2 - TRANSPONDER CHIP
3 - MOLDED CAP REMOVED
4 - TRANSPONDER KEY
SKIS INDICATOR LAMP (Continued)
OPERATION
The Vehi cl e Theft Securi ty System (VTSS) i ndi ca-
tor gi ves a vi si bl e i ndi cati on of the VTSS armi ng sta-
tus. One si de of Li ght-Emi tti ong Di ode (LED) i n the
VTSS i ndi cator i s connected to unswi tched battery
current through a fused B(+) ci rcui t and a fuse i n the
Juncti on Bl ock (JB). The other si de of the LED i s
hard wi red to the Body Control Modul e (BCM), whi ch
control s the operati on of the VTSS i ndi cator by pul l -
i ng thi s si de of the LED ci rcui t to ground. When the
VTSS armi ng i s i n progress, the BCM wi l l fl ash the
LED rapi dl y on and off for about fi fteen seconds.
When the VTSS has been successful l y armed, the
BCM wi l l fl ash the LED on and off conti nual l y at a
much sl ower rate unti l the VTSS has been di sarmed.
The VTSS i ndi cator can be di agnosed usi ng conven-
ti onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - VTSS INDICATOR
Vehi cl e Theft Securi ty System (VTSS) i ndi cator con-
di ti on. I f the probl em bei ng di agnosed i s rel ated to
i ndi cator accuracy, be certai n to confi rm that the
probl em i s wi th the i ndi cator and not wi th an i nop-
erati ve VTSS. (Refer to 8 - ELECTRI CAL/VEHI CLE
THEFT SECURI TY - DI AGNOSI S AND TESTI NG -
VEHI CLE THEFT SECURI TY SYSTEM). I f no VTSS
probl em i s found, the fol l owi ng procedure wi l l hel p to
l ocate a short or open i n the VTSS i ndi cator control
ci rcui t. Refer to the appropri ate wi ri ng i nformati on.
INJURY.
shorted ci rcui t or component and repl ace the faul ty
fuse.
open fused B(+) ci rcui t between the JB and the
Power Di stri buti on Center (PDC).
connector for the automati c headl amp l i ght sensor/
VTSS i ndi cator from the automati c headl amp l i ght
sensor/VTSS i ndi cator pi gtai l wi re connector. Recon-
nect the battery negati ve cabl e. Check for battery
vol tage at the fused B(+) ci rcui t cavi ty of the i nstru-
ment panel wi re harness connector for the automati c
headl amp l i ght sensor/VTSS i ndi cator. I f OK, go to
Step 4. I f not OK, repai r the open fused B(+) ci rcui t
between the VTSS i ndi cator and the JB.
connector for the JB from the JB connector recepta-
cl e. Check for conti nui ty between the VTSS i ndi cator
dri ver ci rcui t cavi ty of the i nstrument panel wi re
harness connector for the automati c headl amp l i ght
sensor/VTSS i ndi cator and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 5. I f not
OK, repai r the shorted VTSS i ndi cator dri ver ci rcui t
(5) Check for conti nui ty between the VTSS i ndi ca-
tor dri ver ci rcui t of the i nstrument panel wi re har-
ness connector for the automati c headl amp l i ght
sensor/VTSS i ndi cator and the i nstrument panel wi re
harness connector for the JB. There shoul d be conti -
nui ty. I f OK, repl ace the faul ty VTSS i ndi cator. I f not
OK, repai r the open VTSS i ndi cator dri ver ci rcui t
VTSS INDICATOR (Continued)
WIPERS/WASHERS
TABLE OF CONTENTS
page page
FRONT WIPERS/WASHERS . . . . . . . . . . . . . . . . . . 1 REAR WIPERS/WASHERS . . . . . . . . . . . . . . . . . . 33
FRONT WIPERS/WASHERS
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - FRONT WIPER &
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . 6
CLEANING - FRONT WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION - FRONT WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT WASHER HOSES/TUBES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT WASHER NOZZLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT WASHER PUMP/MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
FRONT WIPER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT WIPER BLADE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
FRONT WIPER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
RAIN SENSOR MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
RIGHT MULTI-FUNCTION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - RIGHT MULTI-
FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
WASHER FLUID LEVEL SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
WASHER RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
WIPER HIGH/LOW RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING - WIPER HIGH/
LOW RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
WIPER ON/OFF RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
WJ WIPERS/WASHERS 8R - 1
DESCRIPTION
An el ectri cal l y operated i ntermi ttent front wi per
and washer system i s standard factory-i nstal l ed
safety equi pment on thi s model (Fi g. 1). The front
wi per and washer system i ncl udes the fol l owi ng
major components, whi ch are descri bed i n further
detai l el sewhere i n thi s servi ce i nformati on:
Body Control Module - The Body Control
Modul e (BCM) i s l ocated on the Juncti on Bl ock (JB)
under the dri ver si de outboard end of the i nstrument
panel . (Refer to 8 - ELECTRI CAL/ELECTRONI C
CONTROL MODULES/BODY CONTROL MODULE
- DESCRI PTI ON).
Fig. 1 Front Wiper & Washer System
1 - WASHER RESEVOIR FILLER TUBE
2 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL
SWITCH
3 - WASHER NOZZLE (2)
4 - WIPER MODULE
5 - WIPER ARM & BLADE (2)
6 - RIGHT (WIPER) MULTI-FUNCTION SWITCH RIGHT
7 - RAIN SENSOR MODULE
8R - 2 FRONT WIPERS/WASHERS WJ
Front Check Valve - The front washer system
check val ve i s i ntegral to the wye fi tti ng l ocated i n
the washer pl umbi ng between the cowl pl enum
washer hose and the front washer nozzl es, and i s
conceal ed beneath the cowl pl enum cover/gri l l e panel
at the base of the wi ndshi el d.
Front Washer Nozzle - Two fl ui di c front
washer nozzl es are secured wi th i ntegral snap fea-
tures to dedi cated openi ngs i n the cowl pl enum cover/
gri l l e panel l ocated near the base of the wi ndshi el d.
Front Washer Plumbing - The pl umbi ng for
the front washer system consi sts of rubber hoses and
mol ded pl asti c fi tti ngs. The pl umbi ng i s routed al ong
the l eft si de of the engi ne compartment from the
washer reservoi r, and through the dash panel i nto
the cowl pl enum to the front washer nozzl e fi tti ngs
beneath the cowl pl enum cover/gri l l e panel .
Front Washer Pump/Motor - The front washer
pump/motor uni t i s l ocated i n a dedi cated hol e on the
l ower outboard si de of the washer reservoi r, behi nd
the i nner fender l i ner ahead of the l eft front wheel .
The front washer pump i s l ocated ahead of and bel ow
the rear washer pump.
Front Wiper Arm - The two front wi per arms
are secured wi th nuts to the threaded studs on the
ends of the two wi per pi vot shafts, whi ch extend
through the cowl pl enum cover/gri l l e panel l ocated
near the base of the wi ndshi el d.
Front Wiper Blade - The two front wi per
bl ades are secured to the two front wi per arms wi th
an i ntegral l atch, and are parked on the gl ass near
the bottom of the wi ndshi el d when the front wi per
system i s not i n operati on.
Front Wiper Module - The front wi per pi vot
shafts are the onl y vi si bl e components of the front
wi per modul e. The remai nder of the modul e i s con-
ceal ed wi thi n the cowl pl enum beneath the cowl pl e-
num cover/gri l l e panel . The front wi per modul e
i ncl udes the modul e bracket, four rubber-i sol ated
wi per modul e mounts, the front wi per motor, the
wi per motor crank arm, the two wi per dri ve l i nks,
and the two front wi per pi vots.
Rain Sensor Module - Model s equi pped wi th
the opti onal automati c wi per feature have a Rai n
Sensor Modul e (RSM) l ocated behi nd a tri m cover on
a bracket bonded to the i nsi de surface of the wi nd-
shi el d gl ass, just above the i nsi de rear vi ew mi rror
mounti ng button.
Right Multi-Function Switch - The ri ght
(wi per) mul ti -functi on swi tch i s secured to the ri ght
si de of the mul ti -functi on swi tch mounti ng housi ng
near the top of the steeri ng col umn, just bel ow the
steeri ng wheel . Onl y the control stal k for the ri ght
mul ti -functi on swi tch i s vi si bl e, whi l e the remai nder
of the swi tch i s conceal ed beneath the steeri ng col -
umn shrouds. The ri ght mul ti -functi on swi tch con-
tai ns al l of the swi tches and control ci rcui try for both
the front and rear wi per and washer systems.
Washer Fluid Level Switch - The washer fl ui d
l evel swi tch i s l ocated i n a dedi cated hol e near the
center of the forward surface of the washer reservoi r,
behi nd the l eft front wheel house spl ash shi el d.
Washer Reservoir - The washer reservoi r i s
conceal ed between the l eft i nner fender shi el d and
the l eft outer fender panel , behi nd the i nner fender
l i ner and ahead of the l eft front wheel . The washer
reservoi r fi l l er neck i s the onl y vi si bl e porti on of the
reservoi r, and i t i s accessed from the l eft front corner
of the engi ne compartment.
Wiper High-Low Relay - The wi per hi gh-l ow
rel ay i s an I nternati onal Standards Organi zati on
(I SO) mi cro rel ay l ocated i n the Power Di stri buti on
Center (PDC) i n the engi ne compartment near the
battery.
Wiper On-Off Relay - The wi per on-off rel ay i s
an I nternati onal Standards Organi zati on (I SO) mi cro
rel ay l ocated i n the Power Di stri buti on Center (PDC)
i n the engi ne compartment near the battery.
Hard wi red ci rcui try connects the front wi per and
washer system components to the el ectri cal system of
vehi cl e el ectri cal system and to the front wi per and
washer system components through the use of a com-
bi nati on of sol dered spl i ces, spl i ce bl ock connectors,
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, further detai l s on wi re harness routi ng
and retenti on, as wel l as pi n-out and l ocati on vi ews
for the vari ous wi re harness connectors, spl i ces and
grounds.
OPERATING MODES
The components of the front wi per and washer sys-
tem are desi gned to work i n concert to provi de the
fol l owi ng operati ng modes:
Automatic Wiper - I n model s equi pped wi th
the opti onal automati c wi per feature, the i nternal
ci rcui try of both the ri ght (wi per) mul ti -functi on
swi tch, the rai n sensor modul e, and the BCM work
i n concert to provi de an automati c wi per mode wi th
fi ve sensi ti vi ty sel ecti ons. The BCM tel l s the Rai n
Sensor Modul e (RSM) when the automati c wi per
mode i s sel ected and the manual l y sel ected sensi ti v-
i ty l evel , then the rai n sensor modul e tel l s the BCM
each ti me enough water dropl ets have accumul ated
wi thi n the wi pe pattern on the wi ndshi el d to requi re
front wi per operati on. The BCM then automati cal l y
WJ FRONT WIPERS/WASHERS 8R - 3
FRONT WIPERS/WASHERS (Continued)
operates the front wi pers at the programmed speed
and i nterval s requested by the RSM to mai ntai n vi s-
i bi l i ty through the wi ndshi el d.
Continuous Wipe Mode - The control knob on
the control stal k of the ri ght (wi per) mul ti -functi on
swi tch has two conti nuous wi pe posi ti ons, Low and
Hi gh. When sel ected, these swi tch posi ti ons wi l l
cause the two-speed front wi per motor to operate i n a
conti nuous l ow or hi gh speed cycl e.
Headlamps On With Wipers - The BCM pro-
vi des an automati c headl amps on wi th wi pers feature
for model s equi pped wi th the opti onal automati c
headl amps. Thi s i s a customer programmabl e fea-
ture. I f thi s feature i s enabl ed, the headl amps wi l l
turn on automati cal l y when the wi ndshi el d wi pers
are turned on; and, i f the headl amps were turned on
automati cal l y when the wi pers were turned on, they
wi l l turn off automati cal l y when the wi pers are
turned off. I n model s equi pped wi th the opti onal
automati c wi per feature, when the automati c wi per
mode i s sel ected the headl amps wi l l turn on auto-
mati cal l y onl y after the wi pers compl ete three auto-
mati c wi pe cycl es wi thi n about thi rty seconds, and
they wi l l turn off automati cal l y after three mi nutes
el apse wi thout any automati c wi pe cycl es. (Refer to 8
- ELECTRI CAL/OVERHEAD CONSOLE - STAN-
DARD PROCEDURE - ELECTRONI C VEHI CLE
I NFORMATI ON CENTER PROGRAMMI NG).
Mist Wipe Mode - The control stal k of the ri ght
(wi per) mul ti -functi on swi tch has a momentary Mi st
posi ti on. When sel ected, thi s swi tch posi ti on wi l l
operate the front wi pers i n a l ow speed conti nuous
cycl e for as l ong as the swi tch i s hel d cl osed, then
wi l l compl ete the current wi pe cycl e and park the
front wi per bl ades near the base of the wi ndshi el d
when the swi tch i s rel eased.
Speed Sensitive Intermittent Wipe Mode -
Except on model s equi pped wi th the opti onal auto-
mati c wi per system, the i nternal ci rcui try of both the
ri ght (wi per) mul ti -functi on swi tch and the BCM
work i n concert to provi de an i ntermi ttent wi pe mode
wi th fi ve del ay i nterval sel ecti ons. The BCM auto-
mati cal l y adjusts each manual l y sel ected del ay i nter-
val to compensate for vehi cl e speed.
Washer Mode - When the momentary front
wash posi ti on of the control stal k for the ri ght
(wi per) mul ti -functi on swi tch i s sel ected wi th the
front wi per system operati ng i n a conti nuous wi pe
mode, washer fl ui d wi l l be di spensed onto the wi nd-
shi el d gl ass through the washer nozzl es for as l ong
as the washer swi tch i s hel d cl osed. When the front
washer swi tch i s actuated wi th the front wi per sys-
tem operati ng i n an i ntermi ttent wi pe mode, washer
fl ui d i s sti l l di spensed unti l the swi tch i s rel eased;
however, the front wi pers wi l l operate i n a l ow speed
conti nuous cycl e from the ti me the washer swi tch i s
cl osed unti l several wi pe cycl es after the swi tch i s
rel eased, before returni ng to the sel ected i ntermi t-
tent wi pe mode.
Wipe-After-Wash Mode - When the momentary
front wash posi ti on of the control stal k for the ri ght
(wi per) mul ti -functi on swi tch i s sel ected wi th the
front wi per system turned Off, the i nternal ci rcui try
of the BCM provi des a wi pe-after-wash feature.
When sel ected, thi s feature wi l l operate the front
washer pump/motor and the front wi pers for as l ong
as the front washer swi tch i s hel d cl osed, then pro-
vi de several addi ti onal wi pe cycl es after the swi tch i s
rel eased before parki ng the front wi per bl ades near
the base of the wi ndshi el d.
OPERATION
The front wi per and washer system i s desi gned to
provi de the vehi cl e operator wi th a conveni ent, safe,
and rel i abl e means of mai ntai ni ng vi si bi l i ty through
the wi ndshi el d gl ass. The vari ous components of thi s
system are desi gned to convert el ectri cal energy pro-
duced by the vehi cl e el ectri cal system i nto the
mechani cal acti on of the wi per bl ades to wi pe the
outsi de surface of the gl ass, as wel l as i nto the
hydraul i c acti on of the washer system to appl y
washer fl ui d stored i n an on-board reservoi r to the
area of the gl ass to be wi ped. When combi ned, these
components provi de the means to effecti vel y mai n-
tai n cl ear vi si bi l i ty for the vehi cl e operator by remov-
i ng excess accumul ati ons of rai n, snow, bugs, mud, or
other mi nor debri s that mi ght be encountered whi l e
dri vi ng the vehi cl e under numerous types of i ncl em-
ent operati ng condi ti ons from the outsi de wi ndshi el d
gl ass surface.
The vehi cl e operator i ni ti ates al l front wi per and
washer system functi ons wi th the control stal k of the
ri ght (wi per) mul ti -functi on swi tch that extends from
the ri ght si de of the steeri ng col umn, just bel ow the
steeri ng wheel . Rotati ng the control knob on the end
of the ri ght (wi per) mul ti -functi on swi tch control
stal k sel ects the Off, Del ay (on model s not equi pped
wi th the opti onal automati c wi per system), Auto (on
model s equi pped wi th the opti onal automati c wi per
system), Low, or Hi gh front wi per system operati ng
modes. I n the Del ay mode, the control knob al so
al l ows the vehi cl e operator to sel ect from one of fi ve
i ntermi ttent wi pe Del ay i nterval s. I n the Auto mode,
the control knob al so al l ows the vehi cl e operator to
sel ect from one of fi ve automati c wi per sensi ti vi ty
l evel s. Pul l i ng the ri ght control stal k downwards
actuates the momentary front wi per system Mi st
mode swi tch, whi l e pul l i ng the ri ght control stal k
towards the steeri ng wheel actuates the front washer
system swi tch. The mul ti -functi on swi tch provi des
hard wi red resi stor mul ti pl exed i nputs to the Body
Control Modul e (BCM) for al l of the front wi per sys-
tem functi ons, as wel l as separate hard wi red sense
i nputs to the BCM for the hi gh speed conti nuous
wi pe and front washer system functi ons.
The front wi per and washer system wi l l onl y oper-
ate when the i gni ti on swi tch i s i n the Accessory or
On posi ti ons. Battery current i s di rected from a B(+)
fuse i n the Power Di stri buti on Center (PDC) to the
wi per and washer system ci rcui t breaker i n the Junc-
ti on Bl ock (JB) through a fused i gni ti on swi tch out-
put (run-acc) ci rcui t. The automati c resetti ng ci rcui t
breaker then provi des battery current through a
fused i gni ti on swi tch output (run-acc) ci rcui t to the
wi per on/off rel ay, and the park swi tch i n the front
wi per motor. A separate fuse i n the JB provi des bat-
tery current through another fused i gni ti on swi tch
output (run-acc) ci rcui t to the ri ght mul ti -functi on
swi tch. The ri ght mul ti -functi on swi tch ci rcui try uses
thi s battery feed to di rectl y control the operati on of
the front washer pump/motor uni t. The BCM uses
l ow si de dri vers to control front wi per system opera-
ti on by energi zi ng or de-energi zi ng the wi per hi gh/
l ow and wi per on/off rel ays.
The hard wi red ci rcui ts and components of the
front wi per and washer system may be di agnosed
and tested usi ng conventi onal di agnosti c tool s and
procedures. However, conventi onal di agnosti c meth-
ods may not prove concl usi ve i n the di agnosi s of the
Body Control Modul e (BCM), or the i nputs to or out-
puts from the BCM that control the front wi per and
washer system operati ng modes. The most rel i abl e,
effi ci ent, and accurate means to di agnose the BCM,
or the BCM i nputs and outputs rel ated to the vari ous
front wi per and washer system operati ng modes
requi res the use of a DRBI I I scan tool . Refer to the
Fol l owi ng are paragraphs that bri efl y descri be the
operati on of each of the front wi per and washer sys-
tem operati ng modes.
CONTINUOUS WIPE MODE
When the Low posi ti on of the control knob on the
control stal k of the ri ght (wi per) mul ti -functi on
swi tch i s sel ected, the Body Control Modul e (BCM)
energi zes the wi per on/off rel ay. Thi s di rects battery
current through the normal l y open contacts of the
energi zed wi per on/off rel ay and the normal l y cl osed
contacts of the de-energi zed wi per hi gh/l ow rel ay to
the l ow speed brush of the front wi per motor, causi ng
the front wi pers to cycl e at l ow speed. When the
Hi gh posi ti on of the control knob i s sel ected, the
BCM energi zes both the wi per on/off rel ay and the
wi per hi gh/l ow rel ay. Thi s di rects battery current
through the normal l y open contacts of the energi zed
wi per on/off rel ay and the normal l y open contacts of
the energi zed wi per hi gh/l ow rel ay to the hi gh speed
brush of the front wi per motor, causi ng the front wi p-
ers to cycl e at hi gh speed.
When the Off posi ti on of the control knob i s
sel ected, the BCM de-energi zes both the wi per on/off
and wi per hi gh/l ow rel ays, then one of two events
wi l l occur. The event that wi l l occur depends upon
the posi ti on of the wi per bl ades on the wi ndshi el d at
the moment that the control knob Off posi ti on i s
sel ected. I f the wi per bl ades are i n the down posi ti on
on the wi ndshi el d when the Off posi ti on i s sel ected,
the park swi tch that i s i ntegral to the front wi per
motor i s cl osed to ground and the wi per motor ceases
to operate. I f the wi per bl ades are not i n the down
posi ti on on the wi ndshi el d at the moment the Off
posi ti on i s sel ected, the park swi tch i s cl osed to bat-
tery current from the fused i gni ti on swi tch output
(run-acc) ci rcui t of the front wi per motor. The park
swi tch di rects thi s battery current to the l ow speed
brush of the wi per motor through the wi per park
swi tch sense ci rcui t and the normal l y cl osed contacts
of the wi per on/off and wi per hi gh/l ow rel ays. Thi s
causes the wi per motor to conti nue runni ng at l ow
speed unti l the wi per bl ades are i n the down posi ti on
on the wi ndshi el d and the park swi tch i s agai n
cl osed to ground.
INTERMITTENT WIPE MODE
On model s not equi pped wi th the opti onal auto-
mati c wi per system, when the control knob on the
swi tch i s moved to one of the fi ve Del ay i nterval posi -
ti ons, the BCM el ectroni c i ntermi ttent wi pe l ogi c ci r-
cui t responds by cal cul ati ng the correct l ength of
ti me between wi per sweeps based upon the sel ected
del ay i nterval i nput. The BCM moni tors the chang-
i ng state of the wi per motor park swi tch through a
hard wi red front wi per park swi tch sense ci rcui t
i nput. Thi s i nput al l ows the BCM to determi ne the
proper i nterval s at whi ch to energi ze and de-energi ze
the wi per on/off rel ay to operate the front wi per
motor i ntermi ttentl y for one l ow speed cycl e at a
ti me. The BCM l ogi c i s al so programmed to provi de
an i mmedi ate wi pe cycl e and begi n a new del ay
i nterval ti mi ng cycl e each ti me a shorter del ay i nter-
val i s sel ected, and to add the remai ni ng del ay ti m-
i ng i nterval to the new del ay i nterval ti mi ng before
the next wi pe cycl e occurs each ti me a l onger del ay
i nterval i s sel ected.
The i ntermi ttent wi pe mode del ay ti mes are speed
sensi ti ve. The BCM moni tors vehi cl e speed messages
recei ved from the Powertrai n Control Modul e (PCM)
(PCI ) data bus network i n order to provi de the speed
sensi ti ve del ay i nterval s. Above about si xteen ki l ome-
ters-per-hour (ten mi l es-per-hour) the del ay i s dri ver
adjustabl e from about one-hal f second to about ei gh-
teen seconds. Bel ow about si xteen ki l ometers-per-
hour (ten mi l es-per-hour) the del ay ti mes are
doubl ed, from about one second to about thi rty-si x
seconds.
AUTOMATIC WIPE MODE
On model s equi pped wi th the opti onal automati c
wi per system, when the control knob on the control
stal k of the ri ght (wi per) mul ti -functi on swi tch i s
moved to one of the fi ve Auto sensi ti vi ty posi ti ons,
the BCM sends an el ectroni c message to the Rai n
Sensor Modul e (RSM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus network i ndi -
cati ng the sel ected posi ti on. The RSM moni tors an
area wi thi n the wi pe pattern of the wi ndshi el d gl ass
for the accumul ati on of moi sture. Based upon i nter-
nal programmi ng and the sel ected sensi ti vi ty l evel ,
when suffi ci ent moi sture has accumul ated the RSM
sends the appropri ate el ectroni c wi pe command mes-
sages to the BCM over the PCI data bus and the
BCM operates the front wi per system accordi ngl y. As
the sensi ti vi ty l evel i s set hi gher, the RSM i s more
sensi ti ve to moi sture accumul ati on and wi l l send
wi pe commands more frequentl y. The BCM l ogi c i s
al so programmed to provi de an i mmedi ate wi pe cycl e
each ti me the control knob on the control stal k of the
ri ght mul ti -functi on swi tch i s moved from a non-au-
tomati c wi pe posi ti on to one of the fi ve Auto sensi ti v-
i ty posi ti ons, and another i mmedi ate wi pe cycl e each
ti me the control knob i s moved from a l ower Auto
sensi ti vi ty posi ti on to a hi gher Auto sensi ti vi ty posi -
ti on.
MIST WIPE MODE
When the control stal k of the ri ght (wi per) mul ti -
functi on swi tch i s moved to the momentary Mi st
posi ti on, the BCM energi zes the wi per on/off rel ay for
as l ong as the Mi st swi tch i s hel d cl osed, then de-en-
ergi zes the rel ay when the state of the Mi st swi tch
i nput changes to open. The BCM can operate the
front wi per motor i n thi s mode for onl y one l ow speed
cycl e at a ti me, or for an i ndefi ni te number of
sequenti al l ow speed cycl es, dependi ng upon how
l ong the Mi st swi tch i s hel d cl osed.
WASH MODE
functi on swi tch i s moved to the momentary front
Wash posi ti on whi l e the control knob i s i n the Low or
Hi gh posi ti ons, the ci rcui try wi thi n the swi tch di rects
battery current to the front washer pump/motor uni t.
Thi s wi l l cause the front washer pump/motor uni t to
be energi zed for as l ong as the front Wash swi tch i s
hel d cl osed, and to de-energi ze when the front Wash
swi tch i s rel eased. When the control stal k of the
ri ght (wi per) mul ti -functi on swi tch i s moved to the
momentary front Wash posi ti on whi l e the control
knob i s i n one of the Del ay i nterval or Auto sensi ti v-
i ty posi ti ons, the front washer pump/motor operati on
i s the same. However, the BCM energi zes the wi per
on/off rel ay to overri de the sel ected del ay i nterval or
auto sensi ti vi ty l evel and operate the front wi per
motor i n a conti nuous l ow speed mode for as l ong as
the front Wash swi tch i s hel d cl osed, then de-ener-
gi zes the rel ay and reverts to the sel ected del ay mode
i nterval or auto sensi ti vi ty l evel several wi pe cycl es
after the front Wash swi tch i s rel eased. The BCM
detects the front Wash swi tch state through a hard
wi red washer pump motor swi tch output ci rcui t i nput
from the ri ght mul ti -functi on swi tch.
WIPE-AFTER-WASH MODE
functi on swi tch i s moved to the momentary front
Wash posi ti on whi l e the control knob i s i n the Off
posi ti on, the BCM detects that swi tch state through
a hard wi red washer pump motor swi tch output ci r-
cui t i nput from the ri ght mul ti -functi on swi tch. The
BCM responds to thi s i nput by energi zi ng the wi per
on/off rel ay for as l ong as the Wash swi tch i s hel d
cl osed, then de-energi zes the rel ay several wi pe
cycl es after the front Wash swi tch i s rel eased. The
BCM moni tors the changi ng state of the wi per motor
park swi tch through a hard wi red front wi per park
swi tch sense ci rcui t i nput. Thi s i nput al l ows the
BCM to count the number of wi pe cycl es that occur
after the front Wash swi tch state changes to open,
and to determi ne the proper i nterval at whi ch to de-
energi ze the wi per on/off rel ay to compl ete the wi pe-
after-wash mode cycl e.
DIAGNOSIS AND TESTING - FRONT WIPER &
WASHER SYSTEM
FRONT WIPER SYSTEM
I f the front wi per motor operates, but the wi pers
do not move on the wi ndshi el d, repl ace the faul ty
front wi per modul e. I f the wi pers operate, but chat-
ter, l i ft, or do not cl ear the gl ass, cl ean and i nspect
the wi per system components as requi red. (Refer to 8
- ELECTRI CAL/FRONT WI PERS/WASHERS -
I NSPECTI ON) and (Refer to 8 - ELECTRI CAL/
FRONT WI PERS/WASHERS - CLEANI NG). Refer to
The hard wi red ci rcui ts and components of the
front wi per and washer system may be di agnosed
and tested usi ng conventi onal di agnosti c tool s and
procedures. However, conventi onal di agnosti c meth-
ods may not prove concl usi ve i n the di agnosi s of the
Body Control Modul e (BCM), the Rai n Sensor Mod-
ul e (RSM), the Powertrai n Control Modul e (PCM) or
the i nputs to or outputs from these modul es that con-
trol the vari ous front wi per and washer system oper-
ati ng modes. The most rel i abl e, effi ci ent, and
accurate means to di agnose the BCM, the RSM, the
PCM or the BCM i nputs and outputs rel ated to the
vari ous front wi per and washer system operati ng
modes requi res the use of a DRBI I I scan tool . Refer
PERSONAL INJURY.
FRONT WASHER SYSTEM
The di agnosi s found here addresses an el ectri cal l y
i noperati ve washer system. I f the washer pump/mo-
tor operates, but no washer fl ui d i s emi tted from the
front washer nozzl es, be certai n to check the fl ui d
l evel i n the reservoi r. Al so i nspect the front washer
system components as requi red. (Refer to 8 - ELEC-
TRI CAL/FRONT WI PERS/WASHERS - I NSPEC-
TI ON). Refer to the appropri ate wi ri ng i nformati on.
PERSONAL INJURY.
Turn the control knob on the control stal k of the
ri ght (wi per) mul ti -functi on swi tch to the Low or
Hi gh wi per posi ti on. Check whether the front wi per
system i s operati ng. I f OK, go to Step 2. I f not OK,
test and repai r the front wi per system before con-
ti nui ng wi th these tests. Refer to FRONT WI PER
SYSTEM
(2) Turn the control knob on the control stal k of
the ri ght (wi per) mul ti -functi on swi tch to the Off
posi ti on. Pul l the control stal k of the ri ght (wi per)
mul ti -functi on swi tch toward the steeri ng wheel to
cl ose the front washer swi tch. The front washer
pump shoul d operate and the front wi pers shoul d
operate for about three sweep cycl es after the swi tch
i s rel eased before they park. I f the front wi pers are
OK, but the front washers are not, go to Step 3. I f
the front washers are OK, but the front wi pers are
not, go to Step 5.
Di sconnect the l eft headl amp and dash wi re harness
connector for the front washer pump/motor from the
pump/motor connector receptacl e. Check for conti nu-
i ty between the ground ci rcui t cavi ty of the l eft head-
l amp and dash wi re harness connector for the front
washer pump/motor and a good ground. There shoul d
the open ground ci rcui t to ground (G106) as requi red.
i gni ti on swi tch to the On posi ti on. Whi l e pul l i ng the
swi tch toward the steeri ng wheel to cl ose the front
washer swi tch, check for battery vol tage at the
washer pump swi tch sense ci rcui t cavi ty of the l eft
headl amp and dash wi re harness connector for the
front washer pump/motor uni t. I f OK, repl ace the
faul ty front washer pump/motor. I f not OK, repai r
the open washer pump swi tch sense ci rcui t between
the ri ght (wi per) mul ti -functi on swi tch and the front
washer pump/motor uni t as requi red.
Di sconnect the i nstrument panel wi re harness con-
nector (Connector C2) for the Body Control Modul e
(BCM) from the BCM connector receptacl e. Recon-
nect the battery negati ve cabl e. Turn the i gni ti on
swi tch to the On posi ti on. Whi l e pul l i ng the control
stal k of the ri ght (wi per) mul ti -functi on swi tch
toward the steeri ng wheel to cl ose the front washer
swi tch, check for battery vol tage at the washer pump
swi tch sense ci rcui t cavi ty of the i nstrument panel
wi re harness connector (Connector C2) for the BCM.
I f OK, use a DRBI I I scan tool to di agnose the BCM.
Refer to the appropri ate di agnosti c i nformati on. I f
not OK, repai r the open washer pump swi tch sense
ci rcui t between the ri ght (wi per) mul ti -functi on
swi tch and the BCM as requi red.
CLEANING - FRONT WIPER & WASHER
SYSTEM
WIPER SYSTEM
The squeegees of wi per bl ades exposed to the el e-
ments for a l ong ti me tend to l ose thei r wi pi ng effec-
ti veness. Peri odi c cl eani ng of the squeegees i s
suggested to remove any deposi ts of sal t or road fi l m.
The wi per bl ades, arms, and wi ndshi el d gl ass shoul d
onl y be cl eaned usi ng a sponge or soft cl oth and
wi ndshi el d washer fl ui d, a mi l d detergent, or a non-
abrasi ve cl eaner. I f the wi per bl ades conti nue to
l eave streaks, smears, hazi ng, or beadi ng on the
gl ass after thorough cl eani ng of the squeegees and
the gl ass, the enti re wi per bl ade assembl y must be
repl aced.
CAUTION: Protect the rubber squeegees of the
wiper blades from any petroleum-based cleaners,
solvents, or contaminants. These products can rap-
idly deteriorate the rubber squeegees.
WASHER SYSTEM
I f the washer system i s contami nated wi th forei gn
materi al , drai n the washer reservoi r by removi ng the
front washer pump/motor from the reservoi r. Cl ean
forei gn materi al from the i nsi de of the washer reser-
voi r usi ng cl ean washer fl ui d, a mi l d detergent, or a
non-abrasi ve cl eaner. Fl ush forei gn materi al from the
washer system pl umbi ng by fi rst di sconnecti ng the
washer hoses from the washer nozzl es, then runni ng
the washer pump/motor to run cl ean washer fl ui d or
water through the system. Pl ugged or restri cted
washer nozzl es shoul d be careful l y back-fl ushed
usi ng compressed ai r. I f the washer nozzl e obstruc-
ti on cannot be cl eared, repl ace the washer nozzl e.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegees of the wiper blades.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - FRONT WIPER & WASHER
SYSTEM
WIPER SYSTEM
The front wi per bl ades and wi per arms shoul d be
i nspected peri odi cal l y, not just when wi per perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) I nspect the wi per arms for any i ndi cati ons of
damage, or contami nati on. I f the wi per arms are con-
tami nated wi th any forei gn materi al , cl ean them as
requi red. (Refer to 8 - ELECTRI CAL/FRONT WI P-
ERS/WASHERS - CLEANI NG). I f a wi per arm i s
damaged or corrosi on i s evi dent, repl ace the wi per
arm wi th a new uni t. Do not attempt to repai r a
wi per arm that i s damaged or corroded.
(2) Careful l y l i ft the wi per bl ade off of the gl ass.
Note the acti on of the wi per arm hi nge. The wi per
arm shoul d pi vot freel y at the hi nge, but wi th no l at-
eral l ooseness evi dent. I f there i s any bi ndi ng evi dent
i n the wi per arm hi nge, or there i s evi dent l ateral
pl ay i n the wi per arm hi nge, repl ace the wi per arm.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) Once proper hi nge acti on of the wi per arm i s
confi rmed, check the hi nge for proper spri ng tensi on.
Remove the wi per bl ade from the wi per arm. Ei ther
pl ace a smal l postal scal e between the bl ade end of
the wi per arm and the gl ass, or careful l y l i ft the
bl ade end of the arm away from the gl ass usi ng a
smal l fi sh scal e. Compare the scal e readi ngs between
the ri ght and l eft wi per arms. Repl ace a wi per arm i f
i t has comparati vel y l ower spri ng tensi on, as evi -
denced by a l ower scal e readi ng.
(4) I nspect the wi per bl ades and squeegees for any
i ndi cati ons of damage, contami nati on, or rubber dete-
ri orati on (Fi g. 2). I f the wi per bl ades or squeegees
are contami nated wi th any forei gn materi al , cl ean
them and the gl ass as requi red. (Refer to 8 - ELEC-
TRI CAL/FRONT WI PERS/WASHERS - CLEANI NG).
After cl eani ng the wi per bl ade and the gl ass, i f the
wi per bl ade sti l l fai l s to cl ear the gl ass wi thout
smeari ng, streaki ng, chatteri ng, hazi ng, or beadi ng,
repl ace the wi per bl ade. Al so, i f a wi per bl ade i s
damaged or the squeegee rubber i s damaged or dete-
ri orated, repl ace the wi per bl ade wi th a new uni t. Do
not attempt to repai r a wi per bl ade that i s damaged.
WASHER SYSTEM
The washer system components shoul d be
i nspected peri odi cal l y, not just when washer perfor-
(1) Check for i ce or other forei gn materi al i n the
washer reservoi r. I f contami nated, cl ean and fl ush
the washer system. (Refer to 8 - ELECTRI CAL/
FRONT WI PERS/WASHERS - CLEANI NG).
(2) I nspect the washer pl umbi ng for pi nched, l eak-
i ng, deteri orated, or i ncorrectl y routed hoses and
damaged or di sconnected hose fi tti ngs. Repl ace dam-
aged or deteri orated hoses and hose fi tti ngs. Leaki ng
washer hoses can someti mes be repai red by cutti ng
the hose at the l eak and spl i ci ng i t back together
usi ng an i n-l i ne connector fi tti ng. Si mi l arl y, secti ons
of deteri orated hose can be cut out and repl aced by
spl i ci ng i n new secti ons of hose usi ng i n-l i ne connec-
tor fi tti ngs. Whenever routi ng a washer hose or a
wi re harness contai ni ng a washer hose, i t must be
routed away from hot, sharp, or movi ng parts. Al so,
sharp bends that mi ght pi nch the washer hose must
be avoi ded.
FRONT CHECK VALVE
DESCRIPTION
A front washer system check val ve i s standard
equi pment on thi s model . The front check val ve i s
i ntegral to the front washer nozzl e pl umbi ng wye fi t-
ti ng l ocated i n the cowl pl enum beneath the cowl pl e-
num cover/gri l l e panel near the base of the
wi ndshi el d. The check val ve consi sts of a mol ded
pl asti c body wi th a round center secti on. Three
barbed hose ni ppl es are formed i n a wye confi gura-
ti on on the outsi de ci rcumference of the center sec-
ti on of the val ve body. Wi thi n the check val ve body, a
smal l check val ve operated by a smal l coi l ed spri ng
restri cts fl ow through the uni t unti l the val ve i s
unseated by a predetermi ned i nl et fl ui d pressure.
The front check val ve cannot be adjusted or repai red
OPERATION
The front check val ve provi des more than one func-
ti on i n thi s appl i cati on. I t serves as a wye connector
fi tti ng between the cowl gri l l e panel and washer noz-
zl e secti ons of the front washer suppl y hose. I t al so
prevents washer fl ui d from drai ni ng out of the front
washer suppl y hoses back to the washer reservoi r.
Thi s drai n-back woul d resul t i n a l engthy del ay from
when the front washer swi tch i s actuated unti l
washer fl ui d was di spensed through the front washer
nozzl es, because the front washer pump woul d have
to refi l l the front washer pl umbi ng from the reservoi r
to the nozzl es. Fi nal l y, the front check val ve prevents
washer fl ui d from si phoni ng through the front
washer nozzl es after the front washer system i s
turned Off. When the front washer pump pressuri zes
and pumps washer fl ui d from the reservoi r through
the front washer pl umbi ng, the fl ui d pressure over-
ri des the spri ng pressure appl i ed to the check val ve
and unseats the val ve, al l owi ng washer fl ui d to fl ow
toward the front washer nozzl es. When the front
washer pump stops operati ng, spri ng pressure seats
the check val ve and fl ui d fl ow i n ei ther di recti on
wi thi n the front washer pl umbi ng i s prevented.
REMOVAL
cabl e.
(2) Remove the wi per arms from the wi per pi vots.
(Refer to 8 - ELECTRI CAL/FRONT WI PERS/WASH-
ERS/FRONT WI PER ARMS - REMOVAL).
(3) Open the hood and pul l the hood to pl enum
seal off of the forward fl anges of the cowl gri l l e cover
and the pl enum panel .
Fig. 2 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
(4) Remove the si x pl asti c nuts (2 short and 4
l ong) that secure the cowl gri l l e cover to the studs on
the cowl top panel near the base of the wi ndshi el d
(Fi g. 3).
(5) Li ft the l eft end of the cowl gri l l e cover off of
the cowl pl enum panel far enough to access the front
washer pl umbi ng.
(6) Di sconnect the engi ne compartment washer
hose from the cowl gri l l e cover washer hose at the
pl asti c el bow connector.
(7) Remove the cowl gri l l e cover from the cowl pl e-
num and cowl top panel s through the openi ng
between the hood and the base of the wi ndshi el d.
(8) From the undersi de of the cowl gri l l e cover, di s-
connect the washer hoses from the three barbed ni p-
pl es of the wye fi tti ng/check val ve uni t.
(9) Remove the wye fi tti ng/check val ve uni t from
the undersi de of the cowl gri l l e cover.
INSTALLATION
(1) Posi ti on the wye fi tti ng/check val ve uni t to the
undersi de of the cowl gri l l e cover.
(2) From the undersi de of the cowl gri l l e cover,
reconnect the three washer hoses to the barbed ni p-
pl es of the wye fi tti ng/check val ve uni t.
(3) Rei nstal l the washer hoses for the front washer
nozzl es i nto thei r routi ng cl i ps on the undersi de of
the cowl gri l l e cover.
(4) Posi ti on the cowl gri l l e cover onto the cowl pl e-
between the hood and the base of the wi ndshi el d
(Fi g. 3).
washer pl umbi ng.
(6) Reconnect the cowl gri l l e cover washer hose to
the engi ne compartment washer hose at the el bow
connector.
(7) I nstal l the si x pl asti c nuts that secure the cowl
gri l l e cover to the studs on the cowl top panel near
the base of the wi ndshi el d. These nuts are to be
i nstal l ed by pushi ng them onto the studs i n the fol -
l owi ng sequence:
(a) Fi rst, i nstal l the short nuts to the thi rd stud
from the ri ght, then the second stud from the l eft.
(b) Next, i nstal l the l ong nuts to the ri ght out-
board stud, then the l eft outboard stud.
(c) Fi nal l y, i nstal l the two remai ni ng l ong nuts
to the thi rd stud from the l eft, then the second
stud from the ri ght.
(8) Starti ng at the ends and worki ng toward the
center, push the hood to pl enum seal onto the for-
ward fl anges of the cowl gri l l e cover and the pl enum
panel .
(9) Rei nstal l the wi per arms onto the wi per pi vots.
ERS/FRONT WI PER ARMS - I NSTALLATI ON).
FRONT WASHER HOSES/
TUBES
DESCRIPTION
The front washer pl umbi ng consi sts of a smal l
di ameter rubber hose that i s routed from the barbed
outl et ni ppl e of the front washer pump/motor on the
washer reservoi r al ong the fi l l er neck i nto the engi ne
compartment. I n the engi ne compartment, a mol ded
pl asti c i n-l i ne fi tti ng wi th barbed ni ppl es joi ns the
washer hose to another secti on of hose that i s routed
near the l eft headl amp and dash wi re harness to the
cowl pl enum area. The engi ne compartment washer
hose passes from the engi ne compartment i nto the
cowl pl enum area through a dedi cated hol e wi th a
rubber grommet near the l eft end of the cowl pl enum
panel . A mol ded pl asti c el bow fi tti ng wi th barbed ni p-
pl es joi ns the engi ne compartment hose to the cowl
gri l l e cover hose. The cowl gri l l e cover washer hose i s
routed through routi ng cl i ps on the undersi de of the
cowl gri l l e cover to a mol ded pl asti c wye fi tti ng wi th
barbed ni ppl es and an i ntegral check val ve. The cowl
gri l l e cover hose i s connected to one ni ppl e on the
wye fi tti ng and the two washer nozzl e hoses are con-
nected to the other two wye fi tti ng ni ppl es. The
washer nozzl e hoses are routed al ong the undersi de
of the cowl gri l l e cover to the two washer nozzl es.
Fig. 3 Cowl Grille Cover Remove/Install
1 - WASHER HOSE CONNECTION
2 - STUDS (6)
3 - COWL GRILLE COVER
4 - PLASTIC NUT (6)
FRONT CHECK VALVE (Continued)
Washer hose i s avai l abl e for servi ce onl y as rol l
stock, whi ch must then be cut to l ength. The mol ded
pl asti c washer hose fi tti ngs cannot be repai red. I f
these fi tti ngs are faul ty or damaged, they must be
repl aced.
OPERATION
Washer fl ui d i n the washer reservoi r i s pressuri zed
and fed by the front washer pump/motor through the
front washer system pl umbi ng and fi tti ngs to the two
front washer nozzl es. Whenever routi ng the washer
hose or a wi re harness contai ni ng a washer hose, i t
must be routed away from hot, sharp, or movi ng
parts; and, sharp bends that mi ght pi nch the hose
must be avoi ded.
FRONT WASHER NOZZLE
DESCRIPTION
The two front washer nozzl es have i ntegral snap
features that secure them i n dedi cated hol es i n the
cowl pl enum cover/gri l l e panel l ocated near the base
of the wi ndshi el d. The domed upper surface of the
washer nozzl e i s vi si bl e on the top of the pl enum cov-
er/gri l l e panel , and the nozzl e ori fi ce i s ori ented
towards the wi ndshi el d gl ass. The washer pl umbi ng
fi tti ngs for the washer nozzl es are conceal ed beneath
the cowl pl enum cover/gri l l e panel . These fl ui di c
washer nozzl es are constructed of mol ded pl asti c. The
cowl pl enum cover/gri l l e panel must be removed from
the vehi cl e to access the nozzl es for servi ce. The
washer nozzl es cannot be adjusted or repai red. I f
faul ty or damaged, they must be repl aced.
OPERATION
The two front washer nozzl es are desi gned to di s-
pense washer fl ui d i nto the wi per pattern area on the
outsi de of the wi ndshi el d gl ass. Pressuri zed washer
fl ui d i s fed to each nozzl e from the washer reservoi r
by the front washer pump/motor through a si ngl e
hose, whi ch i s attached to a barbed ni ppl e on each
front washer nozzl e bel ow the cowl pl enum cover/
gri l l e panel . The washer nozzl es i ncorporate a fl ui di c
desi gn, whi ch causes the nozzl e to emi t the pressur-
i zed washer fl ui d as an osci l l ati ng stream to more
effecti vel y cover a l arger area of the gl ass area to be
cl eaned.
REMOVAL
cabl e.
(2) Remove the wi per arms from the wi per pi vots.
ERS/FRONT WI PER ARMS - REMOVAL).
(3) Unl atch and open the hood.
(4) Pul l the hood to pl enum seal off of the forward
fl anges of the cowl gri l l e cover and the pl enum panel .
(Fi g. 4).
washer pl umbi ng.
(7) Di sconnect the engi ne compartment washer
hose from the cowl gri l l e cover washer hose at the
pl asti c el bow connector.
(9) From the undersi de of the cowl gri l l e cover, di s-
connect the washer hose(s) from the barbed ni ppl e(s)
of the front washer nozzl e(s).
rel ease the i ntegral snap features of the front washer
nozzl e(s) and push the nozzl e(s) out through the
mounti ng hol e toward the top si de of the cowl gri l l e
cover.
INSTALLATION
(1) From the top si de of the cowl gri l l e cover,
i nsert the ni ppl e end of the front washer nozzl e(s)
through the mounti ng hol e i n the cowl gri l l e cover.
(2) Push fi rml y and evenl y on the top of the front
washer nozzl e unti l the i ntegral snap features l ock
i nto pl ace on the undersi de of the cowl gri l l e cover.
reconnect the washer hose(s) to the barbed ni ppl e(s)
of the front washer nozzl e(s).
2 - STUDS (6)
4 - PLASTIC NUT (6)
FRONT WASHER HOSES/TUBES (Continued)
(4) Rei nstal l the washer hoses for the front washer
nozzl e(s) i nto thei r routi ng cl i ps on the undersi de of
the cowl gri l l e cover.
(Fi g. 4).
washer pl umbi ng.
(7) Reconnect the cowl gri l l e cover washer hose to
the engi ne compartment washer hose at the el bow
connector.
l owi ng sequence:
(b) Next, i nstal l the l ong nuts to the ri ght out-
board stud, then the l eft outboard stud.
panel .
(11) Rei nstal l the wi per arms onto the wi per pi v-
ots. (Refer to 8 - ELECTRI CAL/FRONT WI PERS/
WASHERS/FRONT WI PER ARMS -
I NSTALLATI ON).
FRONT WASHER PUMP/
MOTOR
DESCRIPTION
The front washer pump/motor uni t i s l ocated on
the outboard si de and near the front of the washer
reservoi r, between the l eft front i nner and outer
fender panel s (Fi g. 5). A smal l permanentl y l ubri -
cated and seal ed el ectri c motor i s coupl ed to the
rotor-type washer pump. A seal fl ange wi th a l arge
barbed i nl et ni ppl e on the pump housi ng passes
through a rubber grommet seal i nstal l ed i n one of
two dedi cated mounti ng hol es near the bottom of the
washer reservoi r. The front washer pump/motor uni t
i s al ways mounted i n the l ower pump mounti ng hol e
of the reservoi r. A smal l er barbed outl et ni ppl e on the
pump housi ng connects the uni t to the front washer
hose. The washer pump/motor uni t i s retai ned on the
reservoi r by the i nterference fi t between the barbed
pump i nl et ni ppl e and the grommet seal , whi ch i s a
l i ght press fi t. An i ntegral el ectri cal connector recep-
tacl e i s l ocated on the top of the motor housi ng. The
front washer pump/motor uni t cannot be repai red. I f
faul ty or damaged, the enti re washer pump/motor
OPERATION
The front washer pump/motor uni t i s connected to
the vehi cl e el ectri cal system through a si ngl e take
out and two-cavi ty connector of the l eft headl amp
and dash wi re harness. The washer pump/motor i s
grounded at al l ti mes through a take out of the l eft
headl amp and dash wi re harness wi th a si ngl e eyel et
termi nal connector that i s secured under a ground
screw to the top of the l eft i nner fender shi el d i n the
engi ne compartment. The front washer pump/motor
recei ves battery current on a fused i gni ti on swi tch
output (run-acc) ci rcui t through the cl osed contacts of
the momentary front washer swi tch wi thi n the ri ght
mul ti -functi on swi tch onl y when the swi tch control
stal k i s pul l ed towards the steeri ng wheel . Washer
fl ui d i s gravi ty-fed from the washer reservoi r to the
i nl et si de of the washer pump. When the pump motor
i s energi zed, the rotor-type pump pressuri zes the
washer fl ui d and forces i t through the pump outl et
ni ppl e, the front washer pl umbi ng, and the front
washer nozzl es onto the wi ndshi el d gl ass.
REMOVAL
cabl e.
Fig. 5 Washer Pumps (Viewed from Bottom of
Reservoir)
1 - REAR WASHER PUMP/MOTOR
2 - FRONT WASHER PUMP/MOTOR
3 - WASHER FLUID LEVEL SWITCH
FRONT WASHER NOZZLE (Continued)
(3) Remove the l i ner from the l eft front fender
wheel house.
(4) Di sconnect the l eft headl amp and dash wi re
harness connector for the front washer pump/motor
from the motor connector receptacl e (Fi g. 6).
(5) Di sconnect the washer hose from the barbed
outl et ni ppl e of the front washer pump/motor and
al l ow the washer fl ui d to drai n i nto a cl ean contai ner
for reuse.
fl at-bl aded tool , gentl y pry the barbed i nl et ni ppl e of
the washer pump out of the rubber grommet seal i n
the reservoi r. Care must be taken not to damage the
reservoi r.
(7) Remove the rubber grommet seal from the
washer pump mounti ng hol e i n the washer reservoi r
and di scard.
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
washer pump mounti ng hol e i n the washer reservoi r.
Al ways use a new rubber grommet seal on the reser-
voi r.
(2) Posi ti on the barbed i nl et ni ppl e of the washer
pump to the rubber grommet seal i n the reservoi r
(Fi g. 6).
(3) Press fi rml y and evenl y on the washer pump
unti l the barbed i nl et ni ppl e i s ful l y seated i n the
rubber grommet seal i n the washer reservoi r mount-
i ng hol e.
(4) Reconnect the washer hose to the barbed outl et
ni ppl e of the washer pump.
(5) Reconnect the l eft headl amp and dash wi re
harness connector for the front washer pump/motor
uni t to the motor connector receptacl e.
(6) Rei nstal l the l i ner i nto the l eft front fender
wheel house.
(8) Refi l l the washer reservoi r wi th the washer
fl ui d drai ned from the reservoi r duri ng the removal
procedure.
FRONT WIPER ARM
DESCRIPTION
The front wi per arms are the ri gi d members
l ocated between the wi per pi vots that protrude from
the cowl pl enum cover/gri l l e panel near the base of
the wi ndshi el d and the wi per bl ades on the wi nd-
shi el d gl ass. These wi per arms feature an over-center
hi nge that al l ows easy access to the wi ndshi el d gl ass
for cl eani ng. The wi per arm has a di e cast metal
pi vot end wi th a l arge mounti ng hol e wi th i nternal
serrati ons at one end. A mol ded bl ack pl asti c cap fi ts
over the wi per arm retai ni ng nut to conceal the nut
and thi s mounti ng hol e fol l owi ng wi per arm i nstal l a-
ti on. The wi de end of a tapered, stamped steel chan-
nel hi nges on and i s secured wi th a hi nge pi n to the
bl ade end of the wi per arm pi vot end. One end of a
l ong, ri gi d, stamped steel strap, wi th a smal l hol e
near i ts pi vot end, i s ri veted and cri mped wi thi n the
narrow end of the stamped steel channel . The ti p of
the wi per bl ade end of thi s strap i s bent back under
i tsel f to form a smal l hook. Conceal ed wi thi n the
stamped steel channel , one end of a l ong spri ng i s
engaged wi th a wi re hook on the undersi de of the di e
cast pi vot end, whi l e the other end of the spri ng i s
hooked through the smal l hol e i n the steel strap. The
enti re wi per arm has a sati n bl ack fi ni sh appl i ed to
al l of i ts vi si bl e surfaces.
A wi per arm cannot be adjusted or repai red. I f
damaged or faul ty, the enti re wi per arm uni t must be
repl aced.
OPERATION
The front wi per arms are desi gned to mechani cal l y
transmi t the moti on from the wi per pi vots to the
wi per bl ades. The wi per arm must be properl y
i ndexed to the wi per pi vot i n order to mai ntai n the
proper wi per bl ade travel on the gl ass. The mounti ng
hol e formati on wi th i nternal serrati ons i n the wi per
arm pi vot end i nterl ocks wi th the serrati ons on the
outer ci rcumference of the wi per pi vot dri ver, al l ow-
i ng posi ti ve engagement and fi ni te adjustment of thi s
Reservoir)
FRONT WASHER PUMP/MOTOR (Continued)
connecti on. The mounti ng nut l ocks the wi per arm to
the threaded stud on the wi per pi vot. The spri ng-
l oaded wi per arm hi nge control s the down-force
appl i ed through the ti p of the wi per arm to the wi per
bl ade on the gl ass. The hook formati on on the ti p of
the wi per arm provi des a cradl e for securi ng and
l atchi ng the wi per bl ade pi vot bl ock to the wi per
arm.
REMOVAL
(1) Li ft the front wi per arm to i ts over-center posi -
ti on to hol d the wi per bl ade off of the gl ass and
rel i eve the spri ng tensi on on the wi per arm to wi per
pi vot connecti on.
(2) Careful l y pry the pl asti c nut cap off of the
pi vot end of the wi per arm (Fi g. 7).
(3) Remove the nut that secures the wi per arm to
the wi per pi vot shaft.
(4) Use a sui tabl e battery termi nal pul l er to di sen-
gage the wi per arm from the wi per pi vot shaft
spl i nes (Fi g. 8).
(5) Remove the front wi per arm pi vot end from the
wi per pi vot.
INSTALLATION
NOTE: Be certain that the wiper motor is in the park
position before attempting to install the wiper arms.
Turn the ignition switch to the On position and
move the right multi-function switch control knob to
its Off position. If the wiper pivots move, wait until
they stop moving, then turn the ignition switch
back to the Off position. The wiper motor is now in
its park position.
(1) The front wi per arms must be i ndexed to the
wi per pi vots wi th the wi per motor i n the park posi -
ti on to be properl y i nstal l ed. Posi ti on the front wi per
arm pi vot ends onto the wi per pi vots so that the
l ower edge of the bl ade i s al i gned wi th the wi per
al i gnment l i nes l ocated i n the l ower edge of the
wi ndshi el d gl ass (Fi g. 7).
(2) Once the wi per bl ade i s al i gned, l i ft the wi per
arm away from the wi ndshi el d sl i ghtl y to rel i eve the
spri ng tensi on on the pi vot end and push the pi vot
hol e on the end of the wi per arm down over the
wi per pi vot shaft.
wi per arm to the wi per pi vot shaft. Ti ghten the nut
to 23.7 Nm (210 i n. l bs.).
(4) Wet the wi ndshi el d gl ass, then operate the
front wi pers. Turn the wi per swi tch to the Off posi -
ti on, then check for the correct wi per arm posi ti on
and readjust as requi red.
(5) Rei nstal l the pl asti c nut cap onto the wi per
arm pi vot nut.
FRONT WIPER BLADE
DESCRIPTION
Each front wi per bl ade i s secured by an i ntegral
l atchi ng pi vot bl ock to the hook formati on on the ti p
of the front wi per arms, and rests on the gl ass near
the base of the wi ndshi el d when the wi pers are not
i n operati on (Fi g. 9). The wi per bl ade consi sts of the
fol l owi ng components:
Superstructure - The superstructure i ncl udes
several stamped steel bri dges and l i nks wi th cl aw
Fig. 7 Wiper Arm Remove/Install
1 - ARM AND BLADE
2 - CAP
3 - NUT
4 - PIVOT SHAFT
5 - ALIGNMENT LINE
Fig. 8 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT
FRONT WIPER ARM (Continued)
formati ons that gri p the wi per bl ade el ement. Al so
i ncl uded i n thi s uni t i s the l atchi ng, mol ded pl asti c
pi vot bl ock that secures the superstructure to the
wi per arm. Al l of the metal components of the wi per
bl ade have a sati n bl ack fi ni sh appl i ed.
Element - The wi per el ement or squeegee i s the
resi l i ent rubber member of the wi per bl ade that con-
tacts the gl ass.
Flexor - The fl exor i s a ri gi d metal component
runni ng al ong the l ength of each si de of the wi per
el ement where i t i s gri pped by the cl aws of the
superstructure.
Al l Grand Cherokee model s have two 52.50 centi -
meter (20.67 i nch) l ong wi ndshi el d wi per bl ades wi th
non-repl aceabl e rubber el ements (squeegees). The
wi per bl ades cannot be adjusted or repai red. I f faul ty,
worn, or damaged the enti re wi per bl ade uni t must
be repl aced.
OPERATION
The wi per bl ades are moved back and forth across
the gl ass by the wi per arms when the wi pers are
bei ng operated. The wi per bl ade superstructure i s
the fl exi bl e frame that gri ps the wi per bl ade el ement
and evenl y di stri butes the force of the spri ng-l oaded
wi per arm al ong the l ength of the el ement. The com-
bi nati on of the wi per arm force and the fl exi bi l i ty of
the superstructure makes the el ement conform to
and mai ntai n proper contact wi th the gl ass, even as
the bl ade i s moved over the vari ed curvature found
across the gl ass surface. The wi per el ement fl exor
provi des the cl aws of the bl ade superstructure wi th a
ri gi d, yet fl exi bl e component on the el ement whi ch
can be gri pped. The rubber el ement i s desi gned to be
sti ff enough to mai ntai n an even cl eani ng edge as i t
i s drawn across the gl ass, but resi l i ent enough to
conform to the gl ass surface and fl i p from one cl ean-
i ng edge to the other each ti me the wi per bl ade
changes di recti ons.
REMOVAL
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.
(1) Li ft the front wi per arm to rai se the wi per
bl ade and el ement off of the gl ass, unti l the wi per
arm hi nge i s i n i ts over-center posi ti on.
(2) To remove the wi per bl ade from the wi per arm,
push the pi vot bl ock l atch rel ease tab under the ti p
of the arm and sl i de the bl ade away from the ti p
towards the pi vot end of the arm far enough to di s-
engage the pi vot bl ock from the hook (Fi g. 10).
(3) Extract the hook formati on on the ti p of the
wi per arm from the openi ng i n the wi per bl ade
superstructure ahead of the wi per bl ade pi vot bl ock/
l atch uni t.
(4) Gentl y l ower the wi per arm ti p onto the gl ass.
INSTALLATION
the wiper blade that is nearest to the wiper pivot.
(1) Li ft the front wi per arm off of the wi ndshi el d
gl ass, unti l the wi per arm hi nge i s i n i ts over-center
posi ti on.
(2) Posi ti on the front wi per bl ade near the hook
formati on on the ti p of the arm wi th the notched
retai ner for the wi per el ement ori ented towards the
end of the wi per arm that i s nearest to the wi per
pi vot.
Fig. 9 Wiper Blade - Typical
1 - RELEASE TAB
Fig. 10 Wiper Blade Remove/Install - Typical
1 - RELEASE TAB
FRONT WIPER BLADE (Continued)
(3) I nsert the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
l atch uni t far enough to engage the pi vot bl ock wi th
the hook (Fi g. 10).
(4) Sl i de the wi per bl ade pi vot bl ock/l atch up i nto
the hook formati on on the ti p of the wi per arm unti l
the l atch rel ease tab snaps i nto i ts l ocked posi ti on.
Latch engagement wi l l be accompani ed by an audi bl e
cl i ck.
(5) Gentl y l ower the wi per bl ade onto the gl ass.
FRONT WIPER MODULE
DESCRIPTION
The front wi per modul e i s secured wi th four screws
through rubber i sol ators to the cowl pl enum panel
beneath the cowl pl enum cover/gri l l e panel (Fi g. 11).
The ends of the wi per pi vot shafts that protrude
through dedi cated openi ngs i n the cowl pl enum cov-
er/gri l l e panel to dri ve the wi per arms and bl ades are
the onl y vi si bl e components of the front wi per mod-
ul e. The front wi per modul e consi sts of the fol l owi ng
major components:
Bracket - The front wi per modul e bracket con-
si sts of a l ong tubul ar steel mai n member that has a
stamped pi vot bracket formati on near each end
where the two wi per pi vots are secured. A stamped
steel mounti ng pl ate for the wi per motor i s secured
wi th wel ds near the center of the mai n member.
Crank Arm - The front wi per motor crank arm
i s a stamped steel uni t wi th a sl otted hol e on the
dri ven end that i s secured to the wi per motor output
shaft wi th a nut, and a bal l stud secured to the dri ve
end.
Linkage - Two stamped steel dri ve l i nks con-
nect the wi per motor crank arm to the pi vot l ever
arms. The passenger si de dri ve l i nk has a pl asti c
socket-type bushi ng on each end. The dri ver si de
dri ve l i nk has a pl asti c socket-type bushi ng on one
end, and a pl asti c sl eeve-type bushi ng on the other
end. The socket-type bushi ng on one end of each
dri ve l i nk i s snap-fi t over the bal l stud on the l ever
arm of i ts respecti ve pi vot. The dri ver si de dri ve l i nk
sl eeve-type bushi ng end i s then fi t over the motor
crank arm bal l stud, and the other socket-type bush-
i ng of the passenger si de dri ve l i nk i s snap-fi t over
the exposed end of the wi per motor crank arm bal l
stud.
Motor - The front wi per motor i s secured wi th
three screws to the motor mounti ng pl ate near the
center of the wi per modul e bracket. The wi per motor
output shaft passes through a hol e i n the modul e
bracket, where a nut secures the wi per motor crank
arm to the motor output shaft. The two-speed perma-
nent magnet wi per motor features an i ntegral trans-
mi ssi on, an i nternal park swi tch, and an i nternal
automati c resetti ng ci rcui t breaker.
Pivots - The two front wi per pi vots are secured
to the ends of the wi per modul e bracket. The crank
arms that extend from the bottom of the pi vot shafts
each have a bal l stud on thei r end. The upper end of
each pi vot shaft where the wi per arms wi l l be fas-
tened each has an external l y serrated drum wi th a
threaded stud secured to i t.
The front wi per modul e cannot be adjusted or
repai red. I f any component of the modul e i s faul ty or
damaged, the enti re front wi per modul e uni t must be
repl aced. The rei nforcement bracket and stud pl ate
are avai l abl e for servi ce repl acement.
OPERATION
The front wi per modul e operati on i s control l ed by
the battery current i nputs recei ved by the wi per
motor from the wi per on/off and wi per hi gh/l ow
rel ays. The wi per motor speed i s control l ed by cur-
rent fl ow to ei ther the l ow speed or the hi gh speed
set of brushes. The park swi tch i s a si ngl e pol e, si n-
gl e throw, momentary swi tch wi thi n the wi per motor
that i s mechani cal l y actuated by the wi per motor
transmi ssi on components. The park swi tch al ter-
natel y cl oses the wi per park swi tch sense ci rcui t to
ground or to battery current, dependi ng upon the
posi ti on of the wi pers on the gl ass. Thi s feature
al l ows the motor to compl ete i ts current wi pe cycl e
after the wi per system has been turned Off, and to
park the wi per bl ades i n the l owest porti on of the
wi pe pattern. The automati c resetti ng ci rcui t breaker
protects the motor from overl oads. The wi per motor
Fig. 11 Front Wiper Module
1 - FRONT WIPER MODULE
2 - SCREW (4)
4 - LOWER COWL PLENUM PANEL
FRONT WIPER BLADE (Continued)
crank arm, the two wi per l i nkage members, and the
two wi per pi vots mechani cal l y convert the rotary out-
put of the wi per motor to the back and forth wi pi ng
moti on of the wi per arms and bl ades on the gl ass.
REMOVAL
cabl e.
(2) Remove the front wi per arms from the wi per
pi vots. (Refer to 8 - ELECTRI CAL/FRONT WI PERS/
WASHERS/FRONT WI PER ARMS - REMOVAL).
(3) Unl atch and open the hood.
(4) Remove the hood to pl enum seal from the for-
panel .
(Fi g. 12).
washer pl umbi ng.
(7) Di sconnect the front washer engi ne compart-
ment hose from the cowl gri l l e cover hose at the
el bow connector.
(9) Remove the four screws that secure the front
wi per modul e to the cowl pl enum panel (Fi g. 13).
(10) Li ft the l eft end of the front wi per modul e far
enough to access the front wi per motor wi re harness
connector.
harness connector for the front wi per motor from the
front wi per motor pi gtai l wi re connector.
(12) Remove the front wi per modul e from the cowl
pl enum as a uni t.
INSTALLATION
(1) Posi ti on the front wi per modul e i nto the cowl
pl enum as a uni t (Fi g. 13).
(2) Li ft the l eft end of the front wi per modul e far
enough to access the front wi per motor wi re harness
connector.
harness connector for the front wi per motor to the
front wi per motor pi gtai l wi re connector.
(4) Loosel y i nstal l one of the front wi per modul e
mounti ng screws to the mounti ng hol e near the pi vot
on the ri ght end of the modul e to l ocate the modul e
i n the pl enum.
(5) Worki ng from l eft to ri ght, i nstal l and ti ghten
the four screws that secure the front wi per modul e to
the cowl pl enum panel . Ti ghten the screws to 8 Nm
(72 i n. l bs.).
(Fi g. 12).
washer pl umbi ng.
(8) Reconnect the front washer system engi ne com-
partment hose to the cowl gri l l e cover hose at the
el bow connector.
2 - STUDS (6)
4 - PLASTIC NUT (6)
Fig. 13 Front Wiper Module Remove/Install
1 - FRONT WIPER MODULE
2 - SCREW (4)
4 - LOWER COWL PLENUM PANEL
FRONT WIPER MODULE (Continued)
l owi ng sequence:
(b) Next, i nstal l l ong nuts to the ri ght outboard
stud, then the l eft outboard stud.
panel .
(12) Rei nstal l the wi per arms onto the wi per pi v-
ots. (Refer to 8 - ELECTRI CAL/FRONT WI PERS/
WASHERS/FRONT WI PER ARMS -
I NSTALLATI ON).
RAIN SENSOR MODULE
DESCRIPTION
The Rai n Sensor Modul e (RSM) i s the pri mary
component of the automati c wi per system (Fi g. 14).
The RSM i s l ocated on the i nsi de of the wi ndshi el d,
between the rear vi ew mi rror mounti ng button and
the wi ndshi el d header and i s conceal ed behi nd a
mol ded pl asti c tri m cover that snaps over the modul e
housi ng. The tri angul ar-shaped mol ded bl ack pl asti c
housi ng of the RSM has a rectangul ar openi ng
l ocated on the upper end of the housi ng for the mod-
ul e connector receptacl e, whi ch contai ns four termi -
nal pi ns. These termi nal pi ns connect the rai n sensor
to the vehi cl e el ectri cal system through a dedi cated
take out and connector of the overhead wi re harness
that extends from above the headl i ner. Fi ve openi ngs
on the wi ndshi el d si de of the RSM housi ng are fi tted
wi th ei ght convex cl ear pl asti c l enses. A metal spri ng
cl i p on each si de of the housi ng near the bottom
secures the RSM to a pl asti c mounti ng bracket that
i s bonded to the wi ndshi el d gl ass. Conceal ed wi thi n
the RSM housi ng i s the el ectroni c ci rcui try of the
modul e, whi ch i ncl udes four I nfraRed (I R) di odes,
two photocel l s, and a mi croprocessor.
The RSM software i s Fl ash compati bl e, whi ch
means i t can be reprogrammed usi ng Fl ash repro-
grammi ng procedures. However, i f any of the hard-
ware of the RSM i s damaged or faul ty, the enti re
modul e must be repl aced. The RSM bracket i s ser-
vi ced as a uni t wi th the wi ndshi el d gl ass. I f the
bracket i s faul ty, damaged, or separated from the
wi ndshi el d gl ass, the wi ndshi el d uni t must be
repl aced.
OPERATION
The mi croprocessor-based Rai n Sensor Modul e
(RSM) senses moi sture i n the wi pe pattern on the
outsi de of the wi ndshi el d gl ass and sends wi pe com-
mands to the Body Control Modul e (BCM). Four
I nfraRed (I R) di odes wi thi n the RSM generate I R
l i ght beams that are ai med by four of the convex
opti cal l enses near the base of the modul e through
the wi ndshi el d gl ass. Four addi ti onal convex opti cal
l enses near the top of the RSM are focused on the I R
l i ght beams on the outsi de of the wi ndshi el d gl ass
and al l ow the two photocel l s wi thi n the modul e to
sense changes i n the i ntensi ty of these I R l i ght
beams. When suffi ci ent moi sture accumul ates wi thi n
the wi pe pattern of the wi ndshi el d gl ass, the RSM
detects a change i n the moni tored I R l i ght beam
i ntensi ty.
The i nternal programmi ng of the RSM then sends
the appropri ate el ectroni c wi pe command messages
to the BCM over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The BCM responds by acti -
vati ng or deacti vati ng the front wi per system. The
BCM al so sends el ectroni c sensi ti vi ty l evel messages
to the RSM over the PCI data bus based upon the
dri ver-sel ected sensi ti vi ty setti ng of the control knob
on the control stal k of the ri ght (wi per) mul ti -func-
ti on swi tch. The hi gher the sel ected sensi ti vi ty set-
ti ng the more sensi ti ve the RSM i s to the
accumul ated moi sture on the wi ndshi el d gl ass, and
Fig. 14 Rain Sensor Module
1 - SPRING CLIP (2)
2 - INFRARED LENS (4)
3 - HOUSING
5 - PHOTOCELL LENS (4)
FRONT WIPER MODULE (Continued)
the more frequentl y the RSM wi l l send wi pe com-
mands to the BCM to operate the front wi per system.
The RSM operates on battery current recei ved
through a fuse i n the Juncti on Bl ock (JB) on a fused
B(+) ci rcui t. Thi s ci rcui t i s swi tched by the power
accessory (sunroof) del ay rel ay i n the JB so that the
RSM wi l l operate whenever the rel ay i s energi zed by
the BCM. The RSM recei ves ground at al l ti mes
through a take out of the l eft body wi re harness wi th
an eyel et termi nal that i s secured by a ground screw
to the front seat crossmember on the fl oor panel
under the l eft front seat. I t i s i mportant to note that
the defaul t condi ti on for the wi per system i s auto-
mati c wi pers Off; therefore, i f no message i s recei ved
from the RSM by the BCM for more than about fi ve
seconds, the automati c wi pers wi l l be di sabl ed and
the BCM wi l l defaul t the front wi per system opera-
ti on to the l ow speed conti nuous wi pe mode.
The RSM ground and battery current i nputs can be
methods. However, conventi onal di agnosti c methods
may not prove concl usi ve i n the di agnosi s of the RSM
i nternal ci rcui try, the BCM, the PCI data bus net-
work, or the el ectroni c messages recei ved and trans-
mi tted by the RSM over the PCI data bus. The most
rel i abl e, effi ci ent, and accurate means to di agnose
the RSM requi res the use of a DRBI I I scan tool .
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Adjust the i nsi de rear vi ew mi rror on the wi nd-
shi el d downward far enough to access the l ower edge
of the Rai n Sensor Modul e (RSM) tri m cover (Fi g.
15).
(3) Usi ng a smal l thi n-bl aded screwdri ver i nserted
i nto the notch at the bottom of tri m cover, gentl y pry
the tri m cover away from the wi ndshi el d gl ass unti l
i t unsnaps from the RSM.
(4) Usi ng a smal l thi n-bl aded screwdri ver, gentl y
pry the spri ng cl i ps on each si de of the RSM away
from the bracket on the wi ndshi el d.
(5) Pul l the RSM away from the bracket on the
wi ndshi el d far enough to access and di sconnect the
overhead wi re harness connector for the modul e from
the modul e connector receptacl e.
(6) Remove the RSM from above the i nsi de rear
vi ew mi rror.
INSTALLATION
PERSONAL INJURY.
Fig. 15 Rain Sensor Module Remove/Install
1 - OVERHEAD CONSOLE
2 - REAR VIEW MIRROR CONNECTOR
3 - BRACKET
4 - REAR VIEW MIRROR BUTTON
5 - SPRING CLIP (2)
6 - RAIN SENSOR MODULE
7 - TRIM COVER
RAIN SENSOR MODULE (Continued)
(1) Posi ti on the Rai n Sensor Modul e (RSM) above
the i nsi de rear vi ew mi rror (Fi g. 15).
(2) Reconnect the overhead wi re harness connector
for the RSM to the modul e connector receptacl e.
(3) Posi ti on the RSM to the bracket on the wi nd-
shi el d above the i nsi de rear vi ew mi rror.
(4) Usi ng hand pressure, press the spri ng cl i ps on
each si de of the RSM unti l they snap over the
bracket on the wi ndshi el d.
NOTE: The spring clips on the RSM will become
deformed after numerous (about ten) removal and
installation cycles. If the spring clips become
deformed, the RSM must be replaced with a new
unit.
(5) Al i gn and engage the top of the tri m cover over
the top of the RSM.
(6) Usi ng hand pressure, press the bottom of the
tri m cover toward the wi ndshi el d gl ass unti l i t snaps
over the bottom of the RSM.
RIGHT MULTI-FUNCTION
SWITCH
DESCRIPTION
The ri ght (wi per) mul ti -functi on swi tch i s secured
to the ri ght si de of the mul ti -functi on swi tch mount-
i ng housi ng at the top of the steeri ng col umn, just
bel ow the steeri ng wheel (Fi g. 16). The onl y vi si bl e
component of the ri ght mul ti -functi on swi tch i s the
control stal k that extends through a dedi cated open-
i ng i n the ri ght si de of the steeri ng col umn shrouds.
The remai nder of the ri ght mul ti -functi on swi tch i s
conceal ed beneath the steeri ng col umn shrouds. The
swi tch housi ng and i ts control stal k are constructed
of mol ded bl ack pl asti c. A si ngl e connector receptacl e
contai ni ng up to ten termi nal pi ns i s l ocated on the
back of the swi tch housi ng and connects the swi tch
to the vehi cl e el ectri cal system through a take out
and connector of the i nstrument panel wi re harness.
The swi tch i s secured to the mul ti -functi on swi tch
mounti ng housi ng near the top of the steeri ng col -
umn by two screws.
There are two versi ons of the ri ght mul ti -functi on
swi tch: one to support the standard equi pment speed
sensi ti ve i ntermi ttent front wi per system, and a sec-
ond to support the opti onal front automati c wi per
system. Each versi on of the ri ght mul ti -functi on
swi tch control stal k has both whi te nomencl ature
and I nternati onal Control and Di spl ay Symbol i cons
appl i ed to i t, whi ch cl earl y i denti fy i ts many func-
ti ons. The control stal k has a control knob on i ts end
wi th a fl attened face to al l ow i t to be easi l y rotated.
Just bel ow the control knob i s a knurl ed control
sl eeve. The ri ght mul ti -functi on swi tch i s the pri mary
control for the front and rear wi per and washer sys-
tems, and contai ns swi tches and ci rcui try to provi de
si gnal s to the Body Control Modul e (BCM) and the
rear wi per modul e.
The ri ght (wi per) mul ti -functi on swi tch cannot be
adjusted or repai red. I f any functi on of the swi tch i s
faul ty, or i f the swi tch i s damaged, the enti re swi tch
The ri ght (wi per) mul ti -functi on swi tch supports
the fol l owi ng functi ons and features:
Automatic Front Wipe Mode - On model s
equi pped wi th the opti onal automati c wi per system,
the i nternal ci rcui try and hardware of the ri ght
(wi per) mul ti -functi on swi tch control knob provi de an
automati c front wi pe mode wi th fi ve sensi ti vi ty posi -
ti ons.
Continuous Front Wipe Modes - The i nternal
ci rcui try and hardware of the ri ght (wi per) mul ti -
functi on swi tch control knob provi de two conti nuous
front wi pe swi tch posi ti ons, l ow speed or hi gh speed.
Fig. 16 Right (Wiper) Multi-Function Switch
1 - CONTROL STALK
2 - REAR WIPER CONTROL SLEEVE
3 - FRONT WIPER CONTROL KNOB
4 - RIGHT (WIPER) MULTI-FUNCTION SWITCH
RAIN SENSOR MODULE (Continued)
Continuous Rear Wipe Mode - The i nternal
functi on swi tch control sl eeve provi des one conti nu-
ous rear wi pe swi tch posi ti on.
Front Washer Mode - The i nternal ci rcui try
and hardware of the ri ght (wi per) mul ti -functi on
swi tch control stal k provi de front washer system
operati on.
Front Wipe-After-Wash Mode - The i nternal
functi on swi tch control stal k provi de a wi pe-after-
wash mode.
Front Wiper Mist Mode - The i nternal ci r-
cui try and hardware of the ri ght (wi per) mul ti -func-
ti on swi tch control stal k provi de a front wi per system
mi st mode.
Intermittent Front Wipe Mode - The i nternal
functi on swi tch control knob provi de an i ntermi ttent
front wi pe mode wi th fi ve del ay i nterval posi ti ons,
except on model s equi pped wi th the opti onal auto-
mati c wi per system.
Intermittent Rear Wipe Mode - The i nternal
functi on swi tch control ri ng provi de one fi xed i nter-
val i ntermi ttent rear wi pe mode swi tch posi ti on.
Rear Washer Mode - The i nternal ci rcui try and
hardware of the ri ght (wi per) mul ti -functi on swi tch
control stal k provi de rear washer system operati on.
OPERATION
The ri ght (wi per) mul ti -functi on swi tch uses a com-
bi nati on of resi stor mul ti pl exed and conventi onal l y
swi tched outputs to control the many functi ons and
features i t provi des. The swi tch recei ves battery cur-
rent on a fused i gni ti on swi tch output (run-acc) ci r-
cui t from a fuse i n the Juncti on Bl ock (JB) whenever
the i gni ti on swi tch i s i n the On or Accessory posi -
ti ons, and recei ves ground from the Body Control
Modul e (BCM) on a wi ndshi el d wi per swi tch return
ci rcui t. The ri ght (wi per) mul ti -functi on swi tch may
be di agnosed usi ng conventi onal di agnosti c tool s and
methods.
Fol l owi ng are descri pti ons of how the ri ght (wi per)
mul ti -functi on swi tch control stal k operates to control
the functi ons and features i t provi des:
Automatic Wipe Mode - On model s equi pped
wi th the opti onal automati c wi per system, the control
knob on the end of the ri ght (wi per) mul ti -functi on
swi tch control stal k i s rotated to one of fi ve mi nor
i ntermedi ate detents to sel ect the desi red automati c
wi pe sensi ti vi ty l evel . The control knob i s rotated
rearward (countercl ockwi se) to reduce the sensi ti vi ty
(i ncrease the i nterval between wi pes), or forward
(cl ockwi se) to i ncrease the sensi ti vi ty (decrease the
i nterval between wi pes). The ri ght (wi per) mul ti -
functi on swi tch provi des a resi stor mul ti pl exed out-
put to the Body Control Modul e (BCM) on a
wi ndshi el d wi per swi tch mux ci rcui t. The BCM
responds by sendi ng an el ectroni c message to the
Rai n Sensor Modul e (RSM) over the Programmabl e
Communi cati ons I nterface (PCI ) data bus i ndi cati ng
the sel ected sensi ti vi ty l evel , and by operati ng the
front wi per system based upon el ectroni c wi pe com-
mands recei ved from the RSM over the PCI data bus.
Continuous Front Wipe Modes - The control
knob on the end of the ri ght (wi per) mul ti -functi on
swi tch control stal k i s rotated to an i ntermedi ate
detent that i s one detent rearward (countercl ockwi se)
from the ful l forward (cl ockwi se) detent to sel ect the
l ow speed conti nuous front wi per mode, or to i ts ful l
forward (cl ockwi se) detent to sel ect the hi gh speed
conti nuous front wi per mode. For the l ow speed
mode, the mul ti -functi on swi tch provi des a resi stor
mul ti pl exed output to the Body Control Modul e
(BCM) on a wi ndshi el d wi per swi tch mux ci rcui t, and
the BCM responds by energi zi ng the wi per on/off
rel ay i n the Power Di stri buti on Center (PDC) for the
front l ow speed conti nuous wi pe mode. For the hi gh
speed mode, the mul ti -functi on swi tch provi des the
same resi stor mul ti pl exed output to the BCM on the
wi ndshi el d wi per swi tch mux ci rcui t as the l ow speed
mode, but al so provi des a ground output to the BCM
on a wi per hi gh control ci rcui t. The BCM responds to
these i nputs by energi zi ng the wi per on/off rel ay and
the wi per hi gh/l ow rel ay i n the PDC for the front
hi gh speed conti nuous wi pe mode.
Continuous Rear Wipe Mode - The control
ri ng on the ri ght (wi per) mul ti -functi on swi tch con-
trol stal k i s rotated to the most forward (cl ockwi se)
detent to sel ect the conti nuous rear wi per mode. The
mul ti -functi on swi tch provi des a battery current out-
put to the rear wi per motor on a rear wi per motor
control ci rcui t to si gnal the rear wi per modul e to
operate the rear wi per motor i n the conti nuous wi pe
mode.
Front Washer Mode - The control stal k of the
ri ght (wi per) mul ti -functi on swi tch i s pul l ed toward
the steeri ng wheel to momentari l y acti vate the front
washer pump/motor i n the front washer mode. The
front washer pump wi l l conti nue to operate i n the
front washer mode unti l the control stal k i s rel eased.
The ri ght (wi per) mul ti -functi on swi tch provi des a
battery current output on a washer pump motor
swi tch output ci rcui t to energi ze the front washer
pump i n the front washer mode.
Front Wiper Mist Mode - The control stal k of
the ri ght (wi per) mul ti -functi on swi tch i s pushed
towards the fl oor to momentari l y acti vate the front
wi per motor i n the mi st mode. The front wi per motor
wi l l conti nue to operate i n the mi st mode unti l the
control stal k i s rel eased. The ri ght (wi per) mul ti -
RIGHT MULTI-FUNCTION SWITCH (Continued)
functi on swi tch provi des a resi stor mul ti pl exed out-
put to the Body Control Modul e (BCM) on a
wi ndshi el d wi per swi tch mux ci rcui t, and the BCM
responds by energi zi ng the wi per on/off rel ay i n the
Power Di stri buti on Center (PDC) to operate the front
wi per motor momentari l y at l ow speed to provi de the
front wi per mi st mode.
Intermittent Front Wipe Mode - On model s
not equi pped wi th the opti onal automati c wi per sys-
tem, the control knob on the end of the ri ght (wi per)
mul ti -functi on swi tch control stal k i s rotated to one
of fi ve mi nor i ntermedi ate detents to sel ect the
desi red i ntermi ttent front wi pe del ay i nterval . The
control knob i s rotated rearward (countercl ockwi se)
to i ncrease the del ay, or forward (cl ockwi se) to
decrease the del ay. The ri ght (wi per) mul ti -functi on
swi tch provi des a resi stor mul ti pl exed output to the
Body Control Modul e (BCM) on a wi ndshi el d wi per
swi tch mux ci rcui t. The BCM responds by moni tori ng
el ectroni c vehi cl e speed messages recei ved from the
mabl e Communi cati ons I nterface (PCI ) data bus,
then energi zi ng the wi per on/off rel ay i n the Power
Di stri buti on Center (PDC) to operate the front wi per
motor at the proper del ay i nterval s.
Intermittent Rear Wipe Mode - The control
ri ng on the ri ght (wi per) mul ti -functi on swi tch con-
trol stal k i s rotated to the center detent to sel ect the
i ntermi ttent rear wi per mode. The ri ght (wi per)
mul ti -functi on swi tch provi des a battery current out-
put to the rear wi per motor on a rear wi per motor
del ay control ci rcui t to si gnal the rear wi per modul e
to operate the rear wi per i n the i ntermi ttent wi pe
mode.
Rear Washer Mode - The ri ght (wi per) mul ti -
functi on swi tch control stal k i s pushed forward
toward the i nstrument panel to a momentary posi -
ti ons to acti vate the rear washer pump/motor i n the
rear washer mode. The rear washer pump wi l l con-
ti nue to operate i n the rear washer mode unti l the
control stal k i s rel eased. The ri ght (wi per) mul ti -
functi on swi tch provi des battery current on a rear
washer pump motor control ci rcui t to energi ze the
rear washer pump i n the rear washer mode.
DIAGNOSIS AND TESTING - RIGHT MULTI-
FUNCTION SWITCH
Be certai n to perform the di agnosi s for the front
wi per system, front washer system, rear wi per sys-
tem, and/or rear washer system before testi ng the
ri ght mul ti -functi on swi tch. (Refer to 8 - ELECTRI -
CAL/FRONT WI PERS/WASHERS - DI AGNOSI S
AND TESTI NG) or (Refer to 8 - ELECTRI CAL/REAR
WI PERS/WASHERS - DI AGNOSI S AND TESTI NG).
BAGS, DISABLE THE PASSIVE RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
PASSENGER AIRBAG. SIDE CURTAIN AIRBAG,
SURE WAY TO DISABLE THE PASSIVE RESTRAINT
INJURY.
cabl e.
the steeri ng col umn and di sconnect the i nstrument
panel wi re harness connector for the swi tch from the
swi tch connector receptacl e.
(3) Usi ng an ohmmeter, check the ri ght mul ti -func-
ti on swi tch conti nui ty and resi stances at the swi tch
termi nal s as shown i n the Ri ght Mul ti -Functi on
Swi tch test chart (Fi g. 17).
RIGHT (WIPER) MULTI-FUNCTION SWITCH
FRONT WIPER/WASHER SWITCH TESTS
RESISTANCE
BETWEEN
RESISTANCE RANGE
(OHMS)
Off - Pins 7 & 8 4286-4379
Intermittent Wipe or
Sensitivity Position 1
- Pins 7 & 8 1445-1480
- Pins 7 & 8 847-870
- Pins 7 & 8 556-573
- Pins 7 & 8 367-380
- Pins 7 & 8 218-229
Low Speed - Pins 7 & 8 99-106
High Speed Pins 7 & 9 Pins 7 & 8 99-106
Mist - Pins 7 & 8 49-56
Wash Pins 1 & 3 - -
REAR WIPER/WASHER SWITCH TESTS
RESISTANCE
BETWEEN
RESISTANCE BETWEEN
Off - - -
Delay Pins 1 & 6 - -
On Pins 1 & 5 - -
Wash Pins 1 & 5 & 6 & 2 - -
Fig. 17 Right Multi-Function Switch Tests
(4) I f the ri ght mul ti -functi on swi tch fai l s any of
the conti nui ty or resi stance tests, repl ace the faul ty
ri ght mul ti -functi on swi tch as requi red.
REMOVAL
INJURY.
cabl e.
(2) Remove the screw that secures the l ower ti l ti ng
steeri ng col umn shroud to the steeri ng col umn mul ti -
functi on swi tch mounti ng housi ng (Fi g. 18).
(3) Unsnap the two hal ves of the ti l ti ng steeri ng
col umn shroud from each other and remove both
hal ves from the steeri ng col umn.
connector for the ri ght mul ti -functi on swi tch from the
(5) Remove the two screws that secure the ri ght
mul ti -functi on swi tch to the mul ti -functi on swi tch
mounti ng housi ng (Fi g. 19).
the mul ti -functi on swi tch mounti ng housi ng.
INSTALLATION
INJURY.
(1) Posi ti on the ri ght mul ti -functi on swi tch onto
the mul ti -functi on swi tch mounti ng housi ng (Fi g. 19).
the ri ght mul ti -functi on swi tch to the mul ti -functi on
4 - SCREW
Fig. 19 Right Multi-Function Switch Remove/Install
1 - STEERING COLUMN
2 - SCREWS (2)
3 - RIGHT MULTI-FUNCTION SWITCH
swi tch mounti ng housi ng. Ti ghten the screws to 2.5
Nm (22 i n. l bs.).
connector for the ri ght mul ti -functi on swi tch to the
shroud to the undersi de of the steeri ng col umn (Fi g.
18).
l ower ti l ti ng steeri ng col umn shroud to the mul ti -
functi on swi tch mounti ng housi ng. Ti ghten the screw
to 1.9 Nm (17 i n. l bs.).
(6) Posi ti on the upper ti l ti ng col umn shroud over
the steeri ng col umn wi th the hazard warni ng swi tch
button i nserted through the hol e i n the upper surface
of the shroud. Al i gn the upper ti l ti ng steeri ng col umn
shroud to the l ower shroud and snap the two shroud
hal ves together.
WASHER FLUID LEVEL
SWITCH
DESCRIPTION
The washer fl ui d l evel swi tch i s a si ngl e pol e, si n-
gl e throw reed-type swi tch mounted near the front of
the washer reservoi r, forward of the two washer
pump/motors (Fi g. 20). Onl y the mol ded pl asti c
swi tch mounti ng fl ange and connector receptacl e are
vi si bl e when the swi tch i s i nstal l ed i n the reservoi r.
A short ni ppl e formati on extends from the i nner sur-
face of the swi tch mounti ng fl ange, and a barb on the
ni ppl e near the swi tch mounti ng fl ange i s press-fi t
i nto a rubber grommet seal i nstal l ed i n the mounti ng
hol e of the reservoi r. A smal l pl asti c fl oat pi vots on
the end of a bracket that extends from the swi tch
ni ppl e formati on. Wi thi n the fl oat i s a smal l magnet,
whi ch actuates the reed swi tch. The washer fl ui d
l evel swi tch cannot be adjusted or repai red. I f faul ty
or damaged, the swi tch must be repl aced.
OPERATION
The washer fl ui d l evel swi tch uses a pi voti ng,
obl ong fl oat to moni tor the l evel of the washer fl ui d
i n the washer reservoi r. The fl oat contai ns a smal l
magnet. When the fl oat pi vots, the changi ng proxi m-
i ty of i ts magneti c fi el d wi l l cause the contacts of the
smal l , stati onary reed swi tch to open or cl ose. When
the fl ui d l evel i n the washer reservoi r i s at or above
the fl oat l evel , the fl oat moves to a verti cal posi ti on
and the swi tch contacts open. When the fl ui d l evel i n
the washer reservoi r fal l s bel ow the pi voti ng fl oat,
the fl oat moves to a hori zontal posi ti on and the
swi tch contacts cl ose. The swi tch i s connected to the
vehi cl e el ectri cal system through a dedi cated take
out and connector of the l eft headl amp and dash wi re
harness. The swi tch recei ves a fi ve vol t reference si g-
nal from the Body Control Modul e (BCM) through
the washer fl ui d swi tch output ci rcui t. The swi tch i s
grounded at al l ti mes through another take out of
the l eft headl amp and dash wi re harness wi th a si n-
gl e eyel et termi nal connector that i s secured under a
ground screw near the top of the l eft front fender
i nner shi el d i n the engi ne compartment.
When the swi tch cl oses, the BCM senses the vol t-
age change on the ci rcui t. The BCM i s programmed
to send l ow washer fl ui d messages to the El ectroni c
Vehi cl e I nformati on Center (EVI C) over the Program-
EVI C i s programmed to respond to thi s message by
di spl ayi ng the Washer Fl ui d Low warni ng and send-
i ng a chi me request message back to the BCM over
the PCI data bus. Then the BCM generates an audi -
bl e chi me tone warni ng. A resi stor wi thi n the washer
fl ui d l evel swi tch al l ows the BCM to moni tor and
di agnose thi s ci rcui t. The BCM wi l l store a Di agnos-
ti c Troubl e Code (DTC) for any faul t that i t detects.
For retri eval of thi s faul t i nformati on and further
di agnosi s of the washer fl ui d l evel swi tch, the BCM,
the EVI C, the PCI data bus, the BCM message out-
puts to the EVI C that control the Low Washer Fl ui d
i ndi cator, or the EVI C message outputs to the BCM
that control chi me servi ce, a DRBI I I scan tool and
the appropri ate di agnosti c i nformati on are requi red.
Fig. 20 Washer Fluid Level Switch (Viewed from
Bottom of Reservoir)
REMOVAL
The washer fl ui d l evel swi tch can be removed from
the washer reservoi r wi thout removi ng the reservoi r
from the vehi cl e.
cabl e.
(2) Remove the one screw that secures the washer
reservoi r fi l l er neck to the l eft i nner fender shi el d.
wheel house.
outl et ni ppl e of the rearmost (front) washer pump/
motor uni t and al l ow the washer fl ui d to drai n i nto a
cl ean contai ner for reuse.
(6) Remove the two screws that secure the i nboard
mounti ng fl ange of the washer reservoi r to the l eft
i nner wheel house.
(7) Pul l the bottom of the washer reservoi r rear-
ward far enough to access the l eft headl amp and
dash wi re harness connector for the washer fl ui d
l evel swi tch on the front of the reservoi r.
harness connector for the washer fl ui d l evel swi tch
from the swi tch connector receptacl e.
fl at-bl aded tool , gentl y pry the barbed ni ppl e of the
washer fl ui d l evel swi tch out of the rubber grommet
seal on the front of the reservoi r (Fi g. 21). Care must
be taken not to damage the reservoi r.
(10) Remove the washer fl ui d l evel swi tch and
fl oat from the washer reservoi r.
washer fl ui d l evel swi tch mounti ng hol e i n the
washer reservoi r and di scard.
INSTALLATION
washer fl ui d l evel swi tch mounti ng hol e i n the front
of the washer reservoi r. Al ways use a new rubber
grommet seal on the reservoi r.
(2) Posi ti on the fl oat of the washer fl ui d l evel
swi tch through the rubber grommet seal i n the
washer reservoi r (Fi g. 21). The connector receptacl e
of the washer fl ui d l evel swi tch shoul d be poi nted
downward.
(3) Press fi rml y and evenl y on the washer fl ui d
l evel swi tch usi ng hand pressure unti l the barbed
ni ppl e i s ful l y seated i n the rubber grommet seal i n
the washer reservoi r mounti ng hol e.
harness connector for the washer fl ui d l evel swi tch to
the swi tch connector receptacl e.
ni ppl e of the front washer pump/motor uni t.
the i nboard mounti ng fl ange of the washer reservoi r
to the l eft i nner wheel house. Ti ghten the screws to
7.4 Nm (66 i n. l bs.).
wheel house.
the washer reservoi r fi l l er neck to the l eft i nner
fender shi el d. Ti ghten the screw to 7.4 Nm (66 i n.
l bs.).
(10) Fi l l the washer reservoi r wi th the washer
procedure.
Fig. 21 Washer Fluid Level Switch Remove/Install
1 - WASHER RESERVOIR
3 - GROMMET SEAL
WASHER FLUID LEVEL SWITCH (Continued)
WASHER RESERVOIR
DESCRIPTION
A si ngl e washer fl ui d reservoi r i s used for both the
front and rear washer systems (Fi g. 22). The mol ded
pl asti c washer fl ui d reservoi r i s conceal ed between
the l eft front i nner and outer fender panel s, behi nd
the i nner fender l i ner i n front of the l eft front wheel .
The onl y vi si bl e component of the washer reservoi r i s
the fi l l er neck and cap uni t, whi ch extends through a
hol e i n the l eft front wheel house extensi on panel
i nto the engi ne compartment. A bri ght yel l ow pl asti c
fi l l er cap wi th a rubber seal and an I nternati onal
Control and Di spl ay Symbol i con for Wi ndshi el d
Washer and the text Washer Fl ui d Onl y mol ded
i nto i t snaps over the open end of the fi l l er neck. The
cap hi nges on and i s secured to a mol ded-i n hook for-
mati on on the rear of the reservoi r fi l l er neck.
There are separate, dedi cated hol es on the out-
board si de of the reservoi r provi ded for the mounti ng
of the front and rear washer/pump motor uni ts, and
another dedi cated hol e on the front of the reservoi r
for the washer fl ui d l evel swi tch. The i nboard si de of
the washer reservoi r has an i ntegral fl ange that i s
secured to the i nsi de of the l eft front fender wheel
house by two screws, whi l e an i ntegral mol ded tab
engages a sl ot i n the l eft front fender i nner shi el d to
support the outboard si de of the reservoi r. Another
screw secures the reservoi r fi l l er neck to the l eft
front fender i nner shi el d near the front of the engi ne
compartment. The l eft front fender wheel house
i nner l i ner must be removed to access the washer
reservoi r for servi ce.
The washer reservoi r cannot be repai red and, i f
faul ty or damaged, i t must be repl aced. The washer
reservoi r, the grommet seal s for the washer pump/
motor uni ts and the washer fl ui d l evel swi tch, and
the fi l l er cap are each avai l abl e for servi ce repl ace-
ment.
OPERATION
The washer fl ui d reservoi r provi des a secure,
on-vehi cl e storage l ocati on for a l arge reserve of
washer fl ui d for operati on of the front and rear
washer systems. The washer reservoi r fi l l er neck pro-
vi des a cl earl y marked and readi l y accessi bl e poi nt
from whi ch to add washer fl ui d to the reservoi r. The
front and rear washer/pump motor uni ts are l ocated
i n a sump area near the front of the reservoi r to be
certai n that washer fl ui d wi l l be avai l abl e to the
pumps as the fl ui d l evel i n the reservoi r becomes
depl eted. The front washer pump/motor uni t i s
mounted i n the l owest posi ti on i n the sump so that
the front washers wi l l operate even after the rear
washer system wi l l no l onger operate. The washer
fl ui d l evel swi tch i s mounted just above the sump
area of the reservoi r so that there wi l l be adequate
warni ng to the vehi cl e operator that the washer fl ui d
l evel i s l ow, before the washer system wi l l no l onger
operate.
REMOVAL
cabl e.
(2) Remove the ai r cl eaner housi ng from the top of
the l eft front fender wheel house. (Refer to 9 -
Fig. 22 Washer Reservoir
1 - LEFT FENDER INNER SHIELD
2 - SCREW (2)
3 - WASHER PUMP WIRE HARNESS CONNECTORS
4 - WASHER FLUID LEVEL SWITCH WIRE HARNESS
CONNECTOR
(3) Di sconnect the two washer reservoi r washer
hoses from the two engi ne compartment washer
hoses at the i nl i ne connectors l ocated on the top of
the l eft front fender wheel house (Fi g. 23).
(4) Open the washer reservoi r fi l l er cap and
unsnap the fi l l er cap hi nge from the hook on the
fi l l er neck.
(5) Remove the one screw that secures the washer
reservoi r fi l l er neck to the l eft i nner fender shi el d.
wheel house.
harness connectors for the two washer pump/motor
uni ts from the pump/motor connector receptacl es
(Fi g. 24).
(9) Remove the two screws that secure the i nboard
mounti ng fl ange of the washer reservoi r to the l eft
front i nner wheel house.
ward far enough to access the l eft headl amp and
dash wi re harness connector for the washer fl ui d
l evel swi tch on the front of the reservoi r.
harness connector for the washer fl ui d l evel swi tch
from the swi tch connector receptacl e.
ward far enough to di sengage the outboard mounti ng
tab from the mounti ng sl ot on the l eft front i nner
fender shi el d.
(13) Rotate the washer reservoi r far enough so
that the i nboard mounti ng fl ange cl ears the front
suspensi on components, then l ower the reservoi r far
enough to di sengage the fi l l er neck from the hol e i n
the l eft front wheel house extensi on.
(14) Remove the washer reservoi r from the l eft
front fender wheel house.
INSTALLATION
(1) Posi ti on the washer reservoi r i nto the l eft front
fender wheel house.
(2) Rai se the washer reservoi r fi l l er neck through
the hol e i n the l eft front fender wheel house extensi on
i nto the engi ne compartment and rotate the reservoi r
as needed to ori ent the i nboard mounti ng fl ange over
the top of the front suspensi on components.
ward far enough to engage the outboard mounti ng
tab wi th the mounti ng sl ot i n the l eft front i nner
fender shi el d (Fi g. 24).
ward far enough to access the washer fl ui d l evel
swi tch connector receptacl e on the front of the reser-
voi r.
harness connector for the washer fl ui d l evel swi tch to
the swi tch connector receptacl e.
Fig. 23 Washer Reservoir Filler Neck Mounting
2 - SCREW
3 - WASHER HOSES FROM PUMPS
4 - WASHER HOSES TO NOZZLES
Fig. 24 Washer Reservoir
2 - SCREW (2)
3 - WASHER PUMP WIRE HARNESS CONNECTORS
4 - WASHER FLUID LEVEL SWITCH WIRE HARNESS
CONNECTOR
WASHER RESERVOIR (Continued)
the i nboard mounti ng fl ange of the washer reservoi r
to the l eft i nner wheel house. Ti ghten the screws to
7.4 Nm (66 i n. l bs.).
harness connectors for the two washer pump/motor
uni ts to the pump/motor uni t connector receptacl es.
wheel house.
the washer reservoi r fi l l er neck to the l eft i nner
fender shi el d (Fi g. 23). Ti ghten the screw to 7.4 Nm
(66 i n. l bs.).
(11) Rei nstal l the washer reservoi r fi l l er cap hi nge
onto the hook on the fi l l er neck and cl ose the cap.
(12) Reconnect the two washer reservoi r washer
hoses to the two engi ne compartment washer hoses
at the i nl i ne connectors l ocated on the top of the l eft
front fender wheel house.
(13) Rei nstal l the ai r cl eaner housi ng onto the top
of the l eft front fender wheel house. (Refer to 9 -
WIPER HIGH/LOW RELAY
DESCRIPTION
The wi per hi gh/l ow rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment near the battery. The wi per hi gh/l ow rel ay i s a
conventi onal I nternati onal Standards Organi zati on
(I SO) mi cro rel ay (Fi g. 25). Rel ays conformi ng to the
functi ons. The rel ay i s contai ned wi thi n a smal l , rect-
angul ar, mol ded pl asti c housi ng and i s connected to
al l of the requi red i nputs and outputs by fi ve i ntegral
mal e spade-type termi nal s that extend from the bot-
tom of the rel ay base.
The wi per hi gh/l ow rel ay cannot be adjusted or
repai red and, i f faul ty or damaged, the uni t must be
repl aced.
OPERATION
The wi per hi gh/l ow rel ay i s an el ectromechani cal
swi tch that uses a l ow current i nput from the Body
Control Modul e (BCM) to control a hi gh current out-
put to the front wi per motor. The movabl e common
feed contact poi nt i s hel d agai nst the fi xed normal l y
cl osed contact poi nt by spri ng pressure. When the
rel ay coi l i s energi zed, an el ectromagneti c fi el d i s
produced by the coi l wi ndi ngs. Thi s el ectromagneti c
fi el d draws the movabl e rel ay contact poi nt away
from the fi xed normal l y cl osed contact poi nt, and
hol ds i t agai nst the fi xed normal l y open contact
poi nt. When the rel ay coi l i s de-energi zed, spri ng
pressure returns the movabl e contact poi nt back
agai nst the fi xed normal l y cl osed contact poi nt. A
resi stor i s connected i n paral l el wi th the rel ay coi l i n
the rel ay, and hel ps to di ssi pate vol tage spi kes and
el ectromagneti c i nterference that can be generated as
the el ectromagneti c fi el d of the rel ay coi l col l apses.
The wi per hi gh/l ow rel ay termi nal s are connected
to the vehi cl e el ectri cal system through a connector
receptacl e i n the Power Di stri buti on Center (PDC).
The i nputs and outputs of the wi per hi gh/l ow rel ay
i ncl ude:
Common Feed Terminal - The common feed
termi nal (30) i s connected to the output of the wi per
on/off rel ay at al l ti mes through the wi per on/off
rel ay output ci rcui t.
Coil Ground Terminal - The coi l ground termi -
nal (85) i s connected to a control output of the Body
Control Modul e (BCM) through a front wi per hi gh/
l ow rel ay control ci rcui t. The BCM control s front
wi per motor operati on by control l i ng a ground path
through thi s ci rcui t.
Coil Battery Terminal - The coi l battery ter-
mi nal (86) recei ves battery current at al l ti mes from
a ci rcui t breaker i n the Juncti on Bl ock (JB) through
a fused i gni ti on swi tch output (run-acc) ci rcui t.
Fig. 25 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
WASHER RESERVOIR (Continued)
Normally Open Terminal - The normal l y open
termi nal (87) i s connected to the hi gh speed brush of
the front wi per motor through a front wi per hi gh/l ow
rel ay hi gh speed output ci rcui t, and i s connected to
the hi gh speed brush whenever the rel ay i s ener-
gi zed.
Normally Closed Terminal - The normal l y
cl osed termi nal (87A) i s connected to the l ow speed
brush of the front wi per motor through a front wi per
hi gh/l ow rel ay l ow speed output ci rcui t, and i s con-
nected to the l ow speed brush whenever the rel ay i s
de-energi zed.
The wi per hi gh/l ow rel ay can be di agnosed usi ng
conventi onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - WIPER HIGH/LOW
RELAY
The wi per hi gh/l ow rel ay (Fi g. 26) i s l ocated i n the
Power Di stri buti on Center (PDC) i n the engi ne com-
partment near the battery. Refer to the appropri ate
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
(1) Remove the wi per hi gh/l ow rel ay from the
PDC. (Refer to 8 - ELECTRI CAL/WI PERS/WASH-
ERS/WI PER HI GH/LOW RELAY - REMOVAL).
and 30. I f OK, rei nstal l the rel ay and use a DRBI I I
scan tool to perform further testi ng. Refer to the
REMOVAL
cabl e.
Center (PDC) (Fi g. 27).
the undersi de of the PDC cover for wi per hi gh/l ow
rel ay i denti fi cati on and l ocati on.
(4) Remove the wi per hi gh/l ow rel ay by graspi ng i t
fi rml y and pul l i ng i t strai ght out from the receptacl e
i n the PDC.
INSTALLATION
the undersi de of the PDC cover for the proper wi per
hi gh/l ow rel ay l ocati on (Fi g. 27).
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
1 - RIGHT FENDER
2 - BATTERY
4 - COVER
WIPER HIGH/LOW RELAY (Continued)
(2) Posi ti on the wi per hi gh/l ow rel ay i n the proper
receptacl e i n the PDC.
(3) Al i gn the wi per hi gh/l ow rel ay termi nal s wi th
the termi nal cavi ti es i n the PDC receptacl e.
(4) Push fi rml y and evenl y on the top of the wi per
hi gh/l ow rel ay unti l the termi nal s are ful l y seated i n
the termi nal cavi ti es i n the PDC receptacl e.
(5) Rei nstal l the cover onto the PDC.
WIPER ON/OFF RELAY
DESCRIPTION
The wi per on/off rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC) i n the engi ne compartment
near the battery. The wi per on/off rel ay i s a conven-
ti onal I nternati onal Standards Organi zati on (I SO)
mi cro rel ay (Fi g. 28). Rel ays conformi ng to the I SO
speci fi cati ons have common physi cal di mensi ons, cur-
rent capaci ti es, termi nal patterns, and termi nal func-
ti ons. The rel ay i s contai ned wi thi n a smal l ,
rectangul ar, mol ded pl asti c housi ng and i s connected
to al l of the requi red i nputs and outputs by fi ve i nte-
gral mal e spade-type termi nal s that extend from the
bottom of the rel ay base.
The wi per on/off rel ay cannot be adjusted or
repai red and, i f faul ty or damaged, the uni t must be
repl aced.
OPERATION
The wi per on/off rel ay i s an el ectromechani cal
swi tch that uses a l ow current i nput from the Body
Control Modul e (BCM) to control a hi gh current out-
put to the front wi per motor. The movabl e common
feed contact poi nt i s hel d agai nst the fi xed normal l y
cl osed contact poi nt by spri ng pressure. When the
rel ay coi l i s energi zed, an el ectromagneti c fi el d i s
produced by the coi l wi ndi ngs. Thi s el ectromagneti c
fi el d draws the movabl e rel ay contact poi nt away
from the fi xed normal l y cl osed contact poi nt, and
hol ds i t agai nst the fi xed normal l y open contact
poi nt. When the rel ay coi l i s de-energi zed, spri ng
pressure returns the movabl e contact poi nt back
agai nst the fi xed normal l y cl osed contact poi nt. A
resi stor i s connected i n paral l el wi th the rel ay coi l i n
the rel ay, and hel ps to di ssi pate vol tage spi kes and
el ectromagneti c i nterference that can be generated as
the el ectromagneti c fi el d of the rel ay coi l col l apses.
The wi per on/off rel ay termi nal s are connected to
the vehi cl e el ectri cal system through a connector
receptacl e i n the Power Di stri buti on Center (PDC).
The i nputs and outputs of the wi per on/off rel ay
i ncl ude:
Common Feed Terminal - The common feed
termi nal (30) i s connected to the common feed termi -
nal of the wi per hi gh/l ow rel ay at al l ti mes through
the wi per on/off rel ay output ci rcui t.
Coil Ground Terminal - The coi l ground termi -
nal (85) i s connected to a control output of the Body
Control Modul e (BCM) through a front wi per on/off
rel ay control ci rcui t. The BCM control s front wi per
motor operati on by control l i ng a ground path through
thi s ci rcui t.
Coil Battery Terminal - The coi l battery ter-
mi nal (86) recei ves battery current at al l ti mes from
a ci rcui t breaker i n the Juncti on Bl ock (JB) through
a fused i gni ti on swi tch output (run-acc) ci rcui t.
Normally Open Terminal - The normal l y open
termi nal (87) recei ves battery current at al l ti mes
from a ci rcui t breaker i n the Juncti on Bl ock (JB)
through a fused i gni ti on swi tch output (run-acc) ci r-
cui t, and provi des battery current to the front wi per
on/off rel ay output ci rcui t whenever the rel ay i s ener-
gi zed.
Normally Closed Terminal - The normal l y
cl osed termi nal (87A) i s connected to the wi per park
swi tch i n the front wi per motor through the front
wi per park swi tch sense ci rcui t, and i s connected to
the wi per park swi tch whenever the rel ay i s de-ener-
gi zed.
The wi per on/off rel ay can be di agnosed usi ng con-
venti onal di agnosti c tool s and methods.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
WIPER HIGH/LOW RELAY (Continued)
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY
The wi per on/off rel ay (Fi g. 29) i s l ocated i n the
Power Di stri buti on Center (PDC) i n the engi ne com-
partment near the battery. Refer to the appropri ate
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
(1) Remove the wi per on/off rel ay from the PDC.
(Refer to 8 - ELECTRI CAL/WI PERS/WASHERS/
WI PER ON/OFF RELAY - REMOVAL).
and 30. I f OK, rei nstal l the rel ay and use a DRBI I I
scan tool to perform further testi ng. Refer to the
REMOVAL
cabl e.
the undersi de of the PDC cover for wi per on/off rel ay
i denti fi cati on and l ocati on.
(4) Remove the wi per on/off rel ay by graspi ng i t
fi rml y and pul l i ng i t strai ght out from the receptacl e
i n the PDC.
INSTALLATION
the undersi de of the PDC cover for the proper wi per
on/off rel ay l ocati on (Fi g. 30).
(2) Posi ti on the wi per on/off rel ay i n the proper
receptacl e i n the PDC.
(3) Al i gn the wi per on/off rel ay termi nal s wi th the
termi nal cavi ti es i n the PDC receptacl e.
(4) Push fi rml y and evenl y on the top of the wi per
on/off rel ay unti l the termi nal s are ful l y seated i n the
termi nal cavi ti es i n the PDC receptacl e.
(5) Rei nstal l the cover onto the PDC.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
1 - RIGHT FENDER
2 - BATTERY
4 - COVER
WIPER ON/OFF RELAY (Continued)
REAR WIPERS/WASHERS
TABLE OF CONTENTS
page page
REAR WIPERS/WASHERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . 35
CLEANING - REAR WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSPECTION - REAR WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REAR WASHER HOSES/TUBES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REAR WASHER NOZZLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR WASHER PUMP/MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
REAR WIPER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR WIPER BLADE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
REAR WIPER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
WIPER ARM PARK RAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
REAR WIPERS/WASHERS
DESCRIPTION
An el ectri cal l y operated fi xed i nterval i ntermi ttent
rear wi per and washer system i s standard factory-i n-
stal l ed equi pment on thi s model . The rear wi per and
washer system i ncl udes the fol l owi ng major compo-
nents, whi ch are descri bed i n further detai l el se-
where i n thi s servi ce i nformati on:
Rear Washer Nozzle - The rear washer nozzl e
i s secured by a snap fi t onto the top of the l i ftgate
outer panel above the l i ftgate gl ass. The rear washer
nozzl e i ncl udes an i ntegral check val ve. The rear
washer system pl umbi ng i s conceal ed wi thi n and
routed through the i nteri or of the vehi cl e.
Rear Washer Pump/Motor - The rear washer
pump/motor uni t i s l ocated i n a dedi cated hol e on the
l ower outboard si de of the washer reservoi r, ahead of
the l eft front wheel housi ng. The rear washer pump
mounti ng hol e i s l ocated hi gher on the reservoi r than
the front washer pump mounti ng hol e.
Rear Wiper Arm- The si ngl e rear wi per arm i s
secured by a nut di rectl y to the rear wi per modul e
output shaft, whi ch extends through the l i ftgate
outer panel near the base of the l i ftgate gl ass.
Rear Wiper Arm Park Ramp - The mol ded
rubber rear wi per arm park ramp i s secured wi th a
screw to the l i ftgate outer panel , just bel ow the ri ght
si de of the l i ftgate gl ass. When the rear wi per system
i s not i n operati on, the rear wi per arm i s parked on
thi s ramp so that i t wi l l not i nterfere wi th or be
damaged by l i ftgate fl i p-up gl ass operati on.
Rear Wiper Blade - The si ngl e rear wi per
bl ade i s secured to the rear wi per arm, and i s moved
off of the l i ftgate gl ass when the rear wi per system i s
not i n operati on.
Rear Wiper Module - The rear wi per modul e
output shaft i s the onl y vi si bl e component of the rear
wi per modul e. The remai nder of the modul e i s con-
ceal ed wi thi n the l i ftgate beneath the l i ftgate gl ass
openi ng. The rear wi per modul e i ncl udes the modul e
bracket, the rear wi per motor, and the rear wi per
modul e el ectroni c control ci rcui try.
Right Multi-Function Switch - The ri ght
(wi per) mul ti -functi on swi tch i s secured to the ri ght
si de of the mul ti -functi on swi tch mounti ng housi ng
near the top of the steeri ng col umn. Onl y the control
stal k for the ri ght mul ti -functi on swi tch i s vi si bl e,
the remai nder of the swi tch i s conceal ed beneath the
steeri ng col umn shrouds. The ri ght mul ti -functi on
swi tch contai ns al l of the swi tches and control ci r-
cui try for both the front and rear wi per and washer
systems.
WJ REAR WIPERS/WASHERS 8R - 33
Washer Reservoir - The rear washer system
shares a si ngl e reservoi r wi th the front washer sys-
tem, but has i ts own dedi cated washer pump/motor
and pl umbi ng. The washer reservoi r i s conceal ed
between the l eft i nner fender shi el d and the l eft
outer fender panel , behi nd the i nner fender l i ner and
ahead of the l eft front wheel . The washer reservoi r
fi l l er neck i s the onl y vi si bl e porti on of the reservoi r,
and i t i s accessed from the l eft front corner of the
Features of the rear wi per and washer system
Continuous Wipe Mode - When the ri ght
mul ti -functi on swi tch control sl eeve i s moved to the
On posi ti on, the rear wi per wi l l be operated at a
fi xed speed, conti nual wi pe cycl e unti l the swi tch
sl eeve i s moved to the Del ay or Off posi ti ons, unti l
the i gni ti on swi tch i s turned to the Off posi ti on, or
unti l the l i ftgate fl i p-up gl ass i s ajar.
Intermittent Wipe Mode - When the ri ght
Del ay posi ti on, the rear wi per wi l l be operated i n a
fi xed i nterval , i ntermi ttent wi pe cycl e unti l the
swi tch sl eeve i s moved to the On or Off posi ti ons,
unti l the l i ftgate fl i p-up gl ass i s ajar, or unti l the
ri ght mul ti -functi on swi tch control stal k i s pushed
forward to acti vate the rear washer system. The
i ntermi ttent wi pe mode del ay ti me has a fi xed del ay
i nterval of about fi ve to ei ght seconds between
sweeps.
Washer Mode - When the ri ght mul ti -functi on
swi tch control stal k i s pushed forward to acti vate the
rear washer system, washer fl ui d wi l l be di spensed
from the washer reservoi r onto the l i ftgate gl ass
through the rear washer nozzl e and the rear wi per
wi l l operate i n a fi xed cycl e (not i ntermi ttent) for as
l ong as the rear washer pump/motor uni t remai ns
energi zed. When the control stal k i s rel eased from
the momentary Wash posi ti on, the wi pe-after-wash
feature wi l l conti nue to operate the rear wi per at a
fi xed cycl e for about three addi ti onal wi per sweeps
before returni ng to the previ ousl y sel ected mode.
Hard wi red ci rcui try connects the rear wi per and
washer system components to the el ectri cal system of
vehi cl e el ectri cal system and to the rear wi per and
washer system components through the use of a com-
bi nati on of sol dered spl i ces, spl i ce bl ock connectors,
procedures, further detai l s on wi re harness routi ng
and retenti on, as wel l as pi n-out and l ocati on vi ews
for the vari ous wi re harness connectors, spl i ces and
grounds.
OPERATION
The rear wi per and washer system i s i ntended to
provi de the vehi cl e operator wi th a conveni ent, safe,
and rel i abl e means of mai ntai ni ng vi si bi l i ty through
the l i ftgate gl ass. The vari ous components of thi s sys-
tem are desi gned to convert el ectri cal energy pro-
duced by the vehi cl e el ectri cal system i nto the
mechani cal acti on of the wi per bl ade to wi pe the out-
si de surface of the gl ass, as wel l as i nto the hydraul i c
acti on of the washer system to appl y washer fl ui d
stored i n an on-board reservoi r to the area of the
gl ass to be wi ped. When combi ned, these components
provi de the means to effecti vel y mai ntai n cl ear vi si -
bi l i ty for the vehi cl e operator by removi ng excess
accumul ati ons of rai n, snow, bugs, mud, or other
mi nor debri s from the outsi de l i ftgate gl ass surface
that mi ght be encountered whi l e dri vi ng the vehi cl e
under numerous types of i ncl ement operati ng condi -
ti ons. The vehi cl e operator i ni ti ates al l rear wi per
and washer system functi ons wi th the ri ght mul ti -
functi on swi tch l ocated on the ri ght si de of the steer-
i ng col umn, just bel ow the steeri ng wheel . Movi ng
the swi tch control sl eeve to a detent posi ti on sel ects
the rear wi per system operati ng mode. Movi ng the
swi tch control stal k forward to a momentary posi ti on
acti vates the rear washer pump/motor, whi ch di s-
penses washer fl ui d onto the l i ftgate gl ass through
the rear washer nozzl e and operates the rear wi per
system i n the fi xed cycl e mode for as l ong as the
washer swi tch i s cl osed pl us about three wi per
sweeps.
When the i gni ti on swi tch i s i n the Accessory or On
posi ti ons, battery current from a fuse i n the Juncti on
Bl ock (JB) i s provi ded to the ri ght mul ti -functi on
swi tch through a fused i gni ti on swi tch output (run-
acc) ci rcui t. A separate fuse i n the JB provi des bat-
tery current to the el ectroni c control ci rcui try of the
rear wi per modul e through a fused B(+) ci rcui t.
When the ri ght mul ti -functi on swi tch control sl eeve
On posi ti on i s sel ected, the On posi ti on ci rcui try
wi thi n the swi tch di rects a battery current rear
wi per motor control si gnal i nput to the rear wi per
modul e el ectroni c ci rcui try, whi ch causes the rear
wi per motor to run at a fi xed conti nuous wi pe cycl e.
When the ri ght mul ti -functi on swi tch control sl eeve
Del ay posi ti on i s sel ected, the Del ay posi ti on ci r-
cui try wi thi n the swi tch di rects a battery current
rear washer swi tch output si gnal i nput to the rear
wi per modul e el ectroni c ci rcui try, whi ch causes the
rear wi per motor to run at a fi xed i ntermi ttent wi pe
cycl e. When the ri ght mul ti -functi on swi tch control
8R - 34 REAR WIPERS/WASHERS WJ
REAR WIPERS/WASHERS (Continued)
stal k i s moved to the rear Wash posi ti on, the Wash
posi ti on ci rcui try wi thi n the swi tch di rects battery
current to the rear washer pump/motor uni t, and to
both the rear wi per motor control and rear washer
swi tch output si gnal i nputs of the rear wi per modul e
el ectroni c ci rcui try, whi ch causes the wi per motor to
run at a fi xed cycl e for as l ong as the Wash mode i s
sel ected pl us about three addi ti onal fi xed wi pe cycl es.
The rear wi per modul e el ectroni c ci rcui try control s
the swi tchi ng of battery current to the rear wi per
motor brush, whi ch control s wi per motor operati on.
The i ntermi ttent wi pe and wi pe-after-wash features
of the rear wi per and washer system are both pro-
vi ded by the rear wi per modul e el ectroni c ci rcui try.
The rear wi per modul e el ectroni c ci rcui try al so mon-
i tors the l i ftgate fl i p-up gl ass ajar swi tch and wi l l
park the rear wi per bl ade off of the gl ass any ti me i t
senses that the l i ftgate fl i p-up gl ass i s ajar, the i gni -
ti on swi tch i s turned to the Off posi ti on, or the ri ght
Off posi ti on. Thi s feature ensures that the rear wi per
bl ade wi l l not i nterfere wi th or be damaged by the
operati on of the l i ftgate fl i p-up gl ass. However, i f the
i gni ti on swi tch i s turned to the Off posi ti on or the
l i ftgate fl i p-up gl ass i s opened whi l e the rear wi per i s
operati ng, the ri ght mul ti -functi on swi tch control
sl eeve must be cycl ed to the Off posi ti on and back to
the On or Del ay posi ti on after the i gni ti on swi tch i s
turned back On or the l i ftgate fl i p-up gl ass i s cl osed
before the rear wi per wi l l operate agai n.
Refer to the owners manual i n the vehi cl e gl ove
box for more i nformati on on the features and opera-
ti on of the rear wi per and washer system.
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SYSTEM
WIPER SYSTEM
i noperati ve rear wi per system. I f the rear wi per
motor operates, but the wi per does not move on the
l i ftgate gl ass, repl ace the faul ty rear wi per modul e. I f
the wi per operates, but chatters, l i fts, or does not
cl ear the gl ass, cl ean and i nspect the wi per system
components as requi red. (Refer to 8 - ELECTRI CAL/
REAR WI PERS/WASHERS - I NSPECTI ON) and
(Refer to 8 - ELECTRI CAL/REAR WI PERS/WASH-
ERS - CLEANI NG). Refer to the appropri ate wi ri ng
i nformati on. The wi ri ng i nformati on i ncl udes wi ri ng
grounds.
INJURY.
(1) Check that the i nteri or l i ghti ng swi tch on the
control stal k of the l eft mul ti -functi on swi tch i s not
i n the dome l amp di sabl e posi ti on. Wi th al l four
doors and the l i ftgate cl osed, open the l i ftgate fl i p-up
gl ass. The i nteri or l amps shoul d l i ght. I f not, depress
the cargo l amp l ens to actuate the cargo l amp defeat
swi tch and the i nteri or l amps shoul d l i ght. Cl ose al l
four doors, the l i ftgate and the l i ftgate fl i p-up gl ass.
Note whether the i nteri or l amps remai n l i ghted.
They shoul d turn off after about thi rty seconds. I f
OK, go to Step 2. I f not OK, go to Step 9.
(2) Check the fused B(+) fuse (Fuse 8 - 15 ampere)
i n the Juncti on Bl ock (JB). I f OK, go to Step 3. I f not
(Fuse 8 - 15 ampere) i n the JB. I f OK, go to Step 4. I f
not OK, repai r the open fused B(+) ci rcui t between
the JB and the Power Di stri buti on Center (PDC) as
requi red.
(4) Check the fused i gni ti on swi tch output (run-
acc) fuse (Fuse 29 - 10 ampere) i n the JB. I f OK, go
to Step 5. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
output (run-acc) fuse (Fuse 29 - 10 ampere) i n the
JB. I f OK, turn the i gni ti on swi tch to the Off posi ti on
and go to Step 6. I f not OK, repai r the open fused
i gni ti on swi tch output (run-acc) ci rcui t between the
JB and the i gni ti on swi tch as requi red.
connector for the ri ght mul ti -functi on swi tch from the
swi tch connector receptacl e. Reconnect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
posi ti on. Check for battery vol tage at the fused i gni -
ti on swi tch output (run-acc) ci rcui t cavi ty of the
ri ght mul ti -functi on swi tch. I f OK, go to Step 7. I f
not OK, repai r the open fused i gni ti on swi tch output
(run-acc) ci rcui t between the ri ght mul ti -functi on
swi tch and the JB as requi red.
Test the ri ght mul ti -functi on swi tch. (Refer to 8 -
ELECTRI CAL/FRONT WI PERS/WASHERS/RI GHT
MULTI -FUNCTI ON SWI TCH - DI AGNOSI S AND
TESTI NG). I f the ri ght mul ti -functi on swi tch tests
OK, reconnect the i nstrument panel wi re harness
connector for the ri ght mul ti -functi on swi tch to the
swi tch connector receptacl e and go to Step 8. I f the
ri ght mul ti -functi on swi tch does not test OK, repl ace
the faul ty swi tch.
(8) Remove the l i ftgate i nner tri m panel . Di scon-
nect the l i ftgate wi re harness connector for the rear
wi per modul e from the modul e connector receptacl e.
i ty of the l i ftgate wi re harness connector for the rear
wi per modul e and a good ground. There shoul d be
open ground ci rcui t to ground (G301) as requi red.
(9) Check for conti nui ty between the l i ftgate
fl i p-up gl ass ajar swi tch sense ci rcui t cavi ty of the
l i ftgate wi re harness connector for the rear wi per
modul e and a good ground. There shoul d be conti nu-
i ty wi th the l i ftgate fl i p-up gl ass open, and no conti -
nui ty wi th the l i ftgate fl i p-up gl ass cl osed. I f OK, go
to Step 10. I f not OK, repai r the l i ftgate fl i p-up gl ass
ajar ci rcui t as requi red.
(10) Reconnect the battery negati ve cabl e. Check
for battery vol tage at the fused B(+) ci rcui t cavi ty of
the l i ftgate wi re harness connector for the rear wi per
modul e. I f OK, go to Step 11. I f not OK, repai r the
open fused B(+) ci rcui t between the rear wi per mod-
ul e and the JB as requi red.
Turn the ri ght mul ti -functi on swi tch control sl eeve to
the Del ay posi ti on. Check for battery vol tage at the
rear washer swi tch output ci rcui t cavi ty of the l i ft-
gate wi re harness connector for the rear wi per mod-
ul e. I f OK, go to Step 12. I f not OK, repai r the open
rear washer swi tch output ci rcui t between the rear
wi per modul e and the ri ght mul ti -functi on swi tch as
requi red.
(12) Turn the ri ght mul ti -functi on swi tch control
sl eeve to the On posi ti on. Check for battery vol tage
at the rear wi per motor control ci rcui t cavi ty of the
l i ftgate wi re harness connector for the rear wi per
modul e. I f OK, repl ace the faul ty rear wi per modul e.
I f not OK, repai r the open rear wi per motor control
ci rcui t between the rear wi per modul e and the ri ght
mul ti -functi on swi tch as requi red.
WASHER SYSTEM
i noperati ve rear washer system. I f the rear washer
pump/motor operates, but no washer fl ui d i s emi tted
from the rear washer nozzl e, be certai n to check the
fl ui d l evel i n the reservoi r. Al so i nspect the washer
system components as requi red. (Refer to 8 - ELEC-
TRI CAL/REAR WI PERS/WASHERS - I NSPECTI ON).
INJURY.
Turn the ri ght mul ti -functi on swi tch control sl eeve to
the On posi ti on. Check whether the rear wi per sys-
tem i s operati ng. I f OK, go to Step 2. I f not OK, test
and repai r the rear wi per system before conti nui ng
wi th these tests. Refer to WI PER SYSTEM .
Di sconnect the l eft headl amp and dash wi re harness
connector for the rear washer pump/motor uni t from
the pump/motor uni t connector receptacl e. Check for
conti nui ty between the ground ci rcui t cavi ty of the
l eft headl amp and dash wi re harness connector for
the rear washer pump/motor uni t and a good ground.
OK, repai r the open ground ci rcui t to ground (G106)
as requi red.
i gni ti on swi tch to the On posi ti on. Push the ri ght
mul ti -functi on swi tch control stal k toward the i nstru-
ment panel to actuate the rear washer swi tch. Wi th
the rear washer swi tch actuated, check for battery
vol tage at the rear washer swi tch output ci rcui t cav-
i ty of the l eft headl amp and dash wi re harness con-
nector for the rear washer pump/motor uni t. I f OK,
repl ace the faul ty rear washer pump/motor uni t. I f
not OK, repai r the open rear washer swi tch output
ci rcui t between the rear washer pump/motor uni t
and the ri ght mul ti -functi on swi tch as requi red.
CLEANING - REAR WIPER & WASHER SYSTEM
WIPER SYSTEM
The squeegee of a wi per bl ade exposed to the el e-
ments for a l ong ti me tends to l ose i ts wi pi ng effec-
ti veness. Peri odi c cl eani ng of the squeegee i s
suggested to remove any deposi ts of sal t or road fi l m.
The wi per bl ade, arm, and l i ftgate gl ass shoul d onl y
be cl eaned usi ng a sponge or soft cl oth and wi nd-
shi el d washer fl ui d, a mi l d detergent, or a non-abra-
si ve cl eaner. I f the wi per bl ade conti nues to l eave
streaks, smears, hazi ng, or beadi ng on the gl ass after
thorough cl eani ng of the squeegees and the gl ass, the
enti re wi per bl ade assembl y must be repl aced.
CAUTION: Protect the rubber squeegee of the wiper
blade from any petroleum-based cleaners, solvents,
or contaminants. These products can rapidly deteri-
orate the rubber squeegee.
WASHER SYSTEM
I f the washer system i s contami nated wi th forei gn
materi al , drai n the washer reservoi r by removi ng the
front washer pump/motor from the reservoi r. Cl ean
forei gn materi al from the i nsi de of the washer reser-
voi r usi ng cl ean washer fl ui d, a mi l d detergent, or a
non-abrasi ve cl eaner. Fl ush forei gn materi al from the
washer system pl umbi ng by fi rst di sconnecti ng the
washer hose from the washer nozzl e, then runni ng
the washer pump/motor to run cl ean washer fl ui d or
water through the system. A pl ugged or restri cted
washer nozzl e shoul d be careful l y back-fl ushed usi ng
compressed ai r. I f the washer nozzl e obstructi on can-
not be cl eared, repl ace the washer nozzl e.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegee of the wiper blade.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - REAR WIPER & WASHER
SYSTEM
WIPER SYSTEM
The rear wi per bl ade and wi per arm shoul d be
i nspected peri odi cal l y, not just when wi per perfor-
(1) I nspect the wi per arm for any i ndi cati ons of
damage, or contami nati on. I f the wi per arm i s con-
tami nated wi th any forei gn materi al , cl ean as
requi red. (Refer to 8 - ELECTRI CAL/REAR WI PERS/
WASHERS - CLEANI NG). I f a wi per arm i s damaged
or corrosi on i s evi dent, repl ace the wi per arm wi th a
new uni t. Do not attempt to repai r a wi per arm that
i s damaged or corroded.
(2) Careful l y l i ft the wi per arm off of the ramp.
Note the acti on of the wi per arm hi nge. The wi per
arm shoul d pi vot freel y at the hi nge, but wi th no l at-
eral l ooseness evi dent. I f there i s any bi ndi ng evi dent
i n the wi per arm hi nge, or there i s evi dent l ateral
pl ay i n the wi per arm hi nge, repl ace the wi per arm.
(3) Once proper hi nge acti on of the wi per arm i s
confi rmed, check the hi nge for proper spri ng tensi on.
The spri ng tensi on of the wi per arm shoul d be suffi -
ci ent to cause the rubber squeegee to conform to the
curvature of the gl ass. Repl ace a wi per arm i f i t has
l ow or no spri ng tensi on.
(4) I nspect the wi per bl ade and squeegee for any
i ndi cati ons of damage, contami nati on, or rubber dete-
ri orati on (Fi g. 1). I f the wi per bl ade or squeegee i s
contami nated wi th any forei gn materi al , cl ean them
and the gl ass as requi red. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS - CLEANI NG). I f
after cl eani ng the wi per bl ade and the gl ass, the
wi per bl ade fai l s to cl ear the gl ass wi thout smeari ng,
streaki ng, chatteri ng, hazi ng, or beadi ng, repl ace the
wi per bl ade. Al so, i f a wi per bl ade i s damaged or i f
the squeegee rubber i s damaged or deteri orated,
repl ace the wi per bl ade wi th a new uni t. Do not
attempt to repai r a wi per bl ade that i s damaged.
WASHER SYSTEM
The washer system components shoul d be
i nspected peri odi cal l y, not just when washer perfor-
(1) Check for i ce or other forei gn materi al i n the
washer reservoi r. I f contami nated, cl ean and fl ush
the washer system. (Refer to 8 - ELECTRI CAL/
REAR WI PERS/WASHERS - CLEANI NG).
(2) I nspect the washer pl umbi ng for pi nched, l eak-
i ng, deteri orated, or i ncorrectl y routed hoses and
damaged or di sconnected hose fi tti ngs. Repl ace dam-
aged or deteri orated hoses and hose fi tti ngs. Leaki ng
washer hoses can someti mes be repai red by cutti ng
the hose at the l eak and spl i ci ng i t back together
usi ng an i n-l i ne connector fi tti ng. Si mi l arl y, secti ons
of deteri orated hose can be cut out and repl aced by
spl i ci ng i n new secti ons of hose usi ng i n-l i ne connec-
tor fi tti ngs. Whenever routi ng a washer hose or a
routed away from hot, sharp, or movi ng parts. Al so,
sharp bends that mi ght pi nch the washer hose must
be avoi ded.
REAR WASHER HOSES/TUBES
DESCRIPTION
The rear washer pl umbi ng consi sts of smal l di am-
eter rubber hoses and mol ded pl asti c i nl i ne connector
fi tti ngs (Fi g. 2). The washer reservoi r hose i s con-
nected to the barbed outl et ni ppl e of the rear washer
pump/motor uni t bel ow the l eft front wheel house
extensi on and routed up the washer reservoi r fi l l er
neck to the engi ne compartment. Just rearward of
the washer reservoi r fi l l er neck i n the engi ne com-
partment, an i nl i ne connector wi th barbed ni ppl es
joi ns the reservoi r hose to the engi ne compartment
hose. The engi ne compartment hose i s routed al ong
the top of the l eft front fender wheel house to the
dash panel . The engi ne compartment hose passes
through a hol e wi th a rubber grommet i n the dash
panel i nto the passenger compartment. Bel ow the
i nstrument panel i n the passenger compartment near
the l eft cowl si de i nner panel , another i nl i ne connec-
tor joi ns the engi ne compartment hose to the A-pi l l ar
hose. The A-pi l l ar hose i s routed up the l eft A-pi l l ar
to the headl i ner. At the headl i ner, an i nl i ne connector
joi ns the A-pi l l ar hose to the headl i ner hose. The
headl i ner hose i s routed above the headl i ner and
Fig. 1 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
Fig. 2 Rear Washer Plumbing
1 - UPPER COWL PLENUM PANEL
2 - WASHER HOSE FROM ENGINE COMPARTMENT
3 - A-PILLAR WASHER HOSE
4 - HEADLINER WASHER HOSE
al ong the l eft roof si de rai l to the rear of the vehi cl e.
At the rear of the vehi cl e, the headl i ner hose i s
routed above the headl i ner and al ong the upper l i ft-
gate openi ng panel toward the ri ght si de of the vehi -
cl e. The headl i ner hose then passes through a hol e
wi th a rubber grommet i n the upper l i ftgate openi ng
panel and through another hol e wi th a rubber grom-
met i nto the upper i nner l i ftgate panel to the rear
washer nozzl e.
Washer hose i s avai l abl e for servi ce onl y as rol l
stock, whi ch must then be cut to l ength. The head-
l i ner washer hose i s i ntegral to the headl i ner uni t
and, i f faul ty or damaged, the headl i ner uni t must be
repl aced. The mol ded pl asti c washer hose fi tti ngs
cannot be repai red. I f these fi tti ngs are faul ty or
damaged, they must be repl aced.
OPERATION
Washer fl ui d i n the washer reservoi r i s pressuri zed
and fed by the rear washer pump/motor through the
rear washer system pl umbi ng and fi tti ngs to the rear
washer nozzl e on the l i ftgate outer panel above the
l i ftgate gl ass. Whenever routi ng the washer hose or a
routed away from hot, sharp, or movi ng parts; and,
sharp bends that mi ght pi nch the hose must be
avoi ded.
REAR WASHER NOZZLE
DESCRIPTION
The rear washer nozzl e i s a fl ui di c type uni t that
i ncl udes an i ntegral check val ve (Fi g. 3). The nozzl e
i s constructed of mol ded pl asti c and has a rubber
seal and i ntegral snap features on the back of i t. The
nozzl e i s secured by a snap fi t i n a dedi cated mount-
i ng hol e i n the l i ftgate outer panel above the l i ftgate
fl i p-up gl ass. Wi thi n the rear nozzl e body, a smal l
check bal l i s hel d agai nst an i ntegral val ve seat at
the i nl et end of the nozzl e by a smal l coi l ed spri ng.
The rear washer nozzl e and check val ve uni t cannot
be adjusted or repai red. I f faul ty or damaged, the
enti re nozzl e and check val ve uni t must be repl aced.
OPERATION
The rear washer nozzl e i s desi gned to di spense
washer fl ui d i nto the wi per pattern area on the out-
si de of the l i ftgate gl ass. Pressuri zed washer fl ui d i s
fed to the nozzl e from the washer reservoi r by the
rear washer pump/motor through a si ngl e hose,
whi ch i s attached to a barbed ni ppl e on the back of
the rear washer nozzl e. The rear washer nozzl e
i ncorporates a fl ui di c desi gn, whi ch causes the nozzl e
to emi t the pressuri zed washer fl ui d as an osci l l ati ng
stream to more effecti vel y cover a l arger area of the
gl ass area to be cl eaned. The i ntegral rear nozzl e
check val ve prevents washer fl ui d from drai ni ng out
of the rear washer suppl y hoses back to the washer
reservoi r. Thi s drai n-back woul d resul t i n a l engthy
del ay from when the rear washer swi tch i s actuated
unti l washer fl ui d was di spensed through the rear
washer nozzl e, because the rear washer pump woul d
have to refi l l the rear washer pl umbi ng from the res-
ervoi r to the nozzl e. The check val ve al so prevents
washer fl ui d from si phoni ng through the rear washer
nozzl e after the rear washer system i s turned Off.
When the rear washer pump pressuri zes and pumps
washer fl ui d from the reservoi r through the rear
washer pl umbi ng, the fl ui d pressure overri des the
spri ng pressure appl i ed to the check bal l wi thi n the
val ve and unseats the check bal l , al l owi ng washer
fl ui d to fl ow to the rear washer nozzl e. When the
rear washer pump stops operati ng, spri ng pressure
seats the check bal l i n the val ve and fl ui d fl ow i n
ei ther di recti on wi thi n the rear washer pl umbi ng i s
prevented.
REMOVAL
The check val ve for the rear washer nozzl e i s i nte-
gral to the nozzl e.
fl at-bl aded tool , gentl y pry at the si des of the rear
washer nozzl e to rel ease the snap features that
secure i t i n the mounti ng hol e of the l i ftgate outer
panel .
Fig. 3 Rear Washer Nozzle
2 - ROOF PANEL
3 - REAR WASHER NOZZLE
4 - LIFTGATE
REAR WASHER HOSES/TUBES (Continued)
(2) Pul l the rear washer nozzl e out from the l i ft-
gate outer panel far enough to access the washer
suppl y hose (Fi g. 4).
(3) Di sconnect the washer suppl y hose from the
barbed ni ppl e of the rear washer nozzl e.
(4) Remove the rear washer nozzl e from the l i ft-
gate.
INSTALLATION
(1) Posi ti on the rear washer nozzl e to the l i ftgate
(Fi g. 4).
(2) Reconnect the washer suppl y hose to the
barbed ni ppl e of the rear washer nozzl e.
(3) I nsert the rear washer nozzl e suppl y hose and
ni ppl e i nto the mounti ng hol e i n the l i ftgate outer
panel .
(4) Usi ng hand pressure, push fi rml y and evenl y
on the rear washer nozzl e unti l the snap features
l ock i nto pl ace on the i nsi de of the l i ftgate outer
panel mounti ng hol e.
REAR WASHER PUMP/MOTOR
DESCRIPTION
The rear washer pump/motor uni t i s l ocated on the
outboard si de and near the rear of the washer reser-
voi r, between the l eft front i nner and outer fender
panel s (Fi g. 5). A smal l permanentl y l ubri cated and
seal ed el ectri c motor i s coupl ed to the rotor-type
washer pump. A seal fl ange wi th a l arge barbed i nl et
ni ppl e on the pump housi ng passes through a rubber
grommet seal i nstal l ed i n one of two dedi cated
mounti ng hol es near the bottom of the washer reser-
voi r. The rear washer pump/motor uni t i s al ways
mounted i n the hi gher pump mounti ng hol e of the
reservoi r. A smal l er barbed outl et ni ppl e on the pump
housi ng connects the uni t to the rear washer hose.
The washer pump/motor uni t i s retai ned on the res-
ervoi r by the i nterference fi t between the barbed
pump i nl et ni ppl e and the grommet seal , whi ch i s a
l i ght press fi t. An i ntegral el ectri cal connector recep-
tacl e i s l ocated on the top of the motor housi ng. The
rear washer pump/motor uni t cannot be repai red. I f
faul ty or damaged, the enti re washer pump/motor
OPERATION
The rear washer pump/motor uni t i s connected to
the vehi cl e el ectri cal system through a si ngl e take
out and two-cavi ty connector of the l eft headl amp
and dash wi re harness. The washer pump/motor i s
grounded at al l ti mes through a take out of the l eft
headl amp and dash wi re harness wi th a si ngl e eyel et
termi nal connector that i s secured under a ground
screw to the top of the l eft i nner fender shi el d i n the
engi ne compartment. The rear washer pump/motor
recei ves battery current on a fused i gni ti on swi tch
output (run-acc) ci rcui t through the cl osed contacts of
the momentary rear washer swi tch wi thi n the ri ght
mul ti -functi on swi tch onl y when the swi tch control
stal k i s pushed towards the i nstrument panel .
Washer fl ui d i s gravi ty-fed from the washer reservoi r
to the i nl et si de of the washer pump. When the pump
motor i s energi zed, the rotor-type pump pressuri zes
Fig. 4 Rear Washer Nozzle Remove/Install
2 - ROOF PANEL
3 - REAR WASHER NOZZLE
4 - LIFTGATE
Reservoir)
REAR WASHER NOZZLE (Continued)
the washer fl ui d and forces i t through the pump out-
l et ni ppl e, the rear washer pl umbi ng, and the rear
washer nozzl e onto the l i ftgate gl ass.
REMOVAL
cabl e.
wheel house.
harness connector for the rear washer pump/motor
from the motor connector receptacl e (Fi g. 6).
outl et ni ppl e of the rear washer pump/motor and
al l ow the washer fl ui d to drai n i nto a cl ean contai ner
for reuse.
fl at-bl aded tool , gentl y pry the barbed i nl et ni ppl e of
the washer pump out of the rubber grommet seal i n
the reservoi r. Care must be taken not to damage the
reservoi r.
washer pump mounti ng hol e i n the washer reservoi r
and di scard.
INSTALLATION
washer pump mounti ng hol e i n the washer reservoi r.
Al ways use a new rubber grommet seal on the reser-
voi r.
(2) Posi ti on the barbed i nl et ni ppl e of the washer
pump to the rubber grommet seal i n the reservoi r
(Fi g. 6).
(3) Press fi rml y and evenl y on the washer pump
unti l the barbed i nl et ni ppl e i s ful l y seated i n the
rubber grommet seal i n the washer reservoi r mount-
i ng hol e.
ni ppl e of the washer pump.
harness connector for the rear washer pump/motor
uni t to the motor connector receptacl e.
wheel house.
(8) Refi l l the washer reservoi r wi th the washer
procedure.
REAR WIPER ARM
DESCRIPTION
The rear wi per arm i s the ri gi d member l ocated
between the rear wi per motor output shaft that pro-
trudes from the outer l i ftgate panel near the base of
the l i ftgate gl ass openi ng and the rear wi per bl ade
(Fi g. 7). Thi s wi per arm features an over-center
hi nge that al l ows easy access to the l i ftgate and l i ft-
gate gl ass for cl eani ng. The wi per arm has a di e cast
metal pi vot end. Thi s pi vot end has a hol e i n i t wi th
i nternal serrati ons and a pl asti c pi vot cover i s
Reservoir)
Fig. 7 Rear Wiper Arm
1 - LIFTGATE
2 - REAR WIPER MOTOR OUTPUT SHAFT
3 - PARK RAMP
4 - PIVOT COVER
5 - REAR WIPER ARM
6 - NUT
REAR WASHER PUMP/MOTOR (Continued)
secured l oosel y to and pi vots on the wi per arm hi nge
pi n to conceal the wi per arm retai ni ng nut. The wi de
end of a tapered, stamped steel channel i s secured
wi th a hi nge pi n to the pi vot end of the wi per arm.
One end of a l ong, ri gi d, stamped steel strap, wi th a
smal l hol e near i ts pi vot end, i s ri veted and cri mped
wi thi n the narrow end of the stamped steel channel .
The ti p of the wi per bl ade end of thi s strap i s bent
back under i tsel f to form a smal l hook. Conceal ed
wi thi n the stamped steel channel , one end of a l ong
spri ng i s engaged wi th a wi re hook on the undersi de
of the di e cast pi vot end, whi l e the other end of the
spri ng i s hooked through the smal l hol e i n the steel
strap. A mol ded pl asti c wi per arm support i s snapped
onto the wi per arm strap where i t exi ts the channel .
The enti re wi per arm has a sati n bl ack fi ni sh appl i ed
to al l of i ts vi si bl e surfaces.
A wi per arm cannot be adjusted or repai red. I f
damaged or faul ty, the enti re wi per arm uni t must be
repl aced.
OPERATION
The rear wi per arm i s desi gned to mechani cal l y
transmi t the moti on from the rear wi per motor out-
put shaft to the rear wi per bl ade. The wi per arm
must be properl y i ndexed to the motor output shaft
i n order to mai ntai n the proper wi per bl ade travel on
the gl ass. The wi per arm support i s desi gned to l i ft
and support the rear wi per arm and bl ade off of the
gl ass when the rear wi per bl ade i s parked. Thi s sup-
port and the park ramp on the l i ftgate outer panel
bel ow the gl ass al so provi de an al i gnment reference
to ensure accurate rear wi per arm and bl ade i nstal -
l ati on. The hol e wi th i nternal serrati ons i n the wi per
arm pi vot end i nterl ocks wi th the serrati ons on the
outer ci rcumference of the motor output shaft, al l ow-
i ng posi ti ve engagement and fi ni te adjustment of thi s
connecti on. A hex nut secures the wi per arm pi vot
end to the threads on the motor output shaft and the
pi vot cover hi nges and snaps over thi s connecti on for
a neat appearance. The spri ng-l oaded wi per arm
hi nge control s the down-force appl i ed through the ti p
of the wi per arm to the wi per bl ade on the gl ass. The
hook formati on on the ti p of the wi per arm provi des
a cradl e for securi ng and l atchi ng the wi per bl ade
pi vot bl ock to the wi per arm.
REMOVAL
(1) Li ft the rear wi per arm pi vot cover by l i fti ng i t
at the rear wi per motor output shaft end of the arm
(Fi g. 8).
(2) Remove the nut that secures the rear wi per
arm to the rear wi per motor output shaft.
(3) Li ft the rear wi per arm far enough to engage
the over-center arm hi nge i n i ts upri ght posi ti on to
hol d the wi per bl ade off of the l i ftgate.
(4) Use a battery termi nal pul l er to di sengage the
wi per arm from the rear wi per motor output shaft
spl i nes (Fi g. 9).
(5) Remove the rear wi per arm pi vot end from the
motor output shaft.
INSTALLATION
NOTE: Always install the wiper arm and blade with
the wiper motor in the Park position.
Fig. 8 Rear Wiper Arm Remove/Install
1 - LIFTGATE
3 - PARK RAMP
4 - PIVOT COVER
5 - REAR WIPER ARM
6 - NUT
Fig. 9 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT
REAR WIPER ARM (Continued)
(1) The rear wi per arm must be i ndexed to the
motor output shaft wi th the rear wi per motor i n the
park posi ti on to be properl y i nstal l ed. Pl ace the
wi per arm onto the l i ftgate wi th the wi per arm sup-
port posi ti oned on the park ramp and the pi vot hol e
on the end of the arm posi ti oned over the rear wi per
motor output shaft.
(2) Posi ti on the ri dge of the wi per arm support on
the l i ftgate park ramp i n the I nstal l ati on Posi ti on
(Fi g. 10).
(3) Wi th the wi per arm i n the I nstal l ati on Posi -
ti on, push the pi vot hol e on the end of the wi per arm
down over the rear wi per motor output shaft.
rear wi per arm to the rear wi per motor output shaft.
Ti ghten the nut to 18 Nm (160 i n. l bs.).
(5) Cl ose the rear wi per arm pi vot cover.
(6) Li ft the rear wi per arm support away from the
park ramp, then pl ace the wi per arm support i n the
park ramp i n the Park Posi ti on (Fi g. 10).
REAR WIPER BLADE
DESCRIPTION
The rear wi per bl ade i s secured by an i ntegral
l atchi ng pi vot bl ock to the hook formati on on the ti p
of the rear wi per arm, and rests off the gl ass near
the base of the l i ftgate gl ass openi ng when the wi per
i s not i n operati on. The wi per bl ade consi sts of the
fol l owi ng components:
Superstructure - The superstructure i ncl udes
a stamped steel bri dge and pl asti c l i nks wi th cl aw
formati ons that gri p the wi per bl ade el ement. Al so
i ncl uded i n thi s uni t i s the l atchi ng, mol ded pl asti c
pi vot bl ock that secures the superstructure to the
wi per arm. Al l of the metal components of the wi per
bl ade have a sati n bl ack fi ni sh appl i ed.
Element - The wi per el ement or squeegee i s the
resi l i ent rubber member of the wi per bl ade that con-
tacts the gl ass.
Flexor - The fl exor i s a ri gi d metal component
runni ng al ong the l ength of each si de of the wi per
el ement where i t i s gri pped by the cl aws of the
superstructure.
Al l Grand Cherokee model s have a si ngl e 31.00
centi meter (12.20 i nch) rear wi per bl ade wi th a non-
repl aceabl e rubber el ement (squeegee). The wi per
bl ade cannot be adjusted or repai red. I f faul ty, worn,
or damaged the enti re wi per bl ade uni t must be
repl aced.
OPERATION
The wi per bl ade i s moved back and forth across the
gl ass by the wi per arm when the wi per system i s i n
operati on. The wi per bl ade superstructure i s the fl ex-
i bl e frame that gri ps the wi per bl ade el ement and
evenl y di stri butes the force of the spri ng-l oaded
wi per arm al ong the l ength of the el ement. The com-
bi nati on of the wi per arm force and the fl exi bi l i ty of
the superstructure makes the el ement conform to
and mai ntai n proper contact wi th the gl ass, even as
the bl ade i s moved over the vari ed curvature found
across the gl ass surface. The wi per el ement fl exor
provi des the cl aws of the bl ade superstructure wi th a
ri gi d, yet fl exi bl e component on the el ement whi ch
can be gri pped. The rubber el ement i s desi gned to be
sti ff enough to mai ntai n an even cl eani ng edge as i t
i s drawn across the gl ass, but resi l i ent enough to
conform to the gl ass surface and fl i p from one cl ean-
i ng edge to the other each ti me the wi per bl ade
changes di recti ons.
Fig. 10 Rear Wiper Arm Installation
1 - LIFTGATE
2 - PARK RAMP
3 - REAR WIPER ARM
4 - INSTALLATION POSITION
5 - REAR WIPER ARM AND BLADE
6 - PARK POSITION
7 - PARK RAMP
8 - LIFTGATE
REAR WIPER ARM (Continued)
REMOVAL
the wiper blade that is nearest to the wiper motor
output shaft.
(1) Di sengage the rear wi per arm support from the
rubber rear wi per arm park ramp on the ri ght si de of
the l i ftgate just bel ow the l i ftgate gl ass.
(2) Li ft the rear wi per arm to engage the arm
hi nge i n i ts over-center posi ti on wi th the wi per bl ade
and el ement off of the l i ftgate and the gl ass.
(3) To remove the wi per bl ade from the wi per arm,
push the pi vot bl ock l atch rel ease tab under the ti p
of the arm and sl i de the bl ade away from the ti p
towards the pi vot end of the arm far enough to di s-
engage the pi vot bl ock from the hook (Fi g. 11).
(4) Extract the hook formati on on the ti p of the
wi per arm from the openi ng i n the wi per bl ade
l atch uni t.
back against the liftgate or the glass without the
wiper blade in place or they may be damaged.
(5) Gentl y l ower the wi per arm and pl ace the arm
support i n the park ramp.
INSTALLATION
the wiper blade that is nearest to the wiper motor
output shaft.
(1) Li ft the rear wi per arm off of the l i ftgate park
ramp.
(2) Posi ti on the rear wi per bl ade near the hook for-
mati on on the ti p of the arm wi th the notched
retai ner for the wi per el ement ori ented towards the
end of the wi per arm that i s nearest to the wi per
motor output shaft.
(3) I nsert the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
l atch uni t far enough to engage the pi vot bl ock wi th
the hook (Fi g. 11).
(4) Sl i de the wi per bl ade pi vot bl ock/l atch up i nto
the hook formati on on the ti p of the wi per arm unti l
the l atch rel ease tab snaps i nto i ts l ocked posi ti on.
(5) Gentl y l ower the wi per arm and pl ace the arm
support i n the park ramp.
REAR WIPER MODULE
DESCRIPTION
The rear wi per modul e i s conceal ed wi thi n the l i ft-
gate, bel ow the l i ftgate gl ass and behi nd the l i ftgate
tri m panel (Fi g. 12). The end of the motor output
shaft that protrudes through the l i ftgate outer panel
to dri ve the rear wi per arm and bl ade i s the onl y vi s-
i bl e component of the rear wi per modul e. A rubber
gasket, a bezel , and a nut seal and secure the motor
output shaft to the l i ftgate outer panel . A mol ded
pl asti c nut cover snaps onto the bezel to conceal the
nut and i mprove appearance. The rear wi per modul e
consi sts of the fol l owi ng major components:
Bracket - The rear wi per modul e bracket con-
si sts of a stamped steel mounti ng pl ate for the wi per
Fig. 11 Wiper Blade Remove/Install - Typical
1 - PIVOT BLOCK LATCH RELEASE TAB
Fig. 12 Rear Wiper Module
1 - KEYED SLOTS
2 - LIFTGATE WIRE HARNESS CONNECTOR
3 - REAR WIPER MODULE
4 - NUT (2)
5 - LIFTGATE INNER PANEL
REAR WIPER BLADE (Continued)
motor that i s secured wi th screws to the wi per motor
and to the l i ftgate i nner panel .
Electronic Controls - The rear wi per modul e
el ectroni c control s i ncl ude the rear wi per system
el ectroni c l ogi c and rear wi per motor el ectroni c con-
trol s. The el ectroni c control s for the motor i ncl ude an
el ectroni c speed control that speeds the wi per bl ade
near the center of the gl ass, but sl ows the wi per
bl ade duri ng di recti onal reversal s at each end of the
wi pe pattern and duri ng wi per bl ade off-the-gl ass
parki ng for qui eter operati on.
Motor - The permanent magnet rear wi per
motor i s secured wi th screws to the rear wi per mod-
ul e bracket. The wi per motor i ncl udes an i ntegral
transmi ssi on, and the motor output shaft.
The rear wi per modul e cannot be adjusted or
repai red. I f any component of the modul e i s faul ty or
damaged, the enti re rear wi per modul e uni t must be
repl aced. The motor output shaft gasket, bezel , nut,
and nut cover are avai l abl e for servi ce repl acement.
OPERATION
The rear wi per modul e recei ves non-swi tched bat-
tery current through a fuse i n the Juncti on Bl ock
(JB) and i s grounded at al l ti mes. The rear wi per
modul e operati on i s control l ed by the vehi cl e operator
through battery current si gnal i nputs recei ved by the
rear wi per modul e el ectroni c control s from the ri ght
mul ti -functi on swi tch on the steeri ng col umn. The
modul e al so recei ves an external control i nput from
the l i ftgate fl i p-up gl ass ajar swi tch ci rcui t. The rear
wi per modul e el ectroni c control l ogi c uses these
i nputs, i ts i nternal i nputs, and i ts programmi ng to
provi de conti nuous wi pe, del ay wi pe, wi pe-after-wash
and off-the-gl ass wi per bl ade parki ng. The wi per
bl ade cycl i ng i s control l ed by the rear wi per modul e
el ectroni c control s, whi ch control current fl ow to the
wi per motor brushes. The wi per motor transmi ssi on
converts the rotary output of the wi per motor to the
back and forth wi pi ng moti on of the rear wi per arm
and bl ade on the l i ftgate gl ass.
REMOVAL
cabl e.
(2) Remove the rear wi per arm from the rear
wi per motor output shaft. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER ARM
- REMOVAL).
(3) Use a door tri m panel removal tool to gentl y
pry at the base of the nut cover where i t meets the
wi per motor output shaft bezel and gasket on the
outer l i ftgate panel unti l i t unsnaps from the bezel
(Fi g. 13). Be certai n to use proper cauti on to protect
the outer l i ftgate panel and i ts pai nt fi ni sh from
damage duri ng thi s procedure.
(4) Remove the nut that secures the rear wi per
motor output shaft to the outer l i ftgate panel .
(5) Remove the bezel and gasket from the rear
wi per motor output shaft.
(6) Remove the tri m panel from the i nsi de of the
l i ftgate. (Refer to 23 - BODY/DECKLI D/HATCH/
LI FTGATE/TAI LGATE/TRI M PANEL - REMOVAL).
for the rear wi per modul e from the modul e connector
receptacl e (Fi g. 14).
(8) Loosen the two nuts that secure the rear wi per
modul e mounti ng bracket to the l i ftgate i nner panel .
(9) Sl i de the rear wi per modul e and mounti ng
bracket forward far enough to di sengage the mount-
i ng nuts from the keyed hol es i n the l i ftgate i nner
panel .
(10) Remove the rear wi per modul e and mounti ng
bracket from the l i ftgate as a uni t.
INSTALLATION
(1) Posi ti on the rear wi per modul e and bracket to
the l i ftgate as a uni t (Fi g. 14).
(2) I nsert the rear wi per motor output shaft
through the hol e i n the l i ftgate outer panel and
engage the mounti ng nuts i n the keyed hol es i n the
l i ftgate i nner panel .
(3) From the outsi de of the l i ftgate, center the rear
wi per motor output shaft i n the l i ftgate outer panel
mounti ng hol e and i nstal l the gasket and bezel over
the centered shaft (Fi g. 13).
Fig. 13 Rear Wiper Motor Output Shaft Remove/
Install
1 - NUT
2 - NUT COVER
3 - BEZEL AND GASKET
4 - LIFTGATE OUTER PANEL
REAR WIPER MODULE (Continued)
rear wi per motor output shaft to the outer l i ftgate
panel . Ti ghten the nut to 4.8 Nm (43 i n. l bs.).
(5) From the i nsi de of the l i ftgate, i nstal l and
ti ghten the two nuts that secure the rear wi per mod-
ul e mounti ng bracket to the l i ftgate i nner panel .
(6) Reconnect the l i ftgate wi re harness connector
for the rear wi per modul e to the modul e connector
receptacl e.
(7) Rei nstal l the tri m panel onto the i nsi de of the
l i ftgate. (Refer to 23 - BODY/DECKLI D/HATCH/
LI FTGATE/TAI LGATE/TRI M PANEL - I NSTALLA-
TI ON).
(8) From the outsi de of the l i ftgate, press the nut
cover fi rml y and evenl y over the rear wi per motor
output shaft bezel usi ng thumb pressure unti l i t
snaps i nto pl ace.
(9) Rei nstal l the rear wi per arm onto the rear
wi per motor output shaft. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER ARM
- I NSTALLATI ON).
WIPER ARM PARK RAMP
REMOVAL
(1) Di sengage the rear wi per arm support from the
wi per arm park ramp on the ri ght si de of the l i ftgate
just bel ow the l i ftgate gl ass.
(2) Li ft the wi per arm and bl ade away from the
l i ftgate unti l the wi per arm hi nge i s i n i ts over-center
posi ti on.
(3) Remove the screw that secures the wi per arm
park ramp to the l i ftgate outer panel (Fi g. 15).
(4) Remove the wi per arm park ramp from the l i ft-
gate outer panel .
INSTALLATION
(1) Posi ti on the wi per arm park ramp onto the l i ft-
gate outer panel (Fi g. 15).
wi per arm park ramp to the l i ftgate outer panel .
(3) Lower the rear wi per arm and bl ade and gentl y
pl ace the wi per arm support onto the wi per arm park
ramp.
Fig. 14 Rear Wiper Module Remove/Install
1 - KEYED SLOTS
2 - LIFTGATE WIRE HARNESS CONNECTOR
3 - REAR WIPER MODULE
4 - NUT (2)
5 - LIFTGATE INNER PANEL
Fig. 15 Wiper Arm Park Ramp Remove/Install
1 - RIVET NUT
2 - SCREW
3 - PARK RAMP
4 - LIFTGATE
REAR WIPER MODULE (Continued)
WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1
COMPONENT INDEX. . . . . . . . . . . . . . . . . . 8W-02-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1
JUNCTION BLOCK. . . . . . . . . . . . . . . . . . . . 8W-12-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . 8W-35-1
VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1
BODY CONTROL MODULE . . . . . . . . . . . . . 8W-45-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . 8W-49-1
FRONT LIGHTING. . . . . . . . . . . . . . . . . . . . 8W-50-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
POWER SUNROOF . . . . . . . . . . . . . . . . . . . 8W-64-1
SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
CONNECTOR PIN-OUT . . . . . . . . . . . . . . . . 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-97-1
WJ WIRING 8W - 1
8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - CIRCUIT INFORMATION . . . . 5
DESCRIPTION - CIRCUIT FUNCTIONS . . . . . . 6
DESCRIPTION - SECTION IDENTIFICATION
AND INFORMATION . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - CONNECTOR, GROUND
AND SPLICE INFORMATION . . . . . . . . . . . . . . 7
WARNING
WARNINGS - GENERAL . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - WIRING
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE
STANDARD PROCEDURE -
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL. . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR
CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 9
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS . . . . . . . . . . . 10
VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . 10
CONNECTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIODE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
TERMINAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
WIRE
STANDARD PROCEDURE - WIRE SPLICING . . 15
WIRING DIAGRAM
INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
Dai ml erChrysl er Corporati on wi ri ng di agrams are
desi gned to provi de i nformati on regardi ng the vehi -
cl es wi ri ng content. I n order to effecti vel y use the
wi ri ng di agrams to di agnose and repai r
Dai ml erChrysl er Corporati on vehi cl es, i t i s i mportant
to understand al l of thei r features and characteri s-
ti cs.
Di agrams are arranged such that the power (B+)
si de of the ci rcui t i s pl aced near the top of the page,
and the ground (B-) si de of the ci rcui t i s pl aced near
the bottom of the page (Fi g. 1).
Al l swi tches, components, and modul es are shown
i n the at rest posi ti on wi th the doors cl osed and the
key removed from the i gni ti on (Fi g. 2).
Components are shown two ways. A sol i d l i ne
around a component i ndi cates that the component i s
compl ete. A dashed l i ne around the component i ndi -
cates that the component i s bei ng shown i s not com-
pl ete. I ncompl ete components have a reference
number to i ndi cate the page where the component i s
shown compl ete.
I t i s i mportant to real i ze that no attempt i s made
on the di agrams to represent components and wi ri ng
as they appear on the vehi cl e. For exampl e, a short
pi ece of wi re i s treated the same as a l ong one. I n
addi ti on, swi tches and other components are shown
as si mpl y as possi bl e, wi th regard to functi on onl y.
SYMBOLS
I nternati onal symbol s are used throughout the wi r-
i ng di agrams. These symbol s are consi stent wi th
those bei ng used around the worl d (Fi g. 3).
WJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1
Fig. 1 WIRING DIAGRAM EXAMPLE 1
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WJ
WIRING DIAGRAM INFORMATION (Continued)
Fig. 2 WIRING DIAGRAM EXAMPLE 2
Fig. 3 WIRING DIAGRAM SYMBOLS
TERMINOLOGY
Thi s i s a l i st of terms and defi ni ti ons used i n the
wi ri ng di agrams.
LHD . . . . . . . . . . . . . . . . . Left Hand Dri ve Vehi cl es
RHD . . . . . . . . . . . . . . . . Ri ght Hand Dri ve Vehi cl es
ATX . . Automati c Transmi ssi ons-Front Wheel Dri ve
MTX . . . . Manual Transmi ssi ons-Front Wheel Dri ve
AT . . . . Automati c Transmi ssi ons-Rear Wheel Dri ve
MT . . . . . Manual Transmi ssi ons-Rear Wheel Dri ve
SOHC . . . . . . . . . . . Si ngl e Over Head Cam Engi ne
DOHC . . . . . . . . . . Doubl e Over Head Cam Engi ne
Bui l t-Up-Export . . . . . . . . Vehi cl es Bui l t For Sal e I n
Markets Other Than North Ameri ca
Except Bui l t-Up-Export . . Vehi cl es Bui l t For Sal e I n
North Ameri ca
DESCRIPTION - CIRCUIT INFORMATION
Each wi re shown i n the di agrams contai ns a code
whi ch i denti fi es the mai n ci rcui t, part of the mai n
ci rcui t, gage of wi re, and col or (Fi g. 4).
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
Fig. 4 WIRE CODE IDENTIFICATION
1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
DESCRIPTION - CIRCUIT FUNCTIONS
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i ts functi on. To i denti fy
whi ch ci rcui t code appl i es to a system, refer to the
Ci rcui t I denti fi cati on Code Chart. Thi s chart shows
the mai n ci rcui ts onl y and does not show the second-
ary codes that may appl y to some model s.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wi ri ng di agrams are grouped i nto i ndi vi dual
secti ons. I f a component i s most l i kel y found i n a par-
ti cul ar group, i t wi l l be shown compl ete (al l wi res,
connectors, and pi ns) wi thi n that group. For exam-
pl e, the Auto Shutdown Rel ay i s most l i kel y to be
found i n Group 30, so i t i s shown there compl ete. I t
can, however, be shown parti al l y i n another group i f
i t contai ns some associ ated wi ri ng.
Spl i ce di agrams i n Secti on 8W-70 show the enti re
spl i ce and provi de references to other secti ons the
spl i ces serves. Secti on 8W-70 onl y contai ns spl i ce di a-
grams that are not shown i n thei r enti rety some-
where el se i n the wi ri ng di agrams.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the di a-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru
8W-09
General information and Diagram
Overview
8W-10 thru
8W-19
Main Sources of Power and
Vehicle Grounding
8W-20 thru
8W-29
Starting and Charging
8W-30 thru
8W-39
Powertrain/Drivetrain Systems
8W-40 thru
8W-49
Body Electrical items and A/C
8W-50 thru
8W-59
Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru
8W-69
Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
DESCRIPTION - CONNECTOR, GROUND AND
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
I n-l i ne connectors are i denti fi ed by a number, as
fol l ows:
I n-l i ne connectors l ocated i n the engi ne compart-
ment are C100 seri es numbers
I n-l i ne connectors l ocated i n the I nstrument
Panel area are C200 seri es numbers.
I n-l i ne connectors l ocated i n the body are C300
seri es numbers.
Jumper harness connectors are C400 seri es
numbers.
Grounds and ground connectors are i denti fi ed
wi th a G and fol l ow the same seri es numberi ng as
the i n-l i ne connectors.
Spl i ces are i denti fi ed wi th an S and fol l ow the
same seri es numberi ng as the i n-l i ne connectors.
Component connectors are i denti fi ed by the com-
ponent name i nstead of a number. Mul ti pl e connec-
tors on a component use a C1, C2, etc. i denti fi er.
LOCATIONS
Secti on 8W-91 contai ns connector/ground/spl i ce
l ocati on i l l ustrati ons. The i l l ustrati ons contai n the
connector name (or number)/ground number/spl i ce
number and component i denti fi cati on. Connector/
ground/spl i ce l ocati on charts i n secti on 8W-91 refer-
ence the fi gure numbers of the i l l ustrati ons.
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component. The abbre-
vi ati on N/S means Not Shown i n the i l l ustrati ons
WARNING
WARNINGS - GENERAL
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in todays vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: Most of the electrical components used
in todays vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicles
electrical system can cause damage to the equip-
ment and provide false readings.
Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 5). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y, check the fol l owi ng i tems.
Connectors are ful l y seated
Spread termi nal s, or termi nal push out
Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i nto
posi ti on
Di rt or corrosi on on the termi nal s. Any amount of
corrosi on or di rt coul d cause an i ntermi ttent probl em
Damaged connector/component casi ng exposi ng
the i tem to di rt or moi sture
Wi re i nsul ati on that has rubbed through causi ng
a short to ground
Some or al l of the wi ri ng strands broken i nsi de
of the i nsul ati on
Wi ri ng broken i nsi de of the i nsul ati on
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em area.
(6) Veri fy the proper operati on. For thi s step,
check for proper operati on of al l i tems on the
repai red ci rcui t. Refer to the wi ri ng di agrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 6) i s used to i ndi cate thi s. When handl i ng
any component wi th thi s symbol , compl y wi th the fol -
l owi ng procedures to reduce the possi bi l i ty of el ectro-
stati c charge bui l d up on the body and i nadvertent
di scharge i nto the component. I f i t i s not known
whether the part i s ESD sensi ti ve, assume that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part form i ts protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i ts pakage,
ground the pakage to a known good ground on the
vehi cl e.
Fig. 5 PROBING TOOL
2 - PROBING END
Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 7).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
STANDARD PROCEDURE - TESTING FOR
CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 8).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
Fig. 7 TESTING FOR VOLTAGE POTENTIAL
Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the suspected fused ci rcui ts.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng or energi zi ng the i tems i n the
fuse ci rcui t one at a ti me. When the fuse bl ows the
ci rcui t wi th the short to ground has been i sol ated.
VOLTAGE DROP
the si de of the ci rcui t cl osest to the battery (Fi g. 9).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch, component or ci rcui t.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 9 TESTING FOR VOLTAGE DROP
PROBING TOOL PACKAGE 6807
TERMINAL PICK TOOL SET 6680
TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934
CONNECTOR
REMOVAL
(1) Di sconnect battery.
(2) Rel ease Connector Lock (Fi g. 10).
(3) Di sconnect the connector bei ng repai red from
i ts mati ng hal f/component.
(4) Remove the dress cover (i f appl i cabl e) (Fi g. 10).
(5) Rel ease the Secondary Termi nal Lock, i f
requi red (Fi g. 11).
(6) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper speci al tool . Pul l on
the wi re to remove the termi nal from the connector
(Fi g. 12).
INSTALLATION
(1) I nsert the removed termi nal i n the same cavi ty
on the repai r connector.
(2) Repeat steps for each termi nal i n the connec-
tor, bei ng sure that al l wi res are i nserted i nto the
proper cavi ti es. For addi ti onal connector pi n-out
i denti fi cati on, refer to the wi ri ng di agrams.
(3) When the connector i s re-assembl ed, the sec-
ondary termi nal l ock must be pl aced i n the l ocked
posi ti on to prevent termi nal push out.
(4) Repl ace dress cover (i f appl i cabl e).
(5) Connect connector to i ts mati ng hal f/compo-
nent.
(6) Connect battery and test al l affected systems.
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS
1 - Secondary Terminal Lock
CONNECTOR (Continued)
Fig. 12 TERMINAL REMOVAL
1 - TYPICAL CONNECTOR
2 - PICK FROM SPECIAL TOOL KIT 6680
3 - APEX CONNECTOR
4 - PICK FROM SPECIAL TOOL KIT 6680
5 - AUGAT CONNECTOR
7 - MOLEX CONNECTOR
9 - THOMAS AND BETTS CONNECTOR
11 - TYCO CONNECTOR
CONNECTOR (Continued)
DIODE
REMOVAL
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 13).
INSTALLATION
(1) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(2) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary, refer to the
appropri ate wi ri ng di agram for current fl ow (Fi g. 13).
(3) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(4) Tape the di ode to the harness usi ng el ectri cal
tape. Make sure the di ode i s compl etel y seal ed from
the el ements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Fol l ow steps for removi ng termi nal s descri bed
i n the connector removal secti on.
(2) Cut the wi re 6 i nches from the back of the con-
nector.
INSTALLATION
(1) Sel ect a wi re from the termi nal repai r ki t that
best matches the col or and gage of the wi re bei ng
repai red.
(2) Cut the repai r wi re to the proper l ength and
remove onehal f (1/2) i nch of i nsul ati on.
(3) Spl i ce the repai r wi re to the wi re harness (see
wi re spl i ci ng procedure).
(4) I nsert the repai red wi re i nto the connector.
(5) I nstal l the connector l ocki ng wedge, i f requi red,
and reconnect the connector to i ts mati ng hal f/compo-
nent.
(6) Re-tape the wi re harness starti ng at 11/2
i nches behi nd the connector and 2 i nches past the
repai r.
(7) Connect battery and test al l affected systems.
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When spl i ci ng a wi re, i t i s i mportant that the cor-
rect gage be used as shown i n the wi ri ng di agrams.
(1) Remove one-hal f (1/2) i nch of i nsul ati on from
each wi re that needs to be spl i ced.
(2) Pl ace a pi ece of adhesi ve l i ned heat shri nk tub-
i ng on one si de of the wi re. Make sure the tubi ng wi l l
be l ong enough to cover and seal the enti re repai r
area.
(3) Pl ace the strands of wi re overl appi ng each
other i nsi de of the spl i ce cl i p (Fi g. 14).
(4) Usi ng cri mpi ng tool , Mopar p/n 05019912AA,
cri mp the spl i ce cl i p and wi res together (Fi g. 15).
type sol der onl y (Fi g. 16).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng (Fi g. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . 8W-42
A/C Pressure Transducer . . . . . . . . . . . . . . . . 8W-42
Accel erator Pedal Posi ti on Sensor . . . . . . . . . 8W-30
Accessory Del ay Rel ay . . . . . . . . . . . . . . . . . . 8W-64
Adjustabl e Pedal s . . . . . . . . . . . . . . . . . . . . . 8W-30
Ai rbags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Ambi ent Temperature Sensor . . . . . . . . . . . . 8W-45
Antennas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . . 8W-44
Auto Shut Down Rel ay . . . . . . . . . . . . . . . . . 8W-30
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . 8W-49
Automati c Headl amp Li ght Sensor/VTSS
LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39
Automati c Zone Control Modul e . . . . . . . . . . 8W-42
Back-Up Lamp Rel ay . . . . . . . . . . . . . . . . . . . 8W-51
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Bl end Door Motor/Actuator . . . . . . . . . . . . . . 8W-42
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Body Control Modul e . . . . . . . . . . . . . . . . . . . 8W-45
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . 8W-30
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-33
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . 8W-30
Capaci tors . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Center Hi gh Mounted Stop Lamp . . . . . . . . . 8W-51
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Ci rcui t Breakers . . . . . . . . . . . . . . . . . . . . . . 8W-12
Cl ockspri ng . . . . . . . . . . . . . . . . . . 8W-33, 41, 43, 47
Coi l On Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Coi l Rai l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Combi nati on Fl asher . . . . . . . . . . . . . . . . . . . 8W-52
Compact Di sc Changer . . . . . . . . . . . . . . . . . . 8W-47
Control l er Anti l ock Brake . . . . . . . . . . . . . . . 8W-35
Cool ant Level Sensor . . . . . . . . . . . . . . . . . . . 8W-45
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . 8W-30
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . 8W-30
Cyl i nder Lock Swi tches . . . . . . . . . . . . . . . . . 8W-61
Data Li nk Connector . . . . . . . . . . . . . . . . . . . 8W-18
Di agnosti c Juncti on Port . . . . . . . . . . . . . . . . 8W-18
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . . 8W-54
El ectroni c Speed Control Servo . . . . . . . . . . . 8W-33
Engi ne Control Modul e . . . . . . . . . . . . . . . . . 8W-30
Engi ne Cool ant Temperature Sensor . . . . . . 8W-30
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . . . 8W-30
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . 8W-21
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . . . 8W-30
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 51
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . . 8W-30
Component Page
Fuel Pressure Sol enoi d . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Tank Modul e . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 12
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 20
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20, 30
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-44
Gl ow Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Headl amp Level i ng Motor . . . . . . . . . . . . . . . 8W-50
Heated Seats . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Hi gh Beam Headl amps . . . . . . . . . . . . . . . . . 8W-50
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-39
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Hydraul i c Cool i ng Modul e . . . . . . . . . . . . 8W-30, 42
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
I mpact Sensors . . . . . . . . . . . . . . . . . . . . . . . 8W-43
I nput Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-31
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-40
I ntake Ai r Temperature Sensor . . . . . . . . . . . 8W-30
I ntake Port Swi rl Actuator . . . . . . . . . . . . . . 8W-30
I ntrusi on Transcei ver Modul e . . . . . . . . . . . . 8W-49
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Lamp Assembl i es . . . . . . . . . . . . . . . . . . . 8W-51, 52
Leak Detecti on Pump . . . . . . . . . . . . . . . . . . 8W-30
Li cense Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Li ftgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61
Li ne Pressure Sensor . . . . . . . . . . . . . . . . . . . 8W-31
Low Beam Headl amps . . . . . . . . . . . . . . . . . . 8W-50
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-50
Low Beam/Dayti me Runni ng Lamp Rel ay . . . 8W-50
Lumbar Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Lumbar Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Mani fol d Absol ute Pressure Sensor . . . . . . . . 8W-30
Manual Temperature Control . . . . . . . . . . . . . 8W-42
Mass Ai r Fl ow Sensor . . . . . . . . . . . . . . . . . . 8W-30
Memory Set Swi tch . . . . . . . . . . . . . . . . . 8W-62, 63
Mode Door Motor/Actuator . . . . . . . . . . . . . . . 8W-42
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . 8W-50, 53
Output Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31
Overhead Map/Courtesy Lamp . . . . . . . . . . . 8W-44
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-40
Park Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . . 8W-31
Park/Turn Si gnal Lamps . . . . . . . . . . . . . . . . 8W-50
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Power Connector . . . . . . . . . . . . . . . . . . . . . . 8W-41
Power Di stri buti on Center . . . . . . . . . . . . . . . 8W-10
Power Mi rrors . . . . . . . . . . . . . . . . . . . . . . . . 8W-62
WJ 8W-02 COMPONENT INDEX 8W - 02 - 1
Component Page
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Power Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Power Wi ndows . . . . . . . . . . . . . . . . . . . . . . . 8W-60
Powertrai n Control Modul e . . . . . . . . . . . . . . 8W-30
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Rai n Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49
Reci rcul ati on Door Motor/Actuator . . . . . . . . 8W-42
Red Brake Warni ng I ndi cator Swi tch . . . . . . . 8W-35
Remote Keyl ess Modul e . . . . . . . . . . . . . . . . . 8W-39
Remote Radi o Swi tches . . . . . . . . . . . . . . . . . 8W-47
Spl i ces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-43
Seat Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . 8W-39
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . . . 8W-31
Si de I mpact Sensors . . . . . . . . . . . . . . . . . . . 8W-43
Si de Marker Lamps . . . . . . . . . . . . . . . . . . . . 8W-50
Si de Repeater Lamps . . . . . . . . . . . . . . . . . . . 8W-52
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49
Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Component Page
Speed Control Swi tches . . . . . . . . . . . . . . . . . 8W-33
Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64
Temperature Val ve Actuator . . . . . . . . . . . . . 8W-42
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . 8W-30
Trai l er Tow . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54
Transfer Case Posi ti on Sensor . . . . . . . . . . . . 8W-31
Transmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Turn Si gnal Lamps . . . . . . . . . . . . . . . . . . . . 8W-52
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-44
Vehi cl e I nformati on Center . . . . . . . . . . . . . . 8W-49
Vi scous/Cabi n Heater . . . . . . . . . . . . . . . . . . . 8W-30
Vi sor/Vani ty Lamps . . . . . . . . . . . . . . . . . . . . 8W-44
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . . 8W-53
Wastegate Sol enoi d . . . . . . . . . . . . . . . . . . . . 8W-30
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . . 8W-30
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . 8W-35
Wi ndow Defogger . . . . . . . . . . . . . . . . . . . . . . 8W-48
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . . . . 8W-53
Wi per Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53
Washer Pump . . . . . . . . . . . . . . . . . . . . . . . . . 8W-5
8W - 02 - 2 8W-02 COMPONENT INDEX WJ
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . 8W-10-32
A/C Compressor Cl utch Rel ay . . . 8W-10-13, 14, 25, 26, 32
Accessory Del ay Rel ay . . . . . . . . . . . . . . . . . . 8W-10-24
Auto Shut Down Rel ay . . . . . . . 8W-10-11, 14, 19, 20, 25
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12
Bl ower Motor . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 15
Bl ower Motor Control l er . . . . . . . . . . . . 8W-10-11, 12, 15
Body Control Modul e . . . . . . . . . . . . . . . . 8W-10-27, 29
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . . 8W-10-26
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20
Capaci tor No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Capaci tor No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . 8W-10-15
Ci rcui t Breaker No. 1 (JB) . . . . . . . . . . . . . . . 8W-10-29
Ci rcui t Breaker No. 2 (JB) . . . . . . . . . . . . . . . 8W-10-24
Coi l On Pl ug No. 1 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coi l On Pl ug No. 2 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coi l On Pl ug No. 3 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coi l On Pl ug No. 4 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coi l On Pl ug No. 5 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coi l On Pl ug No. 6 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coi l On Pl ug No. 7 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coi l On Pl ug No. 8 . . . . . . . . . . . . . . . . . . . . 8W-10-22
Coi l Rai l . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20
Control l er Anti l ock
Brake . . . . . . . . . . . . 8W-10-11, 12, 13, 14, 17, 18, 32
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . . . 8W-10-30
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Engi ne Control Modul e . . . . . . . . . . . . 8W-10-14, 26, 31
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . 8W-10-27
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . 8W-10-27
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-24
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Fuel Pressure Sol enoi d . . . . . . . . . . . . . . . . . . 8W-10-26
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . 8W-10-32
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . 8W-10-13, 32
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 15
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 15
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 16
Fuse 4 . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 17, 18
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 17, 30
Fuse 6 . . . . . . . . . . . . . . . . 8W-10-11, 12, 16, 18, 19, 20
Fuse 7 . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 24, 30
Fuse 8 . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 27, 30
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 15, 18
Fuse 12 . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 14, 29, 30
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 14, 25
Fuse 14 . . . . . . . . . . . . . . . . . . 8W-10-11, 13, 14, 16, 27
Fuse 15 . . . . . . . . . . . . . . . . . . 8W-10-11, 13, 14, 16, 30
Fuse 16 . . . . . . . . . . . . . . . . . . 8W-10-16, 19, 20, 23, 25
Component Page
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Fuse 18 . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 30, 31
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
Fuse 21 . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 29, 32
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 29, 31
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 24, 25
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 24, 32
Fuse 25 . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 24, 32
Fuse 26 . . . . . . . . . . . . . . . . . . . . 8W-10-15, 19, 20, 25
Fuse 27 . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 24, 31
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 29
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
Generator . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12, 26
Gl ow Pl ug No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Gl ow Pl ug No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Gl ow Pl ug No. 3 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Gl ow Pl ug No. 4 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Gl ow Pl ug No. 5 . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Gl ow Pl ug Rel ay No. 1 . . . . . . . . . . . . . 8W-10-12, 18, 26
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 31
Hydraul i c Cool i ng Modul e . . . . . . . . 8W-10-19, 20, 23, 26
I gni ti on Swi tch . . . . . . . . . . . . . 8W-10-11, 14, 27, 28, 29
I ntake Port Swi rl Actuator . . . . . . . . . . . . . . . 8W-10-26
Juncti on Bl ock . . . . . . . . . . . . . 8W-10-11, 12, 13, 14, 15,
16, 24, 28, 29, 30
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Low Beam/Dayti me Runni ng Lamp Rel ay . . . . 8W-10-16
Mass Ai r Fl ow Sensor . . . . . . . . . . . . . . . . . . 8W-10-26
Oxygen Sensor 1/1 Upstream . . . . . . . . . . . 8W-10-19, 20
Oxygen Sensor 1/2 Downstream . . . . . . . . . 8W-10-19, 20
Oxygen Sensor 1/2 Downstream . . . . . . . . . . . 8W-10-23
Oxygen Sensor 2/2 Downstream . . . . . . . . . . . 8W-10-23
Oxygen Sensor Downstream Rel ay . . . . 8W-10-19, 20, 23
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Passenger Door Modul e . . . . . . . . . . . . . . . . . 8W-10-30
Power Di stri buti on Center . . . . . . 8W-10-2, 3, 11, 12, 13,
14, 15, 16, 17, 18, 19, 20,
24, 25, 27, 30, 31, 32
Powertrai n Control Modul e . . . . . . . . . 8W-10-13, 19, 20
Rear Power Outl et . . . . . . . . . . . . . 8W-10-13, 14, 24, 31
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . 8W-10-15
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . . 8W-10-15
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . . . . 8W-10-15
Transmi ssi on Control Modul e . . . . . . . . . . . 8W-10-11, 17
Transmi ssi on Control Rel ay . . . . . . . . . . . . 8W-10-11, 17
Transmi ssi on Sol enoi d . . . . . . . . . . . . . . . . . . 8W-10-17
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . . 8W-10-17
Vi scous/Cabi n Heater Rel ay . . . . . . . . . 8W-10-14, 25, 26
Wastegate Sol enoi d . . . . . . . . . . . . . . . . . . . . 8W-10-26
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . . 8W-10-26
WJ 8W-10 POWER DISTRIBUTION 8W - 10 - 1
8W-12 J UNCTION BLOCK
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . . . . 8W-12-18
Accessory Del ay Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-12-25
Adjustabl e Pedal s Modul e . . . . . . . . . . . . . . . . . . 8W-12-11
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . . 8W-12-25
Auto Shut Down Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12-18
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . . . . . 8W-12-23
Automati c Headl amp Li ght Sensor/VTSS LED . . . . . . 8W-12-15
Automati c Zone Control Modul e . . . . . . . . . . 8W-12-15, 17, 22
Back-Up Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-12-22
Body Control Modul e . . . 8W-12-10, 12, 13, 15, 17, 20, 23, 24, 25,
26, 27, 28, 29, 30, 31, 35, 36
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-12-16, 24, 27
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12-17, 26
Ci rcui t Breaker No. 1 . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
Ci rcui t Breaker No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31
Combi nati on Fl asher . . . . . . . . . . . . 8W-12-10, 22, 27, 32, 35
Control l er Anti l ock Brake . . . . . . . . . . . . . . . . . . 8W-12-21
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-12-34
Dri ver Heated Seat Swi tch . . . . . . . . . . . . . . . . . . 8W-12-22
Dri ver Lumbar Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . . . . . . 8W-12-9
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Engi ne Control Modul e . . . . . . . . . . . . . . . . . . . . 8W-12-19
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . . . . 8W-12-26
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . . . . . 8W-12-18
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Front Power Outl et . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10, 20
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18, 19, 21, 34
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 15, 20
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21, 34
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18, 19
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-36
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-35
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . 8W-12-12, 13
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-12-10, 23, 32
I ntrusi on Transcei ver Modul e . . . . . . . . . . . . . . . . 8W-12-16
Juncti on Bl ock . . . . . . . . . 8W-12-2, 3, 9, 10, 11, 12, 13, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25,
26, 27, 28, 29, 30, 31, 32, 34, 35, 36
Component Page
Left Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Left Door Handl e Courtesy Lamp . . . . . . . . . 8W-12-16, 24, 30
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Left Front Park Lamp . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Left Front Park/Turn Si gnal Lamp . . . . . . . . . . . 8W-12-14, 33
Left Front Si de Marker Lamp . . . . . . . . . . . . . . 8W-12-14, 33
Left Front Turn Si gnal Lamp . . . . . . . . . . . . . . . . 8W-12-33
Left Headl amp Level i ng Motor . . . . . . . . . . . . . . . 8W-12-14
Left Hi gh Beam Headl amp . . . . . . . . . . . . . . . . . . 8W-12-10
Left Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . . . 8W-12-30
Left Low Beam Headl amp . . . . . . . . . . . . . . . . . . 8W-12-20
Left Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . 8W-12-10, 35
Left Rear Door Lock Motor/Ajar Swi tch . . . . . . . . . . 8W-12-27
Left Rear Lamp Assembl y . . . . . . . . . . . 8W-12-12, 13, 27, 36
Left Si de Repeater Lamp . . . . . . . . . . . . . . . . . . . 8W-12-32
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . . . 8W-12-16, 30
Li cense Lamp No. 1 . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
Li cense Lamp No. 2 . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
Li ftgate Fl i p-Up Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-12-30
Li ftgate Fl i p-Up Push Button Swi tch . . . . . . . . . . . 8W-12-16
Li ftgate Power Lock Motor . . . . . . . . . . . . . . . . . . 8W-12-16
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Low Beam/Dayti me Runni ng Lamp Rel ay . . . . . . . . . 8W-12-20
Manual Temperature Control . . . . . . . . . . . . . . 8W-12-17, 22
Overhead Map/Courtesy Lamp . . . . . . . . . . . 8W-12-16, 24, 30
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . . . . . . 8W-12-22
Passenger Door Modul e . . . . . . . . . . . . . . . . . . . . 8W-12-34
Passenger Heated Seat Swi tch . . . . . . . . . . . . . . . 8W-12-22
Passenger Lumbar Swi tch . . . . . . . . . . . . . . . . . . . 8W-12-9
Passenger Power Seat Swi tch . . . . . . . . . . . . . . . . . 8W-12-9
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Power Connector . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Power Di stri buti on Center . . . . 8W-12-10, 11, 15, 17, 20, 21, 34
Powertrai n Control Modul e . . . . . . . . . . . . . . . . . 8W-12-18
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 26
Rai n Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . . . 8W-12-17
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . . . . . 8W-12-17
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8W-12-16, 30
Remote Keyl ess Modul e . . . . . . . . . . . . . . . . . . . . 8W-12-15
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Ri ght Door Handl e Courtesy Lamp . . . . . . . . 8W-12-16, 24, 30
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Ri ght Front Park Lamp . . . . . . . . . . . . . . . . . . . . 8W-12-14
Ri ght Front Park/Turn Si gnal Lamp . . . . . . . . . . 8W-12-14, 33
Ri ght Front Si de Marker Lamp . . . . . . . . . . . . . 8W-12-14, 33
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . . . . . . 8W-12-33
Ri ght Headl amp Level i ng Motor . . . . . . . . . . . . . . 8W-12-14
Ri ght Hi gh Beam Headl amp . . . . . . . . . . . . . . . . . 8W-12-10
Ri ght Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . . 8W-12-30
Ri ght Low Beam Headl amp . . . . . . . . . . . . . . . . . 8W-12-20
Ri ght Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . . . 8W-12-26
Ri ght Rear Lamp Assembl y . . . . . . . . . . 8W-12-12, 13, 32, 36
Ri ght Si de Repeater Lamp . . . . . . . . . . . . . . . . . . 8W-12-32
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . . 8W-12-16, 30
Seat Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . . . 8W-12-15, 23
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . . . 8W-12-18, 19
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
Sunroof Control Modul e . . . . . . . . . . . . . . . . . . . . 8W-12-25
Temperature Val ve Actuator . . . . . . . . . . . . . . . . . 8W-12-22
Trai l er Tow Brake Lamp Rel ay . . . . . . . . . . . . . . . 8W-12-21
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . . . . . . . 8W-12-17
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . . . . 8W-12-12
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . . . . . . 8W-12-27
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . . . . . . 8W-12-32
Transmi ssi on Control Modul e . . . . . . . . . . . . . . 8W-12-18, 26
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . . . . . . 8W-12-22
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
Vehi cl e I nformati on Center . . . . . . . . . . . . . . . 8W-12-16, 23
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . . . . 8W-12-28, 29
Wi per On/Off Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
WJ 8W-12 JUNCTION BLOCK 8W - 12 - 1
8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . . 8W-15-4
Adjustabl e Pedal s Modul e . . . . . . . . . . . . . 8W-15-17, 21
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . 8W-15-16
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-14
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . . 8W-15-19
Automati c Zone Control Modul e . . . . . . . . . . . 8W-15-15
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
Bl ower Motor Control l er . . . . . . . . . . . . . . . . . 8W-15-15
Body Control Modul e . . . . . . . . . . . . . . 8W-15-12, 13, 15
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-15-17, 22
Center Hi gh Mounted Stop Lamp . . . . . . . . . . 8W-15-20
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . 8W-15-12
Control l er Anti l ock Brake . . . . . . . . . . . . . . . . 8W-15-12
Cool ant Level Sensor . . . . . . . . . . . . . . . 8W-15-9, 10, 11
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Data Li nk Connector . . . . . . . . . . . . . . . . . . 8W-15-2, 3
Dri ver Cyl i nder Lock Swi tch . . . . . . . . . . . . . . 8W-15-16
Dri ver Door Lock Motor/Ajar Swi tch . . . . . . . . 8W-15-16
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . . . 8W-15-16
Dri ver Heated Seat Swi tch . . . . . . . . . . . . . . . 8W-15-14
Dri ver Lumbar Swi tch . . . . . . . . . . . . . . . 8W-15-18, 21
Dri ver Power Seat Swi tch . . . . . . . . . . . . . 8W-15-18, 21
Dri ver Rear Power Wi ndow Swi tch . . . . . . . 8W-15-18, 21
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
El ectroni c Speed Control Servo . . . . . . . . . . 8W-15-9, 10
Engi ne Control Modul e . . . . . . . . . . . . . . . . . . 8W-15-3
Front Power Outl et . . . . . . . . . . . . . . . . . . . . 8W-15-14
Front Washer Pump . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
G200 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13, 14, 15
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
G300 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16, 17, 18
G301 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19, 21, 22
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . 8W-15-15
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
Hydraul i c Cool i ng Modul e . . . . . . . . . . . 8W-15-9, 10, 11
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-15-13, 14
I ntake Port Swi rl Actuator . . . . . . . . . . . . . . . . 8W-15-3
I ntrusi on Transcei ver Modul e . . . . . . . . . . 8W-15-21, 22
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8W-15-12, 13, 15
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Left Front Park Lamp . . . . . . . . . . . . . . . . . . . 8W-15-5
Left Front Park/Turn Si gnal Lamp . . . . . . . . . . 8W-15-5
Left Front Turn Si gnal Lamp . . . . . . . . . . . . . . 8W-15-5
Left Headl amp Level i ng Motor . . . . . . . . . . . . . 8W-15-5
Left Hi gh Beam Headl amp . . . . . . . . . . . . . . . . 8W-15-5
Component Page
Left Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . 8W-15-20
Left Low Beam Headl amp . . . . . . . . . . . . . . . . 8W-15-5
Left Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . 8W-15-15
Left Rear Door Lock Motor/Ajar Swi tch . . . . 8W-15-21, 22
Left Rear Lamp Assembl y . . . . . . . . . . . . . . . 8W-15-19
Left Si de Repeater Lamp . . . . . . . . . . . . . . . 8W-15-6, 7
Li cense Lamp No. 1 . . . . . . . . . . . . . . . . . . . . 8W-15-20
Li cense Lamp No. 2 . . . . . . . . . . . . . . . . . . . . 8W-15-20
Li ftgate Fl i p-Up Ajar Swi tch . . . . . . . . . . . . . . 8W-15-20
Li ftgate Fl i p-Up Rel ease Sol enoi d . . . . . . . . . . 8W-15-20
Li ne Pressure Sensor . . . . . . . . . . . . . . . . . . . . 8W-15-2
Low Beam/Dayti me Runni ng Lamp Rel ay . . . . 8W-15-12
Manual Temperature Control . . . . . . . . . . . 8W-15-13, 15
Oxygen Sensor 1/2 Downstream . . . . . . . . . . . . 8W-15-4
Oxygen Sensor 2/2 Downstream . . . . . . . . . . . . 8W-15-4
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-15-12
Passenger Door Lock Motor/Ajar Swi tch . . . . . . 8W-15-16
Passenger Door Modul e . . . . . . . . . . . . . . . . . 8W-15-16
Passenger Heated Seat Swi tch . . . . . . . . . . . . 8W-15-14
Passenger Lumbar Swi tch . . . . . . . . . . . . . 8W-15-17, 22
Passenger Power Seat Swi tch . . . . . . . . . . 8W-15-17, 22
Passenger Rear Power Wi ndow Swi tch . . . . 8W-15-16, 22
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Power Connector . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Powertrai n Control Modul e . . . . . . . . . . . . . . . 8W-15-2
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Rai n Sensor . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21, 22
Rear Power Outl et . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Rear Washer Pump . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . 8W-15-20
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8W-15-20
Remote Keyl ess Modul e . . . . . . . . . . . . . . . . . 8W-15-16
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
Ri ght Front Park Lamp . . . . . . . . . . . . . . . . . . 8W-15-8
Ri ght Front Park/Turn Si gnal Lamp . . . . . . . . . 8W-15-8
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . . . . 8W-15-8
Ri ght Headl amp Level i ng Motor . . . . . . . . . . . . 8W-15-8
Ri ght Hi gh Beam Headl amp . . . . . . . . . . . . . . . 8W-15-8
Ri ght Low Beam Headl amp . . . . . . . . . . . . . . . 8W-15-8
Ri ght Rear Door Lock Motor/Ajar Swi tch . . 8W-15-16, 18
Ri ght Rear Lamp Assembl y . . . . . . . . . . . . 8W-15-17, 18
Ri ght Si de Repeater Lamp . . . . . . . . . . . 8W-15-9, 10, 11
Seat Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-15-18, 21
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . . 8W-15-13
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . 8W-15-14, 15
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Sunroof Control Modul e . . . . . . . . . . . . . . . . . 8W-15-19
Sunroof Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
Sunroof Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
Temperature Val ve Actuator . . . . . . . . . . . . . . 8W-15-13
Trai l er Tow Brake Lamp Rel ay . . . . . . . . . . . . 8W-15-19
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . 8W-15-19
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . . . 8W-15-19
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . . . 8W-15-19
Transmi ssi on Control Modul e . . . . . . . . . . . . . . 8W-15-2
Transmi ssi on Control Rel ay . . . . . . . . . . . . 8W-15-9, 10
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Vehi cl e I nformati on Center . . . . . . . . . . . . 8W-15-21, 22
Vi scous/Cabi n Heater . . . . . . . . . . . . . . . . . . . 8W-15-4
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . . 8W-15-6, 7
WJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 1
8W-18 BUS COMMUNICATIONS
Component Page
Adjustabl e Pedal s Modul e . . . . . . . . . . . . . . 8W-18-2
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-18-4, 7
Automati c Zone Control Modul e . . . . . . . 8W-18-4, 7
Body Control Modul e . . . . . . . . . 8W-18-4, 7, 8, 9, 10
Compact Di sc Changer . . . . . . . . . . . . . . 8W-18-3, 5
Control l er Anti l ock Brake . . . . . . . . . . 8W-18-2, 3, 5
Data Li nk Connector . . . . . . . . . 8W-18-4, 7, 8, 9, 10
Di agnosti c Juncti on Port . . . . . . 8W-18-4, 7, 8, 9, 10
Dri ver Door Modul e . . . . . . . . . . . . . . . . 8W-18-2, 5
Engi ne Control Modul e . . . . . . . . . . . 8W-18-3, 5, 10
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . 8W-18-8, 9, 10
G103 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-8, 9, 10
I nstrument Cl uster . . . . . . . . . . 8W-18-4, 7, 8, 9, 10
Component Page
I ntrusi on Transcei ver Modul e . . . . . . . . . 8W-18-2, 6
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8W-18-8, 9, 10
Passenger Door Modul e . . . . . . . . . . . . . . 8W-18-3, 6
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . 8W-18-3, 5
Powertrai n Control Modul e . . . . . . . 8W-18-3, 5, 8, 9
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4, 7
Rai n Sensor . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 6
Seat Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 5
Sentry Key I mmobi l i zer Modul e . . . . . . . 8W-18-4, 7
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . 8W-18-4, 7
Transmi ssi on Control Modul e . . 8W-18-3, 6, 8, 9, 10
Vehi cl e I nformati on Center . . . . . . . . . . . 8W-18-2, 6
WJ 8W-18 BUS COMMUNICATIONS 8W - 18 - 1
8W-20 CHARGING SYSTEM
Component Page
Auto Shut Down Rel ay . . . . . . . . . . . . 8W-20-2, 3, 4
Battery . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
Battery Temperature Sensor . . . . . . . . . . 8W-20-2, 3
Engi ne Control Modul e . . . . . . . . . . . . . . . . 8W-20-4
Engi ne Starter Motor . . . . . . . . . . . . . 8W-20-2, 3, 4
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4
Component Page
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
Generator . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
Power Di stri buti on Center . . . . . . . . . 8W-20-2, 3, 4
Powertrai n Control Modul e . . . . . . . . . . . 8W-20-2, 3
WJ 8W-20 CHARGING SYSTEM 8W - 20 - 1
8W-21 STARTING SYSTEM
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4
Engi ne Control Modul e . . . . . . . . . . . . . . . . 8W-21-4
Engi ne Starter Motor . . . . . . . . . . . . . 8W-21-2, 3, 4
Engi ne Starter Motor Rel ay . . . . . . . . 8W-21-2, 3, 4
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4
Park/Neutral Posi ti on Swi tch . . . . . . . . . 8W-21-2, 3
Transmi ssi on Control Modul e . . . . . . . . . 8W-21-2, 3
Transmi ssi on Sol enoi d/TRS Assembl y . . . 8W-21-2, 3
WJ 8W-21 STARTING SYSTEM 8W - 21 - 1
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . 8W-30-23, 35, 39, 41, 42
A/C Pressure Transducer . . . . . . . . 8W-30-21, 42, 45, 31
Accel erator Pedal Posi ti on Sensor . . . . . . . . 8W-30-37, 48
Adjustabl e Pedal s Modul e . . . . . . . . . . . . . . . . 8W-30-33
Adjustabl e Pedal s Motor/Sensor Assembl y . . . . 8W-30-33
Adjustabl e Pedal s Swi tch . . . . . . . . . . . . . . . . 8W-30-33
Auto Shut Down Rel ay . . . . . . 8W-30-8, 9, 12, 24, 25, 26,
27, 28, 29, 30, 35, 39, 41
Battery Temperature Sensor . . . . . . . . . . 8W-30-2, 11, 50
Body Control Modul e . . . . . . . . . . . . . . . . . . . 8W-30-46
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . 8W-30-45
Brake Lamp Swi tch . . . . . . . . . . . . . . 8W-30-4, 5, 32, 51
Camshaft Posi ti on Sensor . . . . . . . . 8W-30-18, 19, 20, 49
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12
Capaci tor No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16
Capaci tor No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 5, 38
Coi l On Pl ug No. 1 . . . . . . . . . . . . . . . . . . . . 8W-30-17
Coi l On Pl ug No. 2 . . . . . . . . . . . . . . . . . . . . 8W-30-16
Coi l On Pl ug No. 3 . . . . . . . . . . . . . . . . . . . . 8W-30-17
Coi l On Pl ug No. 4 . . . . . . . . . . . . . . . . . . . . 8W-30-16
Coi l On Pl ug No. 5 . . . . . . . . . . . . . . . . . . . . 8W-30-17
Coi l On Pl ug No. 6 . . . . . . . . . . . . . . . . . . . . 8W-30-16
Coi l On Pl ug No. 7 . . . . . . . . . . . . . . . . . . . . 8W-30-17
Coi l On Pl ug No. 8 . . . . . . . . . . . . . . . . . . . . 8W-30-16
Coi l Rai l . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12
Control l er Anti l ock Brake . . . . . . . . . . . 8W-30-2, 36, 51
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . 8W-30-35
Crankshaft Posi ti on Sensor . . . . . . . 8W-30-18, 19, 20, 49
Data Li nk Connector . . . . . . . . . . . . . . . 8W-30-6, 7, 46
Di agnosti c Juncti on Port . . . . . . . . . . 8W-30-6, 7, 33, 46
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-50
El ectroni c Speed Control Servo . . . . . . . . . . . 8W-30-4, 5
Engi ne Control Modul e . . . . 8W-30-34, 35, 36, 37, 38, 39,
40, 41, 42, 43, 44, 45,
46, 47, 48, 49, 50, 51
Engi ne Cool ant Temperature Sensor . . . 8W-30-21, 22, 47
Engi ne Oi l Pressure Sensor . . . . . . . . . 8W-30-21, 22, 45
Engi ne Starter Motor Rel ay . . . . . . . . . 8W-30-18, 19, 39
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . . 8W-30-4, 5
Fuel I njector No. 1 . . . . . . . . . . . . . . . 8W-30-13, 15, 44
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . 8W-30-13, 14
Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . . 8W-30-37
Fuel Pressure Sol enoi d . . . . . . . . . . . . . . . . . . 8W-30-47
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . 8W-30-8, 9, 10
Fuel Tank Modul e . . . . . . . . . . . . . . . . . . . . . 8W-30-45
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 42
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-33
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-43
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 9, 40
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-41
Fuse 16 . . 8W-30-24, 25, 26, 27, 28, 29, 30, 35, 37, 39, 41
Component Page
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 5, 32
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-34
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-39
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9
Fuse 26 . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 12, 41, 47
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-39
G103 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 34, 39, 46
G104 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-26, 27, 30
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-35, 39
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-23, 43
G123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-50
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 33
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5, 10
Generator . . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 23, 35
Gl ow Pl ug No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-30-42
Gl ow Pl ug No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-30-43
Gl ow Pl ug No. 3 . . . . . . . . . . . . . . . . . . . . . . 8W-30-42
Gl ow Pl ug No. 4 . . . . . . . . . . . . . . . . . . . . . . 8W-30-43
Gl ow Pl ug No. 5 . . . . . . . . . . . . . . . . . . . . . . 8W-30-42
Hydraul i c Cool i ng Modul e . . . 8W-30-3, 24, 25, 30, 31, 43
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . 8W-30-20
I ntake Ai r Temperature Sensor . . . . . . . 8W-30-21, 22, 38
I ntake Port Swi rl Actuator . . . . . . . . . . . . . . . 8W-30-39
Juncti on Bl ock . . . . . . . . . 8W-30-4, 5, 8, 9, 32, 33, 39, 40
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11
Leak Detecti on Pump . . . . . . . . . . . . . . . . . . . 8W-30-23
Mani fol d Absol ute Pressure Sensor . . . . 8W-30-20, 21, 22
Mass Ai r Fl ow Sensor . . . . . . . . . . . . . . . . . . 8W-30-37
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-30-2
Oxygen Sensor 1/1 Upstream . . . . . . 8W-30-25, 26, 28, 29
Oxygen Sensor 1/2 Downstream . . . . 8W-30-24, 25, 26, 30
Oxygen Sensor 2/1 Upstream . . . . . . . . 8W-30-27, 28, 29
Oxygen Sensor 2/2 Downstream . . . . . . 8W-30-24, 27, 30
Oxygen Sensor Downstream Rel ay . . 8W-30-24, 26, 27, 30
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . . . 8W-30-33
Power Di stri buti on Center . . . . . . 8W-30-8, 9, 12, 24, 25,
26, 27, 28, 29, 30, 34, 35,
37, 39, 41, 42, 43, 47
Powertrai n Control Modul e . . . 8W-30-2, 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
Shi fter Assembl y . . . . . . . . . . . . . . . 8W-30-2, 32, 38, 40
Speed Control Swi tch No. 1 . . . . . . . . . . . 8W-30-4, 5, 38
Speed Control Swi tch No. 2 . . . . . . . . . . . 8W-30-4, 5, 38
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . . 8W-30-20
Transfer Case Posi ti on Sensor . . . . . . . . . . . 8W-30-8, 51
Transmi ssi on Control
Modul e . . . . . . . . . . . . . 8W-30-6, 7, 20, 23, 32, 36, 40
Transmi ssi on Control Rel ay . . . . . . . . . . . . . . 8W-30-23
Transmi ssi on Sol enoi d . . . . . . . . . . . . . . . . 8W-30-3, 21
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . . 8W-30-33
Vi scous/Cabi n Heater . . . . . . . . . . . . . . . . . . . 8W-30-39
Vi scous/Cabi n Heater Rel ay . . . . . . 8W-30-35, 39, 41, 42
Wastegate Sol enoi d . . . . . . . . . . . . . . . . . . . . 8W-30-35
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . . 8W-30-50
WJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1
8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
Auto Shut Down Rel ay . . . . . . . . . . . . . . . . 8W-31-4
Back-Up Lamp Rel ay . . . . . . . . . . . . . . . . 8W-31-15
Body Control Modul e . . . . . . . . . . . . . . . . 8W-31-14
Brake Lamp Swi tch . . . . . . . . . . . . . . . 8W-31-14, 15
Control l er Anti l ock Brake . . . . . . . . . . . . . 8W-31-17
Crankshaft Posi ti on Sensor . . . . . . . . . . 8W-31-9, 10
Data Li nk Connector . . . . . . . . . . . . 8W-31-9, 10, 16
Di agnosti c Juncti on Port . . . . . . . . . . . . 8W-31-4, 15
Engi ne Control Modul e . . . . . . . . . . . . 8W-31-16, 17
Engi ne Starter Motor Rel ay . . . . . 8W-31-4, 5, 6, 12
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . 8W-31-4
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 3
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4, 15
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5, 6
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-14, 15
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 8
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-11, 13
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-14, 15
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-15
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-15
Component Page
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
I nput Speed Sensor . . . . . . . . . . . . . . . . . . 8W-31-13
Juncti on Bl ock . . . . . . . . . . . . . 8W-31-4, 5, 6, 14, 15
Left Rear Lamp Assembl y . . . . . . . . . . . . 8W-31-5, 6
Li ne Pressure Sensor . . . . . . . . . . . . . . . . 8W-31-13
Output Speed Sensor . . . . . . . . . . . . . . 8W-31-8, 13
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . 8W-31-6
Powertrai n Control
Modul e . . . . . . . . . 8W-31-2, 4, 5, 6, 7, 8, 9, 10, 14
Ri ght Rear Lamp Assembl y . . . . . . . . . . . 8W-31-5, 6
Shi fter Assembl y . . . . . . . . . . . . . . 8W-31-14, 15, 16
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . 8W-31-7
Transfer Case Posi ti on Sensor . . . . . . . . 8W-31-6, 16
Transmi ssi on Control
Modul e . . . . . . . . . . . 8W-31-3, 4, 7, 9, 10, 11, 12,
13, 14, 16, 17, 18
Transmi ssi on Control Rel ay . . . 8W-31-2, 3, 8, 11, 12
Transmi ssi on Sol enoi d . . . . . . . . . . . . . . 8W-31-2, 8
Transmi ssi on Sol enoi d Assembl y . . . . . . . . 8W-31-18
Transmi ssi on Sol enoi d/TRS
Assembl y . . . . . . . . . . . . . . 8W-31-3, 5, 11, 12, 13
WJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
8W-33 VEHICLE SPEED CONTROL
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-33-2
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . 8W-33-3, 4, 5
El ectroni c Speed Control Servo . . . . . . . . . . 8W-33-2
Engi ne Control Modul e . . . . . . . . . . . . . . 8W-33-2, 4
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Component Page
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . . 8W-33-3
Speed Control Swi tch No. 1 . . . . . . . . . . . . 8W-33-5
Speed Control Swi tch No. 2 . . . . . . . . . . . . 8W-33-5
WJ 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1
8W-35 ANTILOCK BRAKES
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-35-5
Control l er Anti l ock Brake . . . . . . 8W-35-2, 3, 4, 5, 6
Di agnosti c Juncti on Port . . . . . . . . . . . . . 8W-35-2, 3
Engi ne Control Modul e . . . . . . . . . . . . . . 8W-35-4, 5
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8W-35-2, 3, 5
Left Front Wheel Speed Sensor . . . . . . . . . 8W-35-6
Left Rear Wheel Speed Sensor . . . . . . . . . . 8W-35-6
Power Di stri buti on Center . . . . . . . . . . . 8W-35-2, 3
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-35-4
Red Brake Warni ng I ndi cator Swi tch . . . . . 8W-35-5
Ri ght Front Wheel Speed Sensor . . . . . . . . 8W-35-6
Ri ght Rear Wheel Speed Sensor . . . . . . . . . 8W-35-6
WJ 8W-35 ANTILOCK BRAKES 8W - 35 - 1
8W-39 VEHICLE THEFT SECURITY SYSTEM
Component Page
Automati c Headl amp Li ght
Sensor/VTSS LED . . . . . . . . . . . . . . . . . . 8W-39-3
Body Control Modul e . . . 8W-39-2, 3, 4, 5, 7, 8, 9, 10
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
Di agnosti c Juncti on Port . . . . . . . . . . . . . . . 8W-39-9
Dri ver Cyl i nder Lock Swi tch . . . . . . . . . . . . 8W-39-6
Dri ver Door Lock Motor/Ajar Swi tch . . . . . . 8W-39-6
Engi ne Starter Motor Rel ay . . . . . . . . . . . . 8W-39-2
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3, 9, 11
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 9
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-10
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-9
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5, 6
Component Page
G301 . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5, 6, 11
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . 8W-39-10
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-39-7, 8
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Juncti on Bl ock . . . . . . . . 8W-39-2, 3, 4, 5, 7, 8, 9, 11
Left Li ftgate Ajar Swi tch . . . . . . . . . . . . . . 8W-39-4
Left Rear Door Lock Motor/Ajar Swi tch . . . 8W-39-5
Li ftgate Fl i p-Up Ajar Swi tch . . . . . . . . . . . . 8W-39-4
Passenger Door Lock Motor/Ajar Swi tch . . . 8W-39-6
Passenger Door Modul e . . . . . . . . . . . . . . . 8W-39-6
Remote Keyl ess Modul e . . . . . . . . . . . . . . 8W-39-11
Ri ght Li ftgate Ajar Swi tch . . . . . . . . . . . . . 8W-39-4
Ri ght Rear Door Lock Motor/Ajar Swi tch . . 8W-39-5
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8W-39-9
WJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
8W-40 INSTRUMENT CLUSTER
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-40-4, 5
Body Control Modul e . . . . . . . 8W-40-2, 4, 5, 6, 7, 10
Combi nati on Fl asher . . . . . . . . . . . . . . . . . 8W-40-3
Control l er Anti l ock Brake . . . . . . 8W-40-4, 5, 6, 7, 9
Data Li nk Connector . . . . . . . . . . . . . . 8W-40-2, 4, 5
Di agnosti c Juncti on Port . . 8W-40-4, 5, 6, 7, 8, 9, 10
Engi ne Control Modul e . . . . . . . . . 8W-40-4, 5, 9, 10
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Component Page
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 3
I nstrument Cl uster . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-40-2, 3
Park Brake Swi tch . . . . . . . . . . . . . . . . . 8W-40-6, 7
Powertrai n Control Modul e . . 8W-40-4, 5, 6, 7, 8, 10
Transmi ssi on Control Modul e . . . . . . . . . . . 8W-40-4
Vehi cl e I nformati on Center . . . . . . . . . . . . . 8W-40-7
WJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
Component Page
Body Control Modul e . . . . . . . . . . . . . . . 8W-41-2, 3
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . 8W-41-4
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Front Power Outl et . . . . . . . . . . . . . . . . . . . 8W-41-5
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-5
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-5
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Component Page
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4, 5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-5
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . 8W-41-2, 3, 4, 5
Power Connector . . . . . . . . . . . . . . . . . . . . . 8W-41-5
Rear Power Outl et . . . . . . . . . . . . . . . . . . . 8W-41-5
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . . 8W-41-4
WJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . 8W-42-3, 4
A/C Compressor Cl utch Rel ay . . . . . . . . . 8W-42-3, 4
A/C Pressure Transducer . . . . . . . . 8W-42-11, 12, 13
Auto Shut Down Rel ay . . . . . . . . . . 8W-42-4, 11, 12
Automati c Zone Control Modul e . 8W-42-2, 5, 6, 7, 8
Bl ower Motor . . . . . . . . . . . . . . . . . . . 8W-42-2, 6, 9
Bl ower Motor Control l er . . . . . . . . . . . . . 8W-42-2, 6
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . 8W-42-9
Body Control Modul e . . . . . . . . . . . 8W-42-5, 6, 9, 10
Dri ver Bl end Door Motor/Actuator . . . . . 8W-42-7, 8
Engi ne Control Modul e . . . . . . . . . . . . . 8W-42-4, 13
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 6, 9
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5, 10
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . 8W-42-4, 11, 12
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 10
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3, 4
Component Page
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-11, 12
G200 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 6, 10
Gl ow Pl ug Rel ay No. 1 . . . . . . . . . . . . . . . . 8W-42-4
Hydraul i c Cool i ng Modul e . . . . . . . . . . 8W-42-11, 12
Juncti on Bl ock . . . . . . . . . . . . . . 8W-42-2, 3, 5, 6, 10
Manual Temperature Control . . . . . . 8W-42-2, 9, 10
Mode Door Motor/Actuator . . . . . . . . . . . 8W-42-7, 8
Oxygen Sensor Downstream Rel ay . . . 8W-42-11, 12
Passenger Bl end Door Motor/Actuator . . 8W-42-7, 8
Power Di stri buti on
Center . . . . . . . . . . . . . 8W-42-2, 3, 4, 6, 9, 11, 12
Powertrai n Control Modul e . . . . . . . 8W-42-3, 11, 12
Rear Wi ndow Defogger . . . . . . . . . . . . . 8W-42-5, 10
Rear Wi ndow Defogger Rel ay . . . . . . . . 8W-42-5, 10
Reci rcul ati on Door Motor/Actuator . . . . . 8W-42-7, 8
Temperature Val ve Actuator . . . . . . . . . . . 8W-42-10
Vi scous/Cabi n Heater Rel ay . . . . . . . . . . . . 8W-42-4
WJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1
8W-43 AIRBAG SYSTEM
Component Page
Ai rbag Control Modul e . . . . . . . . . . 8W-43-2, 3, 4, 5
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Dri ver Ai rbag Squi b 1 . . . . . . . . . . . . . . . . . 8W-43-2
Dri ver Ai rbag Squi b 2 . . . . . . . . . . . . . . . . . 8W-43-2
Dri ver Curtai n Squi b . . . . . . . . . . . . . . . . . 8W-43-5
Dri ver Seat Bel t Swi tch . . . . . . . . . . . . . . . 8W-43-5
Dri ver Si de I mpact Sensor . . . . . . . . . . . . . 8W-43-5
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Component Page
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-43-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
Left Front I mpact Sensor . . . . . . . . . . . . . . 8W-43-4
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . . 8W-43-3
Passenger Curtai n Ai rbag . . . . . . . . . . . . . . 8W-43-5
Passenger Seat Bel t Swi tch . . . . . . . . . . . . 8W-43-5
Passenger Si de I mpact Sensor . . . . . . . . . . 8W-43-5
Ri ght Front I mpact Sensor . . . . . . . . . . . . . 8W-43-4
WJ 8W-43 AIRBAG SYSTEM 8W - 43 - 1
8W-44 INTERIOR LIGHTING
Component Page
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . 8W-44-10
Automati c Zone Control Modul e . . . . . . . . 8W-44-10
Body Control Modul e . . . . . 8W-44-2, 3, 4, 5, 6, 8, 10
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Dri ver Front Door Courtesy Lamp . . . . . . . 8W-44-9
Dri ver Heated Seat Swi tch . . . . . . . . . . . . 8W-44-10
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4, 8
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-10
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6, 7
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5, 6, 7
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . 8W-44-8
Juncti on Bl ock . . . . . . . . . . . . . 8W-44-2, 3, 4, 5, 6, 8
Left Courtesy Lamp . . . . . . . . . . . . . . . . . . 8W-44-8
Left Door Handl e Courtesy Lamp . . . . . . . . 8W-44-3
Component Page
Left Mul ti -Functi on Swi tch . . . . . . . . . . . . 8W-44-10
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . 8W-44-2
Manual Temperature Control . . . . . . . . . . 8W-44-10
Overhead Map/Courtesy Lamp . . . . . . . . . . 8W-44-3
Passenger Door Lock Motor/Ajar Swi tch . . . 8W-44-7
Passenger Door Modul e . . . . . . . . . . . . . . 8W-44-7, 9
Passenger Front Door Courtesy Lamp . . . . 8W-44-9
Passenger Heated Seat Swi tch . . . . . . . . . 8W-44-10
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-10
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-44-8
Ri ght Door Handl e Courtesy Lamp . . . . . . . 8W-44-3
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . 8W-44-2
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . 8W-44-10
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-44-8
WJ 8W-44 INTERIOR LIGHTING 8W - 44 - 1
8W-45 BODY CONTROL MODULE
Component Page
Accessory Del ay Rel ay . . . . . . . . . . . . . . . . 8W-45-9
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-45-7
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . 8W-45-4
Sensor/VTSS LED . . . . . . . . . . . . . . . . 8W-45-3, 7
Automati c Zone Control Modul e . . . . . . 8W-45-4, 10
Body Control
Modul e . . . . . . . . . . 8W-45-2, 3, 4, 5, 6, 7, 8, 9, 10
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
Cool ant Level Sensor . . . . . . . . . . . . . . . 8W-45-5, 6
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-45-5, 6
Dri ver Heated Seat Swi tch . . . . . . . . . . 8W-45-4, 10
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Front Washer Pump . . . . . . . . . . . . . . . . . . 8W-45-8
Front Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-45-8
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2, 5, 6
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . . 8W-45-3
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . . 8W-45-7
Component Page
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
Juncti on Bl ock . . . . . . . . . 8W-45-2, 3, 4, 5, 6, 7, 8, 9
Left Courtesy Lamp . . . . . . . . . . . . . . . . 8W-45-5, 6
Left Mul ti -Functi on Swi tch . . . . . . . . . . . 8W-45-3, 4
Left Remote Radi o Swi tch . . . . . . . . . . . . . . 8W-45-9
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Low Beam/Dayti me Runni ng
Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Manual Temperature Control . . . . . . . . 8W-45-4, 10
Overhead Map/Courtesy Lamp . . . . . . . . 8W-45-5, 6
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8W-45-3, 4
Passenger Heated Seat Swi tch . . . . . . . 8W-45-4, 10
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Rear Wi ndow Defogger Rel ay . . . . . . . . . 8W-45-4, 9
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-45-8
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . 8W-45-5, 6
Ri ght Mul ti -Functi on Swi tch . . . . . . . . . . . 8W-45-8
Ri ght Remote Radi o Swi tch . . . . . . . . . . . . 8W-45-9
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . 8W-45-8
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . . 8W-45-2
Wi per On/Off Rel ay . . . . . . . . . . . . . . . . . . . 8W-45-8
WJ 8W-45 BODY CONTROL MODULE 8W - 45 - 1
8W-47 AUDIO SYSTEM
Component Page
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Antenna Modul e . . . . . . . . . . . . . . . . . . . . . 8W-47-3
Body Control Modul e . . . . . . . . . . . . . 8W-47-2, 3, 13
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-13
Compact Di sc Changer . . . . . . . . . . . . . . 8W-47-6, 7
Di agnosti c Juncti on Port . . . . . . 8W-47-2, 3, 6, 7, 13
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
Component Page
Left Front Door Speaker . . . . . . . . . 8W-47-4, 10, 11
Left I nstrument Panel Speaker . . . . . . . 8W-47-4, 12
Left Rear Door Speaker . . . . . . . . . . 8W-47-5, 10, 11
Left Remote Radi o Swi tch . . . . . . . . . . . . . 8W-47-13
Power Ampl i fi er . . . . . 8W-47-3, 6, 7, 8, 9, 10, 11, 12
Radi o . . . . . . . . . . . . . 8W-47-2, 3, 4, 5, 6, 7, 8, 9, 13
Ri ght Front Door Speaker . . . . . . . . 8W-47-4, 10, 11
Ri ght I nstrument Panel Speaker . . . . . 8W-47-4, 12
Ri ght Rear Door Speaker . . . . . . . . . 8W-47-5, 10, 11
Ri ght Remote Radi o Swi tch . . . . . . . . . . . 8W-47-13
WJ 8W-47 AUDIO SYSTEM 8W - 47 - 1
8W-48 REAR WINDOW DEFOGGER
Component Page
Automati c Zone Control Modul e . . . . . . . . . 8W-48-2
Body Control Modul e . . . . . . . . . . . . . . . . . 8W-48-2
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Manual Temperature Control . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-48-2
WJ 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1
8W-49 OVERHEAD CONSOLE
Component Page
Automati c Day/Ni ght Mi rror . . . . . . . . . . 8W-49-4, 5
Back-Up Lamp Rel ay . . . . . . . . . . . . . . . . . 8W-49-5
Di agnosti c Juncti on Port . . . . . . . . . . . 8W-49-2, 3, 6
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . 8W-49-4
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-7
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3, 4
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-6
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-7
Component Page
G301 . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3, 5, 6
I ntrusi on Transcei ver Modul e . . . . . . . . . . . 8W-49-7
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-49-2, 3, 4, 6, 7
Left Rear Lamp Assembl y . . . . . . . . . . . . . . 8W-49-5
Rai n Sensor . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-6
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-7
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . 8W-49-5
Vehi cl e I nformati on Center . . . . . . . . . . . 8W-49-2, 3
WJ 8W-49 OVERHEAD CONSOLE 8W - 49 - 1
8W-50 FRONT LIGHTING
Component Page
Sensor/VTSS LED . . . . . . . . . . . . . . . . . . 8W-50-2
Body Control Modul e . . . . . . 8W-50-2, 3, 4, 6, 12, 13
Combi nati on Fl asher . . . . . . . . . . . . . . . . 8W-50-3, 6
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-50-12
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 13
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 13
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-12
G106 . . . . . . . . . . . . . . . . . . 8W-50-5, 10, 11, 12, 13
G108 . . . . . . . . . . . . . . . . . . . . 8W-50-5, 7, 8, 12, 13
G200 . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 6, 9, 13
Headl amp Level i ng Swi tch . . . . . . . . . . . . . 8W-50-9
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . 8W-50-3, 4
Juncti on Bl ock . . . . . . . . . . . . . . 8W-50-3, 4, 5, 6, 7,
8, 10, 11, 12, 13
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-12
Left Front Park Lamp . . . . . . . . . . . . . 8W-50-10, 11
Left Front Park/Turn Si gnal Lamp . . . . . . 8W-50-10
Component Page
Left Front Si de Marker Lamp . . . . . . . . . . 8W-50-10
Left Front Turn Si gnal Lamp . . . . . . . . . . 8W-50-11
Left Headl amp Level i ng Motor . . . . . . . . . 8W-50-11
Left Hi gh Beam Headl amp . . . . . . . . . . . . . 8W-50-5
Left Low Beam Headl amp . . . . . . . . . . . 8W-50-5, 13
Left Mul ti -Functi on Swi tch . . . . . . . . . 8W-50-2, 3, 4
Left Si de Repeater Lamp . . . . . . . . . . . . . 8W-50-11
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Low Beam/Dayti me Runni ng
Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-50-13
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-50-6
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-50-12
Ri ght Front Park Lamp . . . . . . . . . . . . . 8W-50-7, 8
Ri ght Front Park/Turn Si gnal Lamp . . . . . . 8W-50-7
Ri ght Front Si de Marker Lamp . . . . . . . . . 8W-50-7
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . 8W-50-8
Ri ght Headl amp Level i ng Motor . . . . . . . . . 8W-50-8
Ri ght Hi gh Beam Headl amp . . . . . . . . . . . . 8W-50-5
Ri ght Low Beam Headl amp . . . . . . . . . 8W-50-5, 13
Ri ght Rear Lamp Assembl y . . . . . . . . . . . 8W-50-7, 8
Ri ght Si de Repeater Lamp . . . . . . . . . . . . . 8W-50-8
WJ 8W-50 FRONT LIGHTING 8W - 50 - 1
8W-51 REAR LIGHTING
Component Page
Adjustabl e Pedal s Modul e . . . . . . . . . . . . . . 8W-51-7
Automati c Day/Ni ght Mi rror . . . . . . . . . . 8W-51-7, 8
Back-Up Lamp Rel ay . . . . . . . . . . . . . . . . . 8W-51-9
Body Control Modul e . . . . . . . . . . . . . 8W-51-2, 3, 10
Brake Lamp Swi tch . . . . . . . . . . . . . . . . 8W-51-5, 6
Center Hi gh Mounted Stop Lamp . . . . . . 8W-51-5, 6
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-51-5, 6
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-9
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5, 6
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-10
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3
G300 . . . . . . . . . . . . . . . . . 8W-51-2, 3, 5, 6, 7, 8, 10
G301 . . . . . . . . . . . . . . . 8W-51-2, 3, 4, 5, 6, 7, 8, 10
Component Page
Juncti on Bl ock . . . . . . . . . . . . 8W-51-2, 3, 5, 6, 9, 10
Left Rear Lamp
Assembl y . . . . . . . . . . . . 8W-51-2, 3, 5, 6, 7, 8, 10
Li cense Lamp No. 1 . . . . . . . . . . . . . . . . . . 8W-51-4
Li cense Lamp No. 2 . . . . . . . . . . . . . . . . . . 8W-51-4
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8W-51-2, 3
Park/Neutral Posi ti on Swi tch . . . . . . . . . 8W-51-7, 8
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . 8W-51-10
Ri ght Rear Lamp
Assembl y . . . . . . . . . . . . 8W-51-2, 3, 5, 6, 7, 8, 10
Trai l er Tow Brake Lamp Rel ay . . . . . . . . . . 8W-51-5
Trai l er Tow Connector . . . . . . . . . . . . . . . . . 8W-51-7
Transmi ssi on Sol enoi d/TRS
Assembl y . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
WJ 8W-51 REAR LIGHTING 8W - 51 - 1
8W-52 TURN SIGNALS
Component Page
Combi nati on Fl asher . . . . . . . . . . 8W-52-2, 3, 5, 7, 8
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 5
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 6
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 4
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3, 5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7, 8
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7, 8
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-52-3, 5
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-52-2, 3, 5, 7, 8
Left Front Park Lamp . . . . . . . . . . . . . . . . 8W-52-6
Left Front Park/Turn Si gnal Lamp . . . . . . . 8W-52-6
Component Page
Left Front Si de Marker Lamp . . . . . . . . . . . 8W-52-6
Left Front Turn Si gnal Lamp . . . . . . . . . 8W-52-5, 6
Left Mul ti -Functi on Swi tch . . . . . . . . . . . . . 8W-52-2
Left Rear Lamp Assembl y . . . . . . . . . . . . 8W-52-7, 8
Left Si de Repeater Lamp . . . . . . . . . . . . . . 8W-52-5
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8W-52-3, 5
Ri ght Front Park Lamp . . . . . . . . . . . . . . . 8W-52-4
Ri ght Front Park/Turn Si gnal Lamp . . . . . . 8W-52-4
Ri ght Front Si de Marker Lamp . . . . . . . . . 8W-52-4
Ri ght Front Turn Si gnal Lamp . . . . . . . . 8W-52-3, 4
Ri ght Rear Lamp Assembl y . . . . . . . . . 8W-52-3, 7, 8
Ri ght Si de Repeater Lamp . . . . . . . . . . . . . 8W-52-3
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . 8W-52-7
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . 8W-52-7
WJ 8W-52 TURN SIGNALS 8W - 52 - 1
8W-53 WIPERS
Component Page
Body Control Modul e . . . . . . . . . . . . 8W-53-2, 3, 4, 6
Ci rcui t Breaker No. 1 . . . . . . . . . . . . . . . 8W-53-3, 4
Front Washer Pump . . . . . . . . . . . . . . . . . . 8W-53-2
Front Wi per Motor . . . . . . . . . . . . . . . 8W-53-3, 4, 5
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-6
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 5, 6
Component Page
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5, 6
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-53-2, 3, 4, 5, 6
Rai n Sensor . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
Rear Washer Pump . . . . . . . . . . . . . . . . . . . 8W-53-6
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-53-6
Ri ght Mul ti -Functi on Swi tch . . . . . . . . . . 8W-53-2, 6
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . 8W-53-2
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . 8W-53-3, 4, 5
Wi per On/Off Rel ay . . . . . . . . . . . . . . . 8W-53-3, 4, 5
WJ 8W-53 WIPERS 8W - 53 - 1
8W-54 TRAILER TOW
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . . . 8W-54-3, 5
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . 8W-54-4
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . . 8W-54-4
Combi nati on Fl asher . . . . . . . . . . . . . . . . . 8W-54-5
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . 8W-54-3, 5
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-5
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
Component Page
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-5
Juncti on Bl ock . . . . . . . . . . . . . . . . 8W-54-2, 3, 4, 5
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-54-2
Trai l er Tow Brake Lamp Rel ay . . . . . . 8W-54-3, 5, 6
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . . 8W-54-4
Trai l er Tow Connector . . . . . . . . . . . 8W-54-2, 3, 4, 6
Trai l er Tow Left Turn Rel ay . . . . . . . . . . 8W-54-5, 6
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . 8W-54-5, 6
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . 8W-54-4
WJ 8W-54 TRAILER TOW 8W - 54 - 1
8W-60 POWER WINDOWS
Component Page
Dri ver Door Modul e . . . . . . . . . . . . 8W-60-2, 3, 4, 5
Dri ver Front Power Wi ndow Motor . . . . . 8W-60-2, 3
Dri ver Rear Power Wi ndow Motor . . . . . . . 8W-60-5
Dri ver Rear Power Wi ndow Swi tch . . . . . . . 8W-60-5
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 4, 5, 6
Component Page
G301 . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3, 4, 5, 6
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8W-60-2, 3, 4
Passenger Door Modul e . . . . . . . . . . 8W-60-2, 3, 4, 6
Passenger Front Power
Wi ndow Motor . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
Passenger Rear Power Wi ndow Motor . . . . 8W-60-6
Passenger Rear Power Wi ndow Swi tch . . . . 8W-60-6
Power Di stri buti on Center . . . . . . . . . . . 8W-60-2, 3
WJ 8W-60 POWER WINDOWS 8W - 60 - 1
8W-61 POWER DOOR LOCKS
Component Page
Body Control Modul e . . . . 8W-61-2, 4, 7, 8, 9, 10, 12
Dri ver Cyl i nder Lock Swi tch . . . . . . . . . . . . 8W-61-3
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-11
G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3, 4, 8, 9
G301 . . . . . . . . . . . . . . . . . 8W-61-3, 4, 7, 10, 11, 12
Juncti on Bl ock . . . . . . . . . . 8W-61-2, 4, 7, 10, 11, 12
Left Li ftgate Ajar Swi tch . . . . . . . . . . . . . 8W-61-12
Left Rear Door Lock Motor/Ajar
Swi tch . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6, 7, 10
Li ftgate Fl i p-Up Ajar Swi tch . . . . . . . . . . . 8W-61-12
Component Page
Li ftgate Fl i p-Up Push Button Swi tch . . . . 8W-61-11
Li ftgate Fl i p-Up Rel ease Sol enoi d . . . . . . . 8W-61-11
Li ftgate Power Lock Motor . . . . . . . . 8W-61-5, 6, 11
Passenger Door Lock Motor/Ajar
Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4, 5, 6
Passenger Door
Modul e . . . . . . . . . . . 8W-61-4, 5, 6, 7, 8, 9, 10, 11
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-61-12
Remote Keyl ess Modul e . . . . . . . . . . . . . . . 8W-61-2
Ri ght Li ftgate Ajar Swi tch . . . . . . . . . . . . 8W-61-12
Ri ght Rear Door Lock Motor/Ajar
Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6, 8, 9
WJ 8W-61 POWER DOOR LOCKS 8W - 61 - 1
8W-62 POWER MIRRORS
Component Page
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . 8W-62-6
Dri ver Door Modul e . . . . . . . . . . . . 8W-62-2, 3, 4, 6
Dri ver Front Door Courtesy Lamp . . . . . . . 8W-62-4
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . 8W-62-6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
Component Page
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
Memory Set Swi tch . . . . . . . . . . . . . . . . . . . 8W-62-4
Passenger Door Modul e . . . . . . . . . . . . 8W-62-2, 3, 5
Passenger Front Door Courtesy Lamp . . . . 8W-62-5
Passenger Power Mi rror . . . . . . . . . . . . . . . 8W-62-5
WJ 8W-62 POWER MIRRORS 8W - 62 - 1
8W-63 POWER SEATS
Component Page
Body Control Modul e . . . . . . . . . . . . . . . . 8W-63-12
Ci rcui t Breaker No. 2 (JB) . . . . 8W-63-2, 3, 4, 10, 11
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . 8W-63-3
Dri ver Heated Seat Back . . . . . . . . . . . . 8W-63-6, 7
Dri ver Heated Seat Cushi on . . . . . . . . . . 8W-63-6, 7
Dri ver Heated Seat Swi tch . . . . . . . . . . . . 8W-63-12
Dri ver Lumbar Motor . . . . . . . . . . . . . 8W-63-10, 11
Dri ver Lumbar Swi tch . . . . . . . . . . . . . 8W-63-10, 11
Dri ver Power Seat Front Ri ser Motor . . . 8W-63-2, 5
Dri ver Power Seat Front Ri ser
Motor Sensor . . . . . . . . . . . . . . . . . . . . . 8W-63-8
Dri ver Power Seat Hori zontal Motor . . . . 8W-63-2, 5
Dri ver Power Seat Hori zontal
Motor Sensor . . . . . . . . . . . . . . . . . . . . 8W-63-8, 9
Dri ver Power Seat Rear Ri ser Motor . . . 8W-63-2, 5
Dri ver Power Seat Rear Ri ser
Motor Sensor . . . . . . . . . . . . . . . . . . . . . 8W-63-8
Dri ver Power Seat Recl i ner Motor . . . . . 8W-63-2, 5
Dri ver Power Seat Recl i ner
Motor Sensor . . . . . . . . . . . . . . . . . . . . 8W-63-8, 9
Component Page
Dri ver Power Seat Swi tch . . . . . . . . . . . . 8W-63-2, 5
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12
G300 . . . . . . . . . . . . . . . . . . . . 8W-63-3, 4, 5, 10, 11
G301 . . . . . . . . . . . . . . . . . . 8W-63-2, 3, 4, 5, 10, 11
Juncti on Bl ock . . . . . . . . . . 8W-63-2, 3, 4, 10, 11, 12
Memory Set Swi tch . . . . . . . . . . . . . . . . . . . 8W-63-3
Passenger Heated Seat Back . . . . . . . . . 8W-63-6, 7
Passenger Heated Seat Cushi on . . . . . . . 8W-63-6, 7
Passenger Heated Seat Swi tch . . . . . . . . . 8W-63-12
Passenger Lumbar Motor . . . . . . . . . . 8W-63-10, 11
Passenger Lumbar Swi tch . . . . . . . . . . 8W-63-10, 11
Passenger Power Seat Front
Ri ser Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
Passenger Power Seat Hori zontal Motor . . . 8W-63-4
Passenger Power Seat Rear
Ri ser Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
Passenger Power Seat Recl i ner Motor . . . . 8W-63-4
Passenger Power Seat Swi tch . . . . . . . . . . . 8W-63-4
Seat Modul e . . . . . . . . . . . . . . 8W-63-3, 5, 6, 7, 8, 9
WJ 8W-63 POWER SEATS 8W - 63 - 1
8W-64 POWER SUNROOF
Component Page
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2, 3
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
Sunroof Control Modul e . . . . . . . . . . . . . 8W-64-2, 3
Sunroof Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
Sunroof Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-64-3
WJ 8W-64 POWER SUNROOF 8W - 64 - 1
8W-70 SPLICE INFORMATION
Component Page
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 12
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-21, 45
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2, 3, 4, 5
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2, 3, 4, 5
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-13
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-9, 10
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5, 6
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-23
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 20
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3, 5
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6, 7
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10, 11
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-3, 32
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5, 32
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-51
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
S153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
S154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-33
S155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-33
S156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
S158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5
S160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11
S162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
S163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7, 15
S165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-9
S168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
S169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-47
S170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-44
S171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-36
S172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-36
S174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
S175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
S176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-10
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4, 7
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-5
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-5
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-13
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-13
S217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-10
Component Page
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-37
S223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-8, 9, 10
S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 6
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-36
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7, 8
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 6
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5, 6
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6, 7
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-9
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3, 5
S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-32
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6
S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5, 6
S341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 22
S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30
S348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
S349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23
S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-8
S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8
S353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
S355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18, 21
S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21, 22
S357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16, 18
S358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22
S359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9
S360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5
S365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-11
S366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
S367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-36
S368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3
S369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21, 22
S370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
S401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
S402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
S403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
S404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30
S405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30
S406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-6
S407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-6
S408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 13
S412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
WJ 8W-70 SPLICE INFORMATION 8W - 70 - 1
8W-80 CONNECTOR PIN-OUT
Component Page
A/C COMPRESSOR CLUTCH . . . . . . . . . . 8W-80-6
A/C PRESSURE TRANSDUCER . . . . . . . . 8W-80-6
ACCELERATOR PEDAL POSI TI ON
SENSOR (DI ESEL) . . . . . . . . . . . . . . . . . 8W-80-6
ADJUSTABLE PEDALS MODULE
(EXCEPT BUI LT-UP-EXPORT) . . . . . . . 8W-80-6
ADJUSTABLE PEDALS MOTOR/SENSOR
ASSEMBLY (EXCEPT
BUI LT-UP-EXPORT) . . . . . . . . . . . . . . . 8W-80-7
ADJUSTABLE PEDALS SWI TCH (EXCEPT
BUI LT-UP-EXPORT) . . . . . . . . . . . . . . . 8W-80-7
AI RBAG CONTROL MODULE C1
(ORC C1) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7
AI RBAG CONTROL MODULE C2
(ORC C2) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8
AMBI ENT TEMPERATURE SENSOR . . . . 8W-80-8
ANTENNA MODULE
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . . . 8W-80-8
ASH RECEI VER LAMP . . . . . . . . . . . . . . . 8W-80-9
AUTOMATI C DAY/NI GHT MI RROR . . . . . 8W-80-9
AUTOMATI C HEADLAMP LI GHT
SENSOR/VTSS LED . . . . . . . . . . . . . . . . 8W-80-9
AUTOMATI C ZONE CONTROL
MODULE C1 (AZC) . . . . . . . . . . . . . . . . 8W-80-9
AUTOMATI C ZONE CONTROL
MODULE C2 (AZC) . . . . . . . . . . . . . . . 8W-80-10
BATTERY TEMPERATURE SENSOR . . . 8W-80-10
BLOWER MOTOR . . . . . . . . . . . . . . . . . . 8W-80-10
BLOWER MOTOR CONTROLLER
(AZC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-10
BLOWER MOTOR RESI STOR
BLOCK (MTC) . . . . . . . . . . . . . . . . . . . 8W-80-10
BODY CONTROL MODULE C1 . . . . . . . . 8W-80-11
BODY CONTROL MODULE C2 . . . . . . . . 8W-80-11
BOOST PRESSURE SENSOR
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
BRAKE LAMP SWI TCH . . . . . . . . . . . . . . 8W-80-12
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C101 (4.0L RHD) . . . . . . . . . . . . . . . . . . . 8W-80-12
C101 (4.0L RHD) . . . . . . . . . . . . . . . . . . . 8W-80-13
C101 (4.7L RHD) . . . . . . . . . . . . . . . . . . . 8W-80-13
C101 (4.7L RHD) . . . . . . . . . . . . . . . . . . . 8W-80-13
C102 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C102 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C102 (GAS RHD) . . . . . . . . . . . . . . . . . . . 8W-80-14
C102 (GAS RHD) . . . . . . . . . . . . . . . . . . . 8W-80-15
C103 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C103 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C103 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C103 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
Component Page
C105 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C105 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C106 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C106 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C106 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C106 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C107 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C107 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-28
C107 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
C107 (GAS) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
C110 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-34
C110 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-34
C111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
C111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
C112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
C112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
C113 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-35
C113 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-35
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-36
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-38
C201 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-39
C201 (DI ESEL) . . . . . . . . . . . . . . . . . . . . . 8W-80-39
C202 (AZC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
C202 (AZC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
C202 (MTC) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
C202 (MTC) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
C203 (AZC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
C203 (AZC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
C300 (LHD) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-42
C300 (LHD) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-44
C301 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-46
C301 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-48
C302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-49
C302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-50
C303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-50
C303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-51
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-51
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-51
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
C308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
C308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-54
C310 (BUI LT-UP-EXPORT) . . . . . . . . . . . 8W-80-54
C310 (BUI LT-UP-EXPORT) . . . . . . . . . . . 8W-80-54
WJ 8W-80 CONNECTOR PIN-OUT 8W - 80 - 1
Component Page
C310 (EXCEPT BUI LT-UP-EXPORT) . . . . 8W-80-55
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-55
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-55
C312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-55
C312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-56
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-57
C315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-57
C315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-57
C317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-58
C317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-58
C318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-58
C318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59
CAMSHAFT POSI TI ON
SENSOR (DI ESEL) . . . . . . . . . . . . . . . . 8W-80-59
CAMSHAFT POSI TI ON
SENSOR (GAS) . . . . . . . . . . . . . . . . . . . 8W-80-59
CAPACI TOR (4.0L) . . . . . . . . . . . . . . . . . . 8W-80-59
CAPACI TOR NO. 1 (4.7L) . . . . . . . . . . . . . 8W-80-60
CAPACI TOR NO. 2 (4.7L) . . . . . . . . . . . . . 8W-80-60
CARGO LAMP . . . . . . . . . . . . . . . . . . . . . 8W-80-60
CENTER HI GH MOUNTED
STOP LAMP . . . . . . . . . . . . . . . . . . . . . 8W-80-60
CI GAR LI GHTER . . . . . . . . . . . . . . . . . . . 8W-80-60
CLOCKSPRI NG C1 . . . . . . . . . . . . . . . . . 8W-80-61
CLOCKSPRI NG C2 . . . . . . . . . . . . . . . . . 8W-80-61
CLOCKSPRI NG C3 . . . . . . . . . . . . . . . . . 8W-80-61
CLOCKSPRI NG C4 . . . . . . . . . . . . . . . . . 8W-80-61
COI L ON PLUG NO. 1 (4.7L) . . . . . . . . . . 8W-80-61
COI L ON PLUG NO. 2 (4.7L) . . . . . . . . . . 8W-80-62
COI L ON PLUG NO. 3 (4.7L) . . . . . . . . . . 8W-80-62
COI L ON PLUG NO. 4 (4.7L) . . . . . . . . . . 8W-80-62
COI L ON PLUG NO. 5 (4.7L) . . . . . . . . . . 8W-80-62
COI L ON PLUG NO. 6 (4.7L) . . . . . . . . . . 8W-80-62
COI L ON PLUG NO. 7 (4.7L) . . . . . . . . . . 8W-80-63
COI L ON PLUG NO. 8 (4.7L) . . . . . . . . . . 8W-80-63
COI L RAI L (4.0L) . . . . . . . . . . . . . . . . . . . 8W-80-63
COMPACT DI SC CHANGER
(PREMI UM RADI O) . . . . . . . . . . . . . . . 8W-80-63
CONTROLLER ANTI LOCK BRAKE . . . . 8W-80-64
COOLANT LEVEL SENSOR . . . . . . . . . . 8W-80-64
CRANKCASE HEATER (DI ESEL) . . . . . . 8W-80-64
CRANKSHAFT POSI TI ON SENSOR
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-65
CRANKSHAFT POSI TI ON SENSOR
(GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-65
DATA LI NK CONNECTOR . . . . . . . . . . . . 8W-80-65
DI AGNOSTI C JUNCTI ON PORT . . . . . . . 8W-80-66
Component Page
DRI VER AI RBAG SQUI B 1 . . . . . . . . . . . 8W-80-66
DRI VER AI RBAG SQUI B 2 . . . . . . . . . . . 8W-80-66
DRI VER BLEND DOOR MOTOR/ACTUATOR
(LHD) (AZC) . . . . . . . . . . . . . . . . . . . . . 8W-80-67
DRI VER BLEND DOOR MOTOR/ACTUATOR
(RHD) (AZC)- BLACK 2 WAY . . . . . . . . 8W-80-67
DRI VER CURTAI N AI RBAG . . . . . . . . . . 8W-80-67
DRI VER CYLI NDER LOCK SWI TCH . . . 8W-80-67
DRI VER DOOR LOCK MOTOR/AJAR
SWI TCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-68
DRI VER DOOR MODULE C1 . . . . . . . . . 8W-80-68
DRI VER FRONT DOOR
COURTESY LAMP . . . . . . . . . . . . . . . . 8W-80-69
DRI VER FRONT POWER
WI NDOW MOTOR . . . . . . . . . . . . . . . . 8W-80-69
DRI VER HEATED SEAT BACK
(PREMI UM I /I I I ) . . . . . . . . . . . . . . . . . 8W-80-69
DRI VER HEATED SEAT CUSHI ON
(PREMI UM I /I I I ) . . . . . . . . . . . . . . . . . 8W-80-69
DRI VER HEATED SEAT SWI TCH . . . . . . 8W-80-70
DRI VER LUMBAR MOTOR
(MI DLI NE/PREMI UM) . . . . . . . . . . . . . 8W-80-70
DRI VER LUMBAR SWI TCH
DRI VER POWER MI RROR . . . . . . . . . . . 8W-80-70
DRI VER POWER SEAT FRONT
RI SER MOTOR . . . . . . . . . . . . . . . . . . . 8W-80-71
DRI VER POWER SEAT FRONT
RI SER MOTOR SENSOR
(PREMI UM I I /I I I ) . . . . . . . . . . . . . . . . . 8W-80-71
DRI VER POWER SEAT HORI ZONTAL
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-71
DRI VER POWER SEAT HORI ZONTAL
MOTOR SENSOR
(PREMI UM I I /I I I ) . . . . . . . . . . . . . . . . . 8W-80-71
DRI VER POWER SEAT REAR
RI SER MOTOR . . . . . . . . . . . . . . . . . . . 8W-80-71
DRI VER POWER SEAT REAR
RI SER MOTOR SENSOR
(PREMI UM I I /I I I ) . . . . . . . . . . . . . . . . . 8W-80-72
DRI VER POWER SEAT
RECLI NER MOTOR . . . . . . . . . . . . . . . 8W-80-72
DRI VER POWER SEAT
RECLI NER MOTOR SENSOR
(PREMI UM I I /I I I ) . . . . . . . . . . . . . . . . . 8W-80-72
DRI VER POWER SEAT SWI TCH
(EXCEPT MI DLI NE/PREMI UM) . . . . . 8W-80-72
DRI VER POWER SEAT SWI TCH
DRI VER REAR POWER
WI NDOW MOTOR . . . . . . . . . . . . . . . . 8W-80-73
DRI VER REAR POWER WI NDOW
SWI TCH . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-73
8W - 80 - 2 8W-80 CONNECTOR PIN-OUT WJ
Component Page
DRI VER SEAT BELT SWI TCH . . . . . . . . 8W-80-74
DRI VER SI DE I MPACT SENSOR . . . . . . 8W-80-74
EGR SOLENOI D (DI ESEL) . . . . . . . . . . . 8W-80-74
ELECTRI C BRAKE
(EXCEPT BUI LT-UP-EXPORT) . . . . . . 8W-80-74
ELECTRONI C SPEED CONTROL
SERVO . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-74
ENGI NE CONTROL MODULE C1
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-75
ENGI NE CONTROL MODULE C2
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-76
ENGI NE COOLANT TEMPERATURE
SENSOR (DI ESEL) . . . . . . . . . . . . . . . . 8W-80-77
ENGI NE COOLANT TEMPERATURE
SENSOR (GAS) . . . . . . . . . . . . . . . . . . . 8W-80-77
ENGI NE OI L PRESSURE
SENSOR (DI ESEL) . . . . . . . . . . . . . . . . 8W-80-77
ENGI NE OI L PRESSURE
SENSOR (GAS) . . . . . . . . . . . . . . . . . . . 8W-80-78
EVAP/PURGE SOLENOI D (GAS) . . . . . . . 8W-80-78
FRONT POWER OUTLET . . . . . . . . . . . . 8W-80-78
FRONT WASHER PUMP . . . . . . . . . . . . . 8W-80-78
FRONT WI PER MOTOR . . . . . . . . . . . . . 8W-80-78
FUEL I NJECTOR NO. 1 (DI ESEL) . . . . . 8W-80-79
FUEL I NJECTOR NO. 1 (GAS) . . . . . . . . 8W-80-79
FUEL I NJECTOR NO. 7 (4.7L) . . . . . . . . 8W-80-81
FUEL I NJECTOR NO. 8 (4.7L) . . . . . . . . 8W-80-81
FUEL PRESSURE SENSOR (DI ESEL) . . 8W-80-82
FUEL PRESSURE SOLENOI D
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-82
FUEL PUMP MODULE (GAS) . . . . . . . . . 8W-80-82
FUEL TANK MODULE (DI ESEL) . . . . . . 8W-80-82
GENERATOR (DI ESEL) . . . . . . . . . . . . . . 8W-80-82
GENERATOR (GAS) . . . . . . . . . . . . . . . . . 8W-80-83
GLOVE BOX LAMP . . . . . . . . . . . . . . . . . 8W-80-83
HEADLAMP LEVELI NG SWI TCH
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . . 8W-80-83
HOOD AJAR SWI TCH
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . . 8W-80-83
HORN NO. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-80-83
HORN NO. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-80-84
HYDRAULI C COOLI NG MODULE . . . . . 8W-80-84
I DLE AI R CONTROL MOTOR . . . . . . . . . 8W-80-84
I GNI TI ON SWI TCH C1 . . . . . . . . . . . . . . 8W-80-84
I GNI TI ON SWI TCH C2 . . . . . . . . . . . . . . 8W-80-84
I NPUT SPEED SENSOR (4.7L) . . . . . . . . 8W-80-85
Component Page
I NSTRUMENT CLUSTER . . . . . . . . . . . . 8W-80-85
I NTAKE AI R TEMPERATURE
SENSOR (DI ESEL) . . . . . . . . . . . . . . . . 8W-80-85
I NTAKE AI R TEMPERATURE
SENSOR (GAS) . . . . . . . . . . . . . . . . . . . 8W-80-85
I NTAKE PORT SWI RL ACTUATOR
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-86
I NTRUSI ON TRANSCEI VER MODULE
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . . 8W-80-86
JUNCTI ON BLOCK BODY
CONTROL MODULE . . . . . . . . . . . . . . 8W-80-86
JUNCTI ON BLOCK C1 . . . . . . . . . . . . . . 8W-80-87
JUNCTI ON BLOCK C2 (LHD) . . . . . . . . . 8W-80-88
JUNCTI ON BLOCK C2 (RHD) . . . . . . . . . 8W-80-89
KNOCK SENSOR . . . . . . . . . . . . . . . . . . . 8W-80-91
LEAK DETECTI ON PUMP (EXCEPT
BUI LT-UP-EXPORT) . . . . . . . . . . . . . . . 8W-80-91
LEFT COURTESY LAMP . . . . . . . . . . . . . 8W-80-91
LEFT DOOR HANDLE COURTESY
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-92
LEFT FOG LAMP . . . . . . . . . . . . . . . . . . . 8W-80-92
LEFT FRONT DOOR SPEAKER . . . . . . . 8W-80-92
LEFT FRONT I MPACT SENSOR . . . . . . . 8W-80-92
LEFT FRONT PARK LAMP . . . . . . . . . . . 8W-80-92
LEFT FRONT PARK/TURN SI GNAL LAMP
LEFT FRONT SI DE MARKER LAMP
LEFT FRONT TURN SI GNAL LAMP
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . . 8W-80-93
LEFT FRONT WHEEL SPEED
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-93
LEFT HEADLAMP LEVELI NG MOTOR
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . . 8W-80-94
LEFT HI GH BEAM HEADLAMP . . . . . . . 8W-80-94
LEFT I NSTRUMENT PANEL SPEAKER . 8W-80-94
LEFT LI FTGATE AJAR SWI TCH . . . . . . . 8W-80-94
LEFT LOW BEAM HEADLAMP . . . . . . . 8W-80-94
LEFT MULTI -FUNCTI ON SWI TCH . . . . 8W-80-95
LEFT REAR DOOR LOCK
MOTOR/AJAR SWI TCH . . . . . . . . . . . . 8W-80-95
LEFT REAR DOOR SPEAKER . . . . . . . . . 8W-80-95
LEFT REAR LAMP ASSEMBLY . . . . . . . . 8W-80-95
LEFT REAR WHEEL SPEED
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-96
LEFT REMOTE RADI O SWI TCH . . . . . . 8W-80-96
LEFT SI DE REPEATER LAMP
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . . 8W-80-96
LEFT VI SOR/VANI TY LAMP . . . . . . . . . . 8W-80-96
LI CENSE LAMP NO. 1 . . . . . . . . . . . . . . 8W-80-96
LI CENSE LAMP NO. 2 . . . . . . . . . . . . . . 8W-80-97
LI FTGATE FLI P-UP AJAR SWI TCH . . . . 8W-80-97
Component Page
LI FTGATE FLI P-UP PUSH
BUTTON SWI TCH . . . . . . . . . . . . . . . . 8W-80-97
LI FTGATE FLI P-UP RELEASE
SOLENOI D . . . . . . . . . . . . . . . . . . . . . . 8W-80-97
LI FTGATE POWER LOCK MOTOR . . . . . 8W-80-97
LI NE PRESSURE SENSOR (4.7L) . . . . . . 8W-80-98
MANI FOLD ABSOLUTE PRESSURE
SENSOR (4.0L) . . . . . . . . . . . . . . . . . . . 8W-80-98
MANI FOLD ABSOLUTE PRESSURE
SENSOR (4.7L) . . . . . . . . . . . . . . . . . . . 8W-80-98
MANUAL TEMPERATURE
CONTROL C1 (MTC) . . . . . . . . . . . . . . 8W-80-98
MANUAL TEMPERATURE
CONTROL C2 (MTC) . . . . . . . . . . . . . . 8W-80-99
MASS AI R FLOW SENSOR (DI ESEL) . . . 8W-80-99
MODE DOOR MOTOR/ACTUATOR
(AZC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-99
NEEDLE MOVEMENT SENSOR
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-99
OUTPUT SPEED SENSOR (4.0L) . . . . . . 8W-80-99
OUTPUT SPEED SENSOR (4.7L) . . . . . 8W-80-100
OVERHEAD MAP/COURTESY LAMP . . 8W-80-100
OXYGEN SENSOR 1/1 UPSTREAM . . . . 8W-80-100
OXYGEN SENSOR 1/2 DOWNSTREAM . 8W-80-100
OXYGEN SENSOR 2/1 UPSTREAM . . . . 8W-80-100
OXYGEN SENSOR 2/2
DOWNSTREAM . . . . . . . . . . . . . . . . . 8W-80-101
PARK/NEUTRAL POSI TI ON SWI TCH
(4.0L) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-101
PARK/NEUTRAL POSI TI ON SWI TCH
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . 8W-80-101
PASSENGER AI RBAG . . . . . . . . . . . . . . 8W-80-101
PASSENGER BLEND DOOR
MOTOR/ACTUATOR (LHD) (AZC) . . . 8W-80-101
PASSENGER BLEND DOOR
MOTOR/ACTUATOR (RHD) (AZC) . . . 8W-80-102
PASSENGER CURTAI N AI RBAG . . . . . . 8W-80-102
PASSENGER DOOR LOCK MOTOR/AJAR
SWI TCH . . . . . . . . . . . . . . . . . . . . . . . 8W-80-102
PASSENGER DOOR MODULE C1 . . . . . 8W-80-102
PASSENGER DOOR MODULE C2 . . . . . 8W-80-103
PASSENGER FRONT DOOR
COURTESY LAMP . . . . . . . . . . . . . . . 8W-80-103
PASSENGER FRONT POWER
WI NDOW MOTOR . . . . . . . . . . . . . . . 8W-80-103
PASSENGER HEATED SEAT BACK
(PREMI UM I /I I I ) . . . . . . . . . . . . . . . . . 8W-80-103
PASSENGER HEATED SEAT CUSHI ON
(PREMI UM I /I I I ) . . . . . . . . . . . . . . . . . 8W-80-104
PASSENGER HEATED SEAT SWI TCH . 8W-80-104
PASSENGER LUMBAR MOTOR
(MI DLI NE/PREMI UM) . . . . . . . . . . . . 8W-80-104
PASSENGER LUMBAR SWI TCH
PASSENGER POWER MI RROR . . . . . . . 8W-80-105
Component Page
PASSENGER POWER SEAT FRONT
RI SER MOTOR . . . . . . . . . . . . . . . . . . 8W-80-105
PASSENGER POWER SEAT
HORI ZONTAL MOTOR . . . . . . . . . . . 8W-80-105
PASSENGER POWER SEAT REAR
RI SER MOTOR . . . . . . . . . . . . . . . . . . 8W-80-105
PASSENGER POWER SEAT RECLI NER
MOTOR (MI DLI NE/PREMI UM) . . . . . 8W-80-106
PASSENGER POWER SEAT SWI TCH
PASSENGER REAR POWER
WI NDOW MOTOR . . . . . . . . . . . . . . . 8W-80-106
PASSENGER REAR POWER
WI NDOW SWI TCH . . . . . . . . . . . . . . . 8W-80-106
PASSENGER SEAT BELT SWI TCH . . . . 8W-80-106
PASSENGER SI DE I MPACT
SENSOR . . . . . . . . . . . . . . . . . . . . . . . 8W-80-107
POWER AMPLI FI ER C1
(PREMI UM RADI O) . . . . . . . . . . . . . . 8W-80-107
POWER AMPLI FI ER C2
(PREMI UM RADI O) . . . . . . . . . . . . . . 8W-80-107
POWER CONNECTOR . . . . . . . . . . . . . . 8W-80-108
POWERTRAI N CONTROL
MODULE C1 (GAS) . . . . . . . . . . . . . . 8W-80-108
POWERTRAI N CONTROL
MODULE C2 (GAS) . . . . . . . . . . . . . . 8W-80-109
POWERTRAI N CONTROL
MODULE C3 (GAS) . . . . . . . . . . . . . . 8W-80-110
RADI ATOR FAN MOTOR . . . . . . . . . . . . 8W-80-110
RADI ATOR FAN RELAY . . . . . . . . . . . . . 8W-80-111
RADI O C1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-111
RADI O C2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-111
RAI N SENSOR (AUTOWI PE) . . . . . . . . . 8W-80-112
REAR POWER OUTLET. . . . . . . . . . . . . 8W-80-112
REAR WASHER PUMP . . . . . . . . . . . . . . 8W-80-112
REAR WI PER MOTOR . . . . . . . . . . . . . . 8W-80-112
RECI RCULATI ON DOOR
MOTOR/ACTUATOR (AZC) . . . . . . . . . 8W-80-112
RED BRAKE WARNI NG I NDI CATOR
SWI TCH . . . . . . . . . . . . . . . . . . . . . . . 8W-80-113
REMOTE KEYLESS MODULE
(JAPAN) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-113
RI GHT COURTESY LAMP . . . . . . . . . . . 8W-80-113
RI GHT DOOR HANDLE
COURTESY LAMP . . . . . . . . . . . . . . . 8W-80-113
RI GHT FOG LAMP . . . . . . . . . . . . . . . . . 8W-80-113
RI GHT FRONT DOOR SPEAKER . . . . . 8W-80-114
RI GHT FRONT I MPACT SENSOR . . . . . 8W-80-114
RI GHT FRONT PARK LAMP . . . . . . . . . 8W-80-114
RI GHT FRONT PARK/TURN SI GNAL LAMP
RI GHT FRONT SI DE MARKER LAMP
RI GHT FRONT TURN SI GNAL LAMP
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . 8W-80-115
Component Page
RI GHT FRONT WHEEL SPEED
SENSOR . . . . . . . . . . . . . . . . . . . . . . . 8W-80-115
RI GHT HEADLAMP LEVELI NG MOTOR
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . 8W-80-115
RI GHT HI GH BEAM HEADLAMP . . . . . 8W-80-116
RI GHT I NSTRUMENT PANEL
SPEAKER . . . . . . . . . . . . . . . . . . . . . . 8W-80-116
RI GHT LI FTGATE AJAR SWI TCH . . . . . 8W-80-116
RI GHT LOW BEAM HEADLAMP . . . . . 8W-80-116
RI GHT MULTI -FUNCTI ON SWI TCH . . . 8W-80-116
RI GHT REAR DOOR LOCK
MOTOR/AJAR SWI TCH . . . . . . . . . . . 8W-80-117
RI GHT REAR DOOR SPEAKER . . . . . . . 8W-80-117
RI GHT REAR LAMP ASSEMBLY . . . . . . 8W-80-117
RI GHT REAR WHEEL SPEED
SENSOR . . . . . . . . . . . . . . . . . . . . . . . 8W-80-117
RI GHT REMOTE RADI O SWI TCH . . . . 8W-80-117
RI GHT SI DE REPEATER LAMP
(BUI LT-UP-EXPORT) . . . . . . . . . . . . . 8W-80-118
RI GHT VI SOR/VANI TY LAMP . . . . . . . . 8W-80-118
SEAT BELT SWI TCH . . . . . . . . . . . . . . . 8W-80-118
SEAT MODULE C1 (PREMI UM) . . . . . . 8W-80-118
SEAT MODULE C2 (PREMI UM) . . . . . . 8W-80-119
SENTRY KEY I MMOBI LI ZER
MODULE . . . . . . . . . . . . . . . . . . . . . . 8W-80-119
SHI FTER ASSEMBLY
(C201 DI ESEL) . . . . . . . . . . . . . . . . . . 8W-80-119
SHI FTER ASSEMBLY (GAS) . . . . . . . . . 8W-80-120
SHI FTER ASSEMBLY C1 (DI ESEL) . . . . 8W-80-120
SHI FTER ASSEMBLY C2 (DI ESEL) . . . . 8W-80-120
SI REN (BUI LT-UP-EXPORT) . . . . . . . . . 8W-80-120
SPEED CONTROL SWI TCH NO. 1 . . . . 8W-80-120
SPEED CONTROL SWI TCH NO. 2 . . . . 8W-80-121
SUNROOF CONTROL MODULE . . . . . . 8W-80-121
SUNROOF MOTOR C1 . . . . . . . . . . . . . . 8W-80-121
SUNROOF MOTOR C2 . . . . . . . . . . . . . . 8W-80-121
SUNROOF SWI TCH . . . . . . . . . . . . . . . . 8W-80-121
Component Page
TEMPERATURE VALVE
ACTUATOR (MTC) . . . . . . . . . . . . . . . 8W-80-122
THROTTLE POSI TI ON
SENSOR (4.0L) . . . . . . . . . . . . . . . . . . 8W-80-122
THROTTLE POSI TI ON
SENSOR (4.7L) . . . . . . . . . . . . . . . . . . 8W-80-122
TRAI LER TOW BRAKE
LAMP RELAY . . . . . . . . . . . . . . . . . . . 8W-80-122
TRAI LER TOW CI RCUI T
BREAKER . . . . . . . . . . . . . . . . . . . . . . 8W-80-122
TRAI LER TOW CONNECTOR . . . . . . . . 8W-80-123
TRAI LER TOW LEFT TURN
RELAY . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-123
TRAI LER TOW RI GHT TURN
RELAY . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-123
TRANSFER CASE POSI TI ON
SENSOR . . . . . . . . . . . . . . . . . . . . . . . 8W-80-123
TRANSMI SSI ON CONTROL
MODULE (4.7L) . . . . . . . . . . . . . . . . . 8W-80-124
MODULE C1 (DI ESEL) . . . . . . . . . . . 8W-80-125
MODULE C2 (DI ESEL) . . . . . . . . . . . 8W-80-125
TRANSMI SSI ON SOLENOI D (4.0L). . . . 8W-80-125
TRANSMI SSI ON SOLENOI D
ASSEMBLY (DI ESEL) . . . . . . . . . . . . 8W-80-126
TRANSMI SSI ON SOLENOI D/TRS
ASSEMBLY (4.7L) . . . . . . . . . . . . . . . . 8W-80-126
UNDERHOOD LAMP . . . . . . . . . . . . . . . 8W-80-126
VEHI CLE I NFORMATI ON CENTER . . . 8W-80-127
VI SCOUS/CABI N HEATER
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . 8W-80-127
WASHER FLUI D LEVEL SWI TCH . . . . 8W-80-127
WASTEGATE SOLENOI D
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . 8W-80-127
WATER I N FUEL SENSOR
(DI ESEL) . . . . . . . . . . . . . . . . . . . . . . 8W-80-127
A/C COMPRESSOR CLUTCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C2 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z18 18BK GROUND
A/C PRESSURE TRANSDUCER - BLACK 4 WAY
1 K4 18BK/LB SENSOR GROUND
2 K6 18VT/WT (DIESEL) SENSOR REFERENCE VOLTAGE B
2 K6 18VT/BK (GAS) 5 VOLT SUPPLY
3 C18 18DB A/C PRESSURE SIGNAL
4 - -
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY
1 - -
2 F855 18BR/YL SENSOR REFERENCE VOLTAGE A
3 K22 14RD/DB ACCELERATOR PEDAL POSITION SENSOR 2 SIGNAL
4 - -
5 - -
6 K225 18BK ACCELERATOR PEDAL POSITION SENSOR 2 GROUND
7 K81 20DB/DG ACCELERATOR PEDAL POSITION SENSOR 1 SIGNAL
8 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR 1 GROUND
9 - -
10 Y43 20WT/VT ACCELERATOR PEDAL POSITION SENSOR 1 5-VOLT
SUPPLY
ADJ USTABLE PEDALS MODULE (EXCEPT BUILT-UP-EXPORT) - GREEN 14 WAY
1 Y151 20LG/BR ADJ USTABLE PEDALS SWITCH SENSE (FORWARD)
2 Y152 20LG/OR ADJ USTABLE PEDALS SWITCH SENSE (REARWARD)
3 Q110 16OR/VT ADJ USTABLE PEDALS MOTOR (FORWARD)
4 F72 16RD/YL FUSED B(+)
5 - -
6 Q111 16OR/GY ADJ USTABLE PEDALS MOTOR (REARWARD)
7 Q113 20OR/DB (MEMORY) PEDAL POSITION SENSOR FEED
8 Q112 20OR/YL (MEMORY) PEDAL POSITION SENSOR SENSE
9 Q114 20OR/TN (MEMORY) PEDAL POSITION SENSOR RETURN
10 Z151 16BK GROUND
11 Z155 20BK/OR GROUND
12 L1 18WT/BR BACK-UP LAMP FEED
13 D25 20VT/YL PCI BUS
14 Y153 16DB/RD ADJ USTABLE PEDALS SWITCH FEED
ADJ USTABLE PEDALS MOTOR/SENSOR ASSEMBLY (EXCEPT BUILT-UP-EXPORT) - 6 WAY
1 Q113 20OR/DB PEDAL POSITION SENSOR FEED
2 Q112 20OR/YL PEDAL POSITION SENSOR SENSE
3 Q114 20OR/TN PEDAL POSITION SENSOR RETURN
4 - -
5 Q111 16OR/GY AJ DUSTABLE PEDALS MOTOR (REARWARD)
6 Q110 16OR/VT ADJ USTABLE PEDALS MOTOR (FORWARD)
ADJ USTABLE PEDALS SWITCH (EXCEPT BUILT-UP-EXPORT) - WHITE 3 WAY
1 Y153 20BD/RD ADJ USTABLE PEDALS SWITCH FEED
2 Y152 20LG/OR ADJ USTABLE PEDALS SWITCH SENSE (REARWARD)
3 Y151 20LG/BR ADJ USTABLE PEDALS SWITCH SENSE (FORWARD)
AIRBAG CONTROL MODULE C1 (ORC C1) - YELLOW 32 WAY
1 R72 20LB/WT (SIDE AIRBAGS) PASSENGER CURTAIN SQUIB LINE 2
2 R74 20LB/YL (SIDE AIRBAGS) PASSENGER CURTAIN SQUIB LINE 1
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 R58 20GY PASSENGER SEAT BELT SWITCH SENSE
10 R60 20VT PASSENGER SEAT BELT SWITCH GROUND
11 - -
12 - -
13 - -
14 - -
15 R132 20LG/VT (SIDE AIRBAGS) PASSENGER SIDE IMPACT SENSOR SIGNAL
16 R134 20LB/BR (SIDE AIRBAGS) PASSENGER SIDE IMPACT SENSOR GROUND
17 R131 20LG/YL (SIDE AIRBAGS) DRIVER SIDE IMPACT SENSOR SIGNAL
18 R133 20LB/DG (SIDE AIRBAGS) DRIVER SIDE IMPACT SENSOR GROUND
19 - -
20 - -
21 - -
22 - -
23 R59 20LB DRIVER SEAT BELT SWITCH GROUND
24 R57 20DG DRIVER SEAT BELT SWITCH SENSE
25 R73 20LB/BR (SIDE AIRBAGS) DRIVER CURTAIN SQUIB LINE 2
26 R75 20LB/OR (SIDE AIRBAGS) DRIVER CURTAIN SQUIB LINE 1
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
AIRBAG CONTROL MODULE C2 (ORC C2) - YELLOW 32 WAY
1 R45 20DG/LB DRIVER SQUIB 1 LINE 2
2 R43 20BK/LB DRIVER SQUIB 1 LINE 1
3 R42 20BK/YL PASSENGER SQUIB 1 LINE 1
4 R44 20DG/YL PASSENGER SQUIB 1 LINE 2
5 - -
6 - -
7 - -
8 - -
9 R49 20LB LEFT FRONT IMPACT SENSOR SIGNAL
10 R47 20DB/LB LEFT FRONT IMPACT SENSOR GROUND
11 R46 20BR/LB RIGHT FRONT IMPACT SENSOR GROUND
12 R48 20TN RIGHT FRONT IMPACT SENSOR SIGNAL
13 - -
14 - -
15 - -
16 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
17 Z6 20BK/PK GROUND
18 - -
19 - -
20 - -
21 - -
22 - -
23 D25 20YL/VT/OR PCI BUS
24 F14 20LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
25 R63 20TN/LB DRIVER SQUIB 2 LINE 2
26 R61 20OR/LB DRIVER SQUIB 2 LINE 1
27 R62 20OR/YL PASSENGER SQUIB 2 LINE 2
28 R64 20TN/YL PASSENGER SQUIB 2 LINE 1
29 - -
30 - -
31 - -
32 - -
AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY
1 G32 20BK/LB SENSOR GROUND
2 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
ANTENNA MODULE (BUILT-UP-EXPORT) - WHITE 2 WAY
1 X64 18BK/WT ENABLE SIGNAL TO AMPLIFIER
2 - -
ASH RECEIVER LAMP - BLACK 2 WAY
1 Z300 20BK GROUND
2 E2 20OR PANEL LAMPS DRIVER
AUTOMATIC DAY/NIGHT MIRROR - BLACK 7 WAY
1 G5 20BK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 Z150 20BK GROUND
3 L1 20BK/VT BACK-UP LAMP FEED
4 P112 20BK/WT AUTO DAY/NIGHT MIRROR (+)
5 P114 20BK/YL AUTO DAY/NIGHT MIRROR (-)
6 - -
7 - -
AUTOMATIC HEADLAMP LIGHT SENSOR/VTSS LED - BLACK 4 WAY
1 L109 20WT ULTRALIGHT SENSOR SIGNAL
2 L110 20BK/YL ULTRALIGHT SENSOR RETURN
3 G69 20BK/OR VTSS INDICATOR DRIVER
4 M1 20PK FUSED B(+)
AUTOMATIC ZONE CONTROL MODULE C1 (AZC) - WHITE 16 WAY
1 C102 20TN/BK MODE DOOR DRIVER (B)
2 - -
3 C32 20GY/DB RECIRCULATION DOOR DRIVER (A)
4 C100 20YL/DB RECIRCULATION DOOR DRIVER (B)
5 - -
6 C79 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
7 - -
8 Z118 20BK GROUND
9 C35 20DG/YL MODE DOOR DRIVER (A)
10 C33 20DB/RD DRIVER BLEND DOOR DRIVER (A)
11 - -
12 - -
13 - -
14 C81 20LB/WT REAR WINDOW DEFOGGER SWITCH SENSE
15 - -
16 - -
AUTOMATIC ZONE CONTROL MODULE C2 (AZC) - WHITE 12 WAY
1 - -
2 C94 20WT/DG PASSENGER BLEND DOOR DRIVER (A)
3 C95 20WT/BK DRIVER BLEND DOOR DRIVER (B)
4 C96 20WT/DB PASSENGER BLEND DOOR DRIVER (B)
5 - -
7 C56 20RD/LG BLOWER MOTOR CONTROL
8 D25 20YL/VT/DG PCI BUS
9 C103 20DG A/C SWITCH SIGNAL
10 - -
11 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY
1 K4 18BK/LB (GAS LHD) SENSOR GROUND
1 K4 20BK/LB (DIESEL/RHD) SENSOR GROUND
2 K25 18VT/LG BATTERY TEMPERATURE SENSOR SIGNAL
BLOWER MOTOR - BLACK 2 WAY
1 C1 12DG BLOWER MOTOR SUPPLY
2 C7 12BK/TN BLOWER MOTOR HIGH DRIVER
BLOWER MOTOR CONTROLLER (AZC) - BLACK 3 WAY
A Z118 12BK GROUND
B C56 20RD/LG BLOWER MOTOR CONTROL
C C1 12DG BLOWER MOTOR SUPPLY
BLOWER MOTOR RESISTOR BLOCK (MTC) - BLACK 4 WAY
H C7 12BK/TN BLOWER MOTOR HIGH DRIVER
L C4 16TN BLOWER MOTOR LOW DRIVER
M1 C5 16LG BLOWER MOTOR M1 DRIVER
M2 C6 14LB BLOWER MOTOR M2 DRIVER
BODY CONTROL MODULE C1 - GRAY 26 WAY
2 G52 20YL HEADLAMP SWITCH MUX
3 E19 20RD PANEL LAMPS DIMMER SIGNAL
4 - -
5 G70 20BR/TN (BUILT-UP-EXPORT LHD
RHD)
HOOD AJ AR SWITCH SENSE
6 G26 20LB KEY-IN IGNITION SWITCH SENSE
7 G76 18TN/YL RIGHT REAR DOOR AJ AR SWITCH SENSE
11 - -
15 D25 20YL/VT/WT PCI BUS
16 L80 20WT/DG HEADLAMP SWITCH RETURN
17 D19 20VT/OR BODY CONTROL MODULE FLASH ENABLE
18 - -
19 - -
20 G69 20BK/OR VTSS INDICATOR DRIVER
21 - -
22 V14 20RD/VT WIPER ON/OFF RELAY CONTROL
23 M20 20BR/OR COURTESY LAMP LOAD SHED
24 M2 20YL COURTESY LAMP DRIVER
25 Z234 20BK GROUND
26 - -
BODY CONTROL MODULE C2 - GRAY 22 WAY
2 V10 20BR WASHER PUMP SWITCH SENSE
3 V48 20RD/GY WIPER HIGH CONTROL
4 L40 20BR HIGH BEAM SWITCH SENSE
5 V11 20BK/TN WASHER FLUID SWITCH SENSE
6 P134 20TN/LG PASSENGER SEAT HEATER SWITCH MUX
7 P133 20TN/DG DRIVER SEAT HEATER SWITCH MUX
8 X20 20RD/YL RADIO CONTROL MUX
9 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
10 L109 20WT ULTRALIGHT SENSOR SIGNAL
11 V52 20DG/RD WINDSHIELD WIPER SWITCH MUX
13 - -
14 - -
15 L27 20WT/TN FOG LAMP SWITCH SENSE
16 C201 20LB/YL EVAPORATOR TEMPERATURE SENSOR SIGNAL
17 G18 20PK/BK COOLANT LEVEL SWITCH SENSE
18 P132 20OR/BK SEAT HEATER SWITCH SENSOR GROUND
19 X10 20RD/BK RADIO CONTROL MUX RETURN
20 G32 20BK/LB SENSOR GROUND
21 L110 20BK/YL ULTRALIGHT SENSOR RETURN
22 V9 20WT/BK WINDSHIELD WIPER SWITCH RETURN
BOOST PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
2 Y53 20BK/YL BOOST PRESSURE SENSOR SIGNAL
3 K6 20VT/WT SENSOR REFERENCE VOLTAGE B
BRAKE LAMP SWITCH - GRAY 6 WAY
1 K29 18WT/PK SECONDARY BRAKE SWITCH SIGNAL
2 Z238 18BK (LHD) GROUND
2 Z243 18BK (RHD) GROUND
3 V32 22OR/DG (GAS) SPEED CONTROL POWER SUPPLY
4 V30 22DB/RD (GAS) SPEED CONTROL BRAKE SWITCH OUTPUT
5 L50 20VT/TN (LHD) PRIMARY BRAKE SWITCH SIGNAL
5 L50 20WT/TN (RHD) PRIMARY BRAKE SWITCH SIGNAL
6 F32 20PK/DB FUSED B(+)
C100 - BLACK (RIGHT HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 T40 12LG
2 K125 18WT/DB
3 K20 18DG
C100 - BLACK (BATTERY SIDE)
CAV CIRCUIT
1 T40 12LG
2 K125 18WT/DB
3 K20 18DG
C101 (4.0L RHD) - LT. GRAY (ENGINE SIDE)
CAV CIRCUIT
1 B22 18DG/YL
2 K99 18BR/OR
3 K299 18BR/WT
4 K6 18VT/BK
5 C18 18DB
6 -
C101 (4.0L RHD) - LT. GRAY (HEADLAMP AND
DASH SIDE)
CAV CIRCUIT
1 B22 18DG/YL
2 K99 18LB/OR
3 K299 18BR/WT
4 K6 18VT/BK
5 C18 18DB
6 -
C101 (4.7L RHD) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 K4 18BK/LB (HIGH OUTPUT)
2 K99 18BR/OR
3 C18 18DB
4 K299 18BR/WT
5 T6 18VT/WT
6 K6 18VT/BK
7 K4 18BK/LB (HIGH OUTPUT)
8 K142 18GY/BK (HIGH OUTPUT)
9 T10 18YL/DG
10 -
11 -
12 B22 18DG/YL
13 -
14 K42 18DB/LG (HIGH OUTPUT)
C101 (4.7L RHD) - BLACK (LEFT HEADLAMP
AND DASH SIDE)
CAV CIRCUIT
1 K4 18BK/LB
2 K99 18BR/OR
3 C18 18DB
4 K299 18BR/WT
5 T6 18OR/WT
6 K6 18VT/BK
7 K4 18BK/LB
8 K142 18GY/BK
9 T10 18YL/DG
10 -
11 -
12 B22 18DG/YL
13 -
14 K42 18DB/LG
C102 (DIESEL) - BLACK (LEFT HEADLAMP AND
DASH SIDE)
CAV CIRCUIT
1 D21 18PK
2 D25 18VT/YL
3 K226 18DB/WT
4 D52 18LG/VT
5 D51 18DG/WT
6 B22 18DG/YL
7 F991 20OR/DB
8 T752 18DG/OR
9 K236 18GY/PK
10 K132 18BR/PK
11 A82 18PK/LG
12 K152 18WT
13 L50 18WT/TN
14 K29 18WT/PK
C102 (DIESEL) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 D21 20PK
2 D25 20VT/YL
3 K226 20DB/WT
4 D52 16DG/WT
5 D51 16WT
6 B22 20DG/YL
7 F991 20RD/DB
8 T752 20DG/RD
9 K236 20GY/PK
10 K132 20BR/PK
11 A82 16PK/DG
12 K152 20WT
13 L50 20WT/DB
14 K29 20WT/PK
C102 (GAS RHD) - BLACK (RIGHT HEADLAMP
AND DASH SIDE)
CAV CIRCUIT
1 A30 14RD/WT (4.7L)
2 F991 20OR/DB
3 K173 18LG
4 F42 18DG/LG
5 A7 14RD/BK
6 L1 18VT/BK
7 Z306 20BK/LG
8 T41 18BK/WT
9 -
10 K4 20BK/LB
11 K200 18VT/OR (4.7L)
12 C2 18DB/YL
13 -
14 A142 14DG/OR
C102 (GAS RHD) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 A30 14RD/WT (4.7L)
2 F991 18OR/DB
3 K173 18LG
4 F42 18DG/LG
5 A7 14RD/BK
6 L1 18VT/BK
7 Z306 20BK/LG
8 T41 18BK/WT
9 -
10 K4 18BK/LB
11 K200 18VT/OR (4.7L)
12 C2 18DB/YL
13 -
14 A142 14DG/OR
C103 (DIESEL) - GRAY (LEFT HEADLAMP AND
DASH SIDE)
CAV CIRCUIT
1 T41 18BK/WT
2 K173 18LG
3 C2 18DB/PK
4 -
5 F142 14OR/DG
6 K51 18DB/YL
7 K25 18VT/LG
8 Y42 18OR/DB
9 C18 18DB
10 K4 20BK/LB
11 K6 18VT/WT
12 -
13 T40 12BR
14 F15 18DB/WT
C103 (DIESEL) - GRAY (ENGINE SIDE)
CAV CIRCUIT
1 T41 20BK/WT
2 K173 20GY
3 C3 14DB/BK
4 -
5 F142 16RD/DG
6 K51 20DB/YL
7 K25 20VT/DG
8 Y42 20RD/DB
9 C18 20DB
10 K4 16BK/LB
11 K6 16VT/WT
12 -
13 T40 12DG
14 F15 20DB/WT
C103 (GAS) - GRAY (RIGHT HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 F22 20WT/PK (EXCEPT 4.7L RHD)
1 F22 18WT/TN (4.7L RHD)
2 T6 18OR/WT (4.7L LHD)
2 C18 20DB (4.0L LHD BUILT-UP-EXPORT)
2 C18 18DB (4.0L EXCEPT BUILT-UP-EXPORT)
3 D20 20LG (4.7L LHD)
3 D20 18LG (4.7L RHD)
4 D21 20PK (4.7L LHD)
4 K299 18BR/WT (4.0L LHD)
4 D21 18PK (4.7L RHD)
5 B22 18DG/YL (LHD)
6 K20 18DG
7 K30 20PK (4.0L RHD)
7 K30 18PK/YL (4.7L RHD)
7 K30 20PK/YL (LHD)
8 A142 14DG/OR (4.0L LHD)
8 T10 18DG/LG (4.7L LHD)
9 T16 14RD (4.7L LHD)
10 D25 18VT/YL (4.7L RHD)
10 D25 18VT/YL (4.7L EXCEPT BUILT-UP-EXPORT)
10 D25 20VT/YL (4.7L LHD BUILT-UP-EXPORT)
11 Z305 20BK/OR
12 F45 18YL/RD (4.7L RHD)
12 T15 18YL/BR (4.0L)
12 F45 18YL/RD (4.7L EXCEPT BUILT-UP-EXPORT)
12 F45 20YL/RD (4.7L LHD BUILT-UP-EXPORT)
13 K6 18VT/BK (4.0L LHD)
14 F142 18OR/DG
C103 (GAS) - GRAY (ENGINE SIDE)
CAV CIRCUIT
1 F22 18WT/PK
2 C18 18DB (4.0L LHD)
2 K200 18VT/OR (4.7L RHD)
3 K99 18BR/OR (4.0L LHD)
3 D20 18LG (4.7L RHD)
4 K299 18BR/WT (4.0L BUILT-UP-EXPORT)
4 D21 18PK (4.7L RHD)
5 B22 18DG/YL (4.0L LHD)
6 K20 18DG
7 K30 18PK/YL
8 A142 14DG/OR (4.0L LHD)
9 T16 14RD (4.7L)
10 D25 18WT/VT (4.7L)
11 Z305 20BK/OR
12 T15 18LG (4.0L LHD)
12 F45 18YL/RD (4.7L)
13 K6 18VT/BK (4.0L LHD)
13 K199 18DB/WT (4.7L LHD)
14 F142 18OR/DG
C104 - LT. GRAY (RIGHT HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 K200 18VT/OR (4.0L EXCEPT BUILT-UP-EXPORT)
1 K4 18BK/LB (4.7L HIGH OUTPUT)
2 K99 18BR/OR (4.7L)
2 F991 20OR/DB (4.0L)
3 K173 18LG (4.0L)
4 F42 18DG/LG (4.0L)
5 A7 14RD/BK (4.0L)
5 K4 18BK/LB (4.7L HIGH OUTPUT)
6 L1 18VT/BK (4.0L)
6 K142 18GY/BK (4.7L HIGH OUTPUT)
7 Z306 20BK/LG (4.0L)
7 K299 18BR/WT (4.7L)
8 C18 18DB (4.7L)
8 T41 18BK/WT (4.0L)
9 K6 18VT/BK (4.7L)
9 C2 18DB/YL (4.0L)
10 K4 18BK/LB (4.0L)
10 K42 18DB/LG (4.7L HIGH OUTPUT)
C104 - LT. GRAY (ENGINE SIDE)
CAV CIRCUIT
1 K200 18VT/OR (EXCEPT 4.0L BUILT-UP-EXPORT)
2 F991 18OR/DB
3 K173 18LG
4 F42 18DG/LG
5 A7 14RD/BK
6 L1 18VT/BK
7 Z306 20BK/LG
8 T41 18BK/WT
9 C2 18DB/YL
10 K4 18BK/LB
C105 (DIESEL) - GRAY (LEFT HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 C13 18DB/OR
2 F300 18RD/BK
3 V37 18RD/LG
4 Z305 20BK/OR
5 Z306 20BK/LG
6 L1 18VT/BK
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
C105 (DIESEL) - GRAY (ENGINE SIDE)
CAV CIRCUIT
1 C13 20DB/RD
2 F300 20RD/BK
3 V37 20RD/DG
4 Z305 18BK/DB
5 Z306 18BK/DB
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
C106 (DIESEL) - GRAY (BODY SIDE)
CAV CIRCUIT
A B10 14BR/WT (LHD)
B -
C -
D -
E -
F -
G -
H -
J -
K -
L -
M B29 14DG/OR
1 F15 20DB/WT
2 -
3 G31 20VT/LG
4 G32 20DB/OR (RHD)
4 G32 20BK/LB (LHD)
5 G18 20PK/BK
6 -
7 -
8 F12 20DB/WT (LHD)
9 -
10 Z231 18BK (RHD)
11 K4 20BK/LB (LHD)
11 G9 18GY/BK (RHD)
12 K6 18VT/WT (LHD)
13 -
14 -
15 -
16 K173 18LG
17 -
18 X2 18DG/RD
19 C18 18DB (LHD)
20 Y42 18OR/DB
21 -
CAV CIRCUIT
22 -
23 -
24 -
25 B7 18WT
26 B6 18WT/DB
27 -
28 -
29 -
30 -
31 -
32 -
33 -
34 -
35 -
36 -
37 -
38 L13 18BR/YL (BUILT-UP-EXPORT)
39 -
40 -
41 -
42 R46 20BR/LB
43 R48 20TN
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 -
53 L7 20BK/YL
54 L60 20TN
55 -
56 -
57 L39 20LB
58 -
59 L44 18VT/RD
60 L34 18RD/OR
C106 (DIESEL) - GRAY (RIGHT HEADLAMP AND
DASH SIDE)
CAV CIRCUIT
A -
B -
C -
D -
E -
F -
G -
H -
J -
K -
L -
M -
1 F15 18DB/WT
2 -
3 G31 20VT/LG
4 G32 20BK/LB
5 G18 20PK/BK
6 -
7 -
8 -
9 -
10 Z231 18BK (RHD)
11 K4 18BK/LB (LHD)
11 G9 18GY/BK (RHD)
12 K6 18VT/WT (LHD)
13 -
14 -
15 -
16 K173 18LG
17 -
18 X2 18DG/RD
19 C18 18DB (LHD)
20 Y42 18OR/DB
21 -
22 -
23 -
24 -
25 B7 18WT
26 B6 18WT/DB
27 -
28 -
29 -
30 -
31 -
C106 (DIESEL) - GRAY (RIGHT HEADLAMP AND
DASH SIDE)
CAV CIRCUIT
32 -
33 -
34 -
35 -
36 -
37 -
38 L13 18BR/YL
39 -
40 -
41 -
42 R46 18BR/LB
43 R47 18TN
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 -
53 L7 20BK/YL
54 L60 20TN
55 -
56 -
57 L39 20LB
58 -
59 L44 18VT/RD
60 L34 18RD/OR
C106 (GAS) - GRAY/RHD BLACK/LHD (BODY SIDE)
CAV CIRCUIT
A A149 12RD/TN
B A148 16LG/RD
C C1 12DG
D -
E A10 12RD/DG (LHD)
E A10 10RD/DG (RHD)
F A1 12RD
G A145 10WT/RD
H A146 10OR/WT
J A147 10RD/GY
K A148 10PK/WT
L A2 12PK/BK
M A20 14RD/DB
1 A141 16DG/BK
2 G18 20PK/BK (LHD)
2 F42 18DG/LG (RHD)
3 V3 16BR/WT
4 V4 16RD/YL
5 V55 16TN/RD
6 V6 16DB
7 F22 18WT/TN (RHD)
7 F22 20WT/PK (LHD)
8 F12 20DB/WT
9 K52 20PK/BK (LHD)
10 K29 20WT/PK (LHD)
10 Z231 18BK (RHD)
11 K512 18LB (RHD)
11 K226 20LB/YL (LHD)
12 K107 20OR/YL (LHD)
13 K251 18LB (RHD)
13 K106 20WT/DG (LHD)
14 T41 18BK/WT (LHD)
14 C13 20DB/OR (RHD)
15 V35 20LG/RD (RHD)
16 V36 20TN/RD (RHD)
17 G9 18GY/BK (RHD)
18 K25 18VT/LG (RHD)
19 K51 20DB/YL (RHD)
20 K125 18WT/DB (LHD)
21 K125 18WT/DB (RHD)
22 K31 18BR (RHD)
23 -
24 -
25 B7 18WT
26 B6 18WT/DB
27 X3 22GY/OR (LHD)
27 X3 22BK/RD (RHD)
28 G32 20BK/LB (LHD)
28 G32 20DB/OR (RHD)
29 -
30 G31 20VT/LG
31 -
32 V32 22OR/DG (LHD)
33 V30 22DB/RD
34 V16 22VT
C106 (GAS) - GRAY/RHD BLACK/LHD (BODY SIDE)
CAV CIRCUIT
35 V14 22RD/VT
36 -
37 F45 20YL/RD
39 -
40 Z306 20BK/LG
41 Z305 20BK/OR
42 R46 20BR/LB
43 R48 20TN
44 F991 20OR/DB
45 B22 18DG/YL (LHD)
46 -
47 -
48 D25 18YL/VT
49 D21 20PK
50 D20 20LG
51 D32 20LG/DG (LHD)
52 T41 18BK/WT (RHD)
52 T6 18OR/BK (LHD)
53 L7 20BK/YL
54 L60 20TN
55 G18 20PK/BK (RHD)
55 V37 22RD/LG (LHD)
56 L1 18VT/BK
57 L39 20LB
58 K4 18BK/LB (LHD)
58 K4 20BK/LB (RHD)
59 L44 18VT/RD
60 L34 18RD/OR
C106 (GAS) - GRAY/RHD BLACK/LHD (RIGHT
HEADLAMP AND DASH SIDE)
CAV CIRCUIT
A A149 12RD/TN
B A148 16LG/RD
C C1 12DG
D -
E A10 12RD/DG
F A1 12RD
G A145 10WT/RD
H A146 10OR/WT
J A147 10RD/GY
L A2 12PK/BK
K A148 10PK/WT
M A20 12RD/DB
1 A141 16DG/BK (RHD)
1 A141 16DG/WT (LHD)
2 F42 18DG/LG (RHD)
2 G18 18PK/BK (LHD)
3 V3 16BR/WT
4 V4 16RD/YL
5 V55 16TN/RD
6 V6 16DB
7 F22 18WT/TN (4.7L RHD)
7 F22 20WT/PK (EXCEPT 4.7L RHD)
8 F12 18DB/WT
9 K52 18PK/BK (LHD)
10 K29 18WT/PK (LHD)
10 Z231 18BK (RHD)
11 K226 18LB/YL (LHD)
11 K512 18RD/YL (4.7L RHD)
12 K107 18OR/PK (EXCEPT
BUILT-UP-EXPORT)
13 K106 18WT/DG (EXCEPT
BUILT-UP-EXPORT)
14 T41 18BK/WT (LHD)
17 G9 18GY/BK (RHD)
20 K125 18WT/DB (EXCEPT
BUILT-UP-EXPORT)
21 K125 18WT/DB (RHD)
22 K31 18BR (RHD)
23 -
24 -
25 B7 18WT
26 B6 18WT/DB
27 X3 20BK/RD
28 G32 20BK/LB
29 -
30 G31 20VT/LG
31 -
32 V32 18OR/DG (LHD)
33 V30 20DB/RD
34 V16 20VT
C106 (GAS) - GRAY/RHD BLACK/LHD (RIGHT
CAV CIRCUIT
35 V14 20RD/VT
36 -
37 F45 18YL/RD (LHD/4.7L RHD)
37 F45 20YL/RD (RHD)
39 -
40 Z306 20BK/LG
41 Z305 20BK/OR
42 R46 18BR/LB
43 R48 18TN
44 F991 20OR/DB
46 -
47 -
48 D25 18VT/YL (LHD/4.7L RHD)
49 D21 18PK (4.0L LHD/4.7L RHD)
49 D21 20PK (4.7L LHD)
50 D20 20LG (4.7L LHD)
50 D20 18LG (4.7L RHD)
51 D32 18LG (EXCEPT BUILT-UP-EXPORT)
51 D32 18LG/DG (LHD BUILT-UP-EXPORT)
52 T41 18BK/WT (RHD)
52 T6 18OR/WT (LHD)
53 L7 20BK/YL
54 L60 20TN
55 G18 20PK/BK (RHD)
56 L1 18VT/BK
57 L39 20LB
58 K4 18BK/LB (LHD)
58 K4 20BK/LB (RHD)
59 L44 18VT/RD
60 L34 18RD/OR
CAV CIRCUIT
A B10 14BR/WT
B A148 16LG/RD
C C1 12DG
D A149 12RD/TN
E -
F A1 12RD
G A145 10WT/RD
H A146 10OR/WT
J A147 10RD/GY
K A148 10PK/WT
L A2 12PK/BK
M B29 14DG/OR
1 X2 18DG/RD
2 V11 20BK/TN
3 K4 20BK/LB
4 V37 22RD/LG (LHD)
4 V37 20RD/LG (RHD)
5 V55 16TN/RD
6 V6 16DB
7 V10 22BR (LHD)
7 V10 20BR (RHD)
8 -
9 K226 18LB/YL (LHD)
9 K226 20LB/YL (RHD)
10 X3 22GY/OR (LHD)
10 X3 22BK/RD (RHD)
11 F15 20DB/WT
12 F45 20YL/RD
13 T41 18BK/WT
14 -
15 G70 20BR/TN
16 G9 18GY/BK (RHD)
17 Z231 18BK (RHD)
18 -
19 -
20 -
21 F991 20OR/DB
22 -
23 X75 20GY/LG
24 Y42 18OR/DB
25 B7 18WT
26 B6 18WT/DB
27 B4 18LG
28 B3 18LG/DB
29 B2 18YL
CAV CIRCUIT
30 B1 18YL/DB
31 -
32 M1 20PK/RD
33 F20 18DB/PK
34 L50 18WT/TN (RHD)
34 L50 18VT/TN (LHD)
35 R47 20DB/LB
36 T2 18TN/BK
37 Z305 20BK/OR
38 Z306 20BK/LG
39 R49 20LB
40 K29 18WT/PK
41 C18 20DB (LHD)
42 -
43 K6 18VT/WT (LHD)
44 -
45 V16 22VT
46 V14 22RD/VT
47 L13 18BR/YL
48 D25 18YL/VT
49 D21 20PK
50 K173 18LG
51 -
52 -
53 L7 20BK/YL
54 L61 20TN/LG
55 L1 18VT/BK
56 V20 18BK/WT (LHD)
56 V20 20BK/WT (RHD)
57 L39 20LB
58 F22 20WT/PK (LHD)
58 F22 18WT/TN (RHD)
59 L43 18VT
60 L33 18RD
DASH SIDE)
CAV CIRCUIT
A -
B A148 16LG/RD
C C1 12DG
D A149 12RD/TN
E -
F A1 12RD
G A145 10WT/RD
H A146 10OR/WT
J A147 10RD/GY
K A148 10PK/WT
L A2 12PK/BK
M -
1 X2 18DG/RD
2 V11 20BK/TN
3 K4 18BK/LB
4 V37 18RD/LG
5 V55 16TN/RD
6 V6 16DB
7 V10 20BR
8 -
9 K226 18DB/WT
10 X3 20BK/RD
11 F15 18DB/WT
12 F45 18YL/RD
13 T41 18BK/WT
14 -
15 G70 20BR/TN
16 G9 18GY/BK (RHD)
17 Z231 18BK (RHD)
18 -
19 -
20 -
21 F991 20OR/DB
22 -
23 X75 18GY/LB
24 Y42 18OR/DB
25 B7 18WT
26 B6 18WT/DB
27 B4 18LG
28 B3 18LG/DB
29 B2 18YL
30 B1 18YL/DB
31 -
32 M1 18PK
DASH SIDE)
CAV CIRCUIT
33 F20 18DB/PK
34 L50 18WT/TN
35 R47 18DB/LB
36 T2 18TN/BK
37 Z305 20BK/OR
38 Z306 20BK/LG
39 R49 18LB
40 K29 18WT/PK
41 C18 18DB (RHD)
42 -
43 K6 18VT/WT (RHD)
44 -
45 V16 20VT
46 V14 20RD/VT
47 L13 18BR/YL
48 D25 18VT/YL
49 D21 18PK
50 K173 18LG
51 -
52 -
53 L7 18BK/YL
54 L61 20LG
55 L1 18VT/BK
56 V20 18BK/WT
57 L39 20LB
58 F22 18WT/PK
59 L43 18VT
60 L33 18LG/BR
C107 (GAS) - GRAY/RHD BLACK/LHD (BODY
SIDE)
CAV CIRCUIT
A -
B -
C -
D -
E A10 12RD/DG (LHD)
E A10 10RD/DG (RHD)
F -
G -
H -
J -
K -
L -
M A20 14RD/DB
1 V37 20RD/LG (RHD)
2 V11 20BK/TN
3 V3 16BR/WT (GAS)
4 V4 16RD/YL (GAS)
5 V55 16TN/RD
6 V6 16DB
7 V10 20BR (RHD)
7 V10 22BR (LHD)
8 F12 20DB/WT
9 K52 20PK/BK (LHD)
11 K512 18LB
12 K4 20BK/LB
13 -
14 T6 18OR/BK (RHD)
15 G70 20BR/TN (BUILT-UP-EXPORT)
16 G9 18GY/BK (RHD)
17 Z231 18BK (RHD)
18 -
19 D32 20LG/DG (RHD)
20 -
21 -
22 -
23 X75 20GY/LG (BUILT-UP-EXPORT)
24 F42 18DG/LG (RHD)
25 B7 18WT
26 B6 18WT/DB
27 B4 18LG
28 B3 18LG/DB
29 B2 18YL
30 B1 18YL/DB
31 -
32 M1 20PK/RD
33 F20 18DB/PK
34 L50 18VT/TN (LHD)
34 L50 18WT/TN (RHD)
35 R47 20DB/LB (LHD)
36 -
C107 (GAS) - GRAY/RHD BLACK/LHD (BODY
SIDE)
CAV CIRCUIT
39 K31 18BR (RHD)
39 R49 20DB (LHD)
40 K29 18WT/PK (RHD)
41 K125 18WT/DB (RHD)
42 V32 22OR/DG (RHD)
43 R47 20DB/LB (RHD)
47 L13 18BR/YL (RHD)
48 D25 18YL/VT
49 D21 20PK (RHD)
50 R49 20LB (RHD)
51 -
52 -
53 L7 20BK/YL
54 L61 20TN/LG
55 -
57 L39 20LB
58 -
59 L43 18VT
60 L33 18RD
C107 (GAS) - GRAY/RHD BLACK/LHD (LEFT
CAV CIRCUIT
A -
B -
C -
D -
E A10 12RD/DG
F -
G -
H -
J -
K -
L -
M A20 12RD/DB
1 V37 18RD/LG (RHD)
2 V11 20BK/TN
3 V3 16BR/WT
4 V4 16RD/YL
5 V55 16TN/RD
6 V6 16DB
7 V10 20BR
8 F12 20DB/WT
9 K52 20PK/BK (LHD)
10 -
11 K512 18RD/YL (4.7L RHD)
12 K4 18BK/LB (RHD)
13 -
14 T6 18OR/BK (4.0L RHD)
14 T6 18OR/WT (4.7L RHD)
15 G70 20BR/TN (RHD)
16 G9 18GY/BK (RHD)
17 Z231 18BK (RHD)
18 -
19 D32 18LG/DG (RHD)
20 -
21 -
22 -
23 X75 18GY/LG (RHD)
24 F42 18DG/LG (RHD)
25 B7 18WT
26 B6 18WT/DB
27 B4 18LG
28 B3 18LG/DB
29 B2 18YL
30 B1 18YL/DB
31 -
32 M1 20PK/RD (LHD)
32 M1 18PK (RHD)
33 F20 18DB/PK
34 L50 18WT/TN
35 R47 18DB/LB (LHD)
36 -
39 R49 18LB (LHD)
C107 (GAS) - GRAY/RHD BLACK/LHD (LEFT
CAV CIRCUIT
39 K31 18BR (RHD)
40 K29 18WT/PK (RHD)
41 K125 18WT/DB (RHD)
42 V32 18OR/DG (RHD)
43 R47 18DB/LB (RHD)
47 L13 18BR/YL (RHD)
48 D25 18VT/YL
49 D21 18PK (RHD)
50 R49 18LB (RHD)
51 -
52 -
53 L7 20BK/YL
54 L61 20TN/LG
55 -
56 V20 18BK/WT
57 L39 20LB
58 -
59 L43 18VT
60 L33 18RD
C108 - BLACK (LEFT HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 M1 20PK (BUILT-UP-EXPORT)
1 M1 20PK/RD (EXCEPT
BUILT-UP-EXPORT)
2 Z141 20BK
C108 - BLACK (UNDERHOOD LAMP SIDE)
CAV CIRCUIT
1 M1 20PK/RD
2 Z141 20BK
C109 - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 K77 18LG/BK
2 K4 18BK/LB
C109 - BLACK (TRANSFER CASE J UMPER SIDE)
CAV CIRCUIT
1 K77 18LG/BK
2 K4 18BK/LB
DASH SIDE)
CAV CIRCUIT
1 K154 10GY
2 K254 10GY/YL
C110 (DIESEL) - GRAY (GLOW PLUG SIDE)
CAV CIRCUIT
1 K154 10GY
2 K254 10GY/YL
C111 - BLACK (LEFT FRONT LIGHTING MODULE
SIDE)
CAV CIRCUIT
1 L33 18RD
2 L43 18VT
3 L61 20TN/LG
4 L7 20BK/YL
6 Z141 18BK
C111 - BLACK (LEFT HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 L33 18LG/BR (DIESEL)
1 L33 18RD (GAS)
2 L43 18VT
3 L61 20LG (DIESEL)
3 L61 20TN/LG (GAS)
4 L7 18BK/YL (DIESEL)
4 L7 20BK/YL (GAS)
6 Z141 18BK
C112 - BLACK (RIGHT HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 L34 18RD/OR
2 L44 18VT/RD
3 L60 20TN
4 L7 20BK/YL
6 Z142 18BK
C112 - BLACK (RIGHT FRONT LIGHTING
MODULE SIDE)
CAV CIRCUIT
1 L34 18RD/OR
2 L44 18VT/RD
3 L60 20TN
4 L7 20BK/YL
6 Z142 18BK
C113 (DIESEL) - LT. GRAY (ENGINE SIDE)
CAV CIRCUIT
1 D51 16WT
2 D52 16DG/WT
C113 (DIESEL) - LT. GRAY (TRANSMISSION
SIDE)
CAV CIRCUIT
1 D52 18LG/WT
2 D51 18DG/WT
C200 - GRAY/LHD BLACK/RHD (LEFT BODY
SIDE)
CAV CIRCUIT
A -
B -
C A1 12RD
D -
E -
F -
G A2 12PK/BK
H C1 12DG
J -
K -
M -
L -
1 X56 18DB/PK (BASE)
1 X84 18OR/GY (EXCEPT BASE)
2 X86 18OR/RD (EXCEPT BASE)
2 X54 18VT (BASE)
3 X81 18YL/BK (EXCEPT BASE)
3 X55 18BR/RD (BASE)
4 X53 18DG/OR (BASE)
4 X83 18YL/RD (EXCEPT BASE)
5 X53 18DG/OR
6 X55 18BR/RD
7 X54 18VT
8 X56 18DB/PK
9 Y152 20LG/OR (EXCEPT
BUILT-UP-EXPORT)
10 D20 20LG (GAS)
11 Y151 20LG/BR (EXCEPT
BUILT-UP-EXPORT)
12 Y153 20DB/RD (EXCEPT
BUILT-UP-EXPORT)
13 X40 20RD/WT (CD)
14 D25 20YL/VT
15 D25 20YL/VT
16 D32 20LG/DG (GAS)
17 T41 18BK/WT
18 Z4 20WT/BK (CD)
19 X41 20WT/DG (CD)
20 T6 18OR/BK (GAS)
21 D21 20PK (GAS)
22 K29 18WT/PK
23 X160 20YL (CD)
24 X112 20RD (CD)
25 -
26 -
28 R47 20DB/LB
29 Z17 20BK (CD)
30 R49 20LB
31 G76 20TN/YL (RHD)
31 G76 18TN/YL (LHD)
32 T2 18TN/BK (DIESEL)
33 -
34 -
C200 - GRAY/LHD BLACK/RHD (LEFT BODY
SIDE)
CAV CIRCUIT
35 X51 18WT/DG
36 X57 18DG/WT
37 L7 18BK/YL (BUILT-UP-EXPORT)
39 V10 22BR (LHD)
39 V10 20BR (RHD)
40 X52 18DB/WT
41 X58 18DB/OR
42 -
43 V13 18BR/LG
44 V14 22RD/VT
45 -
47 V22 18BR/YL
48 R46 20BR/LB (RHD)
48 R46 18BK/LB (LHD)
49 X64 18BR/WT
50 Z305 20BK/OR
51 Z306 20BK/LG
52 R48 20TN
53 G32 20BK/LG (LHD)
53 G32 20DB/OR (RHD)
54 G31 20VT/LG
55 Z9 16BK
56 V11 20BK/TN
57 G18 20PK/BK
58 V37 20RD/LG (RHD)
59 K4 20BK/LB
60 -
C200 - GRAY/LHD BLACK/RHD (INSTRUMENT
PANEL SIDE)
CAV CIRCUIT
A -
B -
C A1 12RD
D -
E -
F -
G A2 12PK/BK
H C1 12DG
J -
K -
L -
M -
1 X84 18OR/BK
2 X86 18OR/RD
3 X81 18YL/BK
4 X83 18YL/RD
5 X53 18DG/OR
6 X55 18BR/RD
7 X54 18VT
8 X56 18DB/PK
BUILT-UP-EXPORT)
10 D20 20LG
BUILT-UP-EXPORT)
12 Y153 20DB/RD (EXCEPT
BUILT-UP-EXPORT)
13 X40 20WT/RD
14 D25 20YL/VT/GY
15 D25 20YL/VT/BR
16 D32 20LG/DG
17 T41 18BK/WT (DIESEL)
18 Z4 20WT/BK
19 X41 20WT/DG
20 T6 18OR/WT (GAS)
21 D21 20PK
22 K29 18WT/PK
23 X160 20YL
24 X112 20RD
25 -
26 -
28 R47 20DB/LB
29 Z17 20BK
30 R49 20LB
31 G76 18TN/YL
32 T2 20TN/BK (DIESEL)
33 -
34 -
35 X51 18WT/DG
36 X57 18DG/WT
37 L7 18BK/YL (BUILT-UP-EXPORT)
39 V10 20BR
40 X52 18DB/WT
C200 - GRAY/LHD BLACK/RHD (INSTRUMENT
PANEL SIDE)
CAV CIRCUIT
41 X58 18DB/OR
42 -
43 V13 18BR/LG
44 V14 20RD/VT
45 -
46 V20 18BK/WT
47 V22 18BR/YL
48 R46 20BR/LB
49 X64 18BR/WT
50 Z305 20BK/OR
51 Z306 20BK/LG
52 R48 20TN
53 G32 20BK/LB
54 G31 20VT/LG
55 Z9 16BK
56 V11 20BK/TN
57 G18 20PK/BK
58 V37 20RD/LG
59 K4 20BK/LB
60 -
C201 (DIESEL) - WHITE (INSTRUMENT PANEL
SIDE)
CAV CIRCUIT
1 -
2 Z300 18BK
3 E2 20OR
4 K29 18WT/PK
5 D25 20YL/VT
6 D19 20VT/OR
7 D21 20PK
8 F12 20DB/WT
9 T2 20TN/BK
10 Z234 18BK
11 T41 18BK/WT
12 F991 18OR/DB
C201 (DIESEL) - WHITE (SHIFTER ASSEMBLY SIDE)
CAV CIRCUIT
1 -
2 -
3 -
4 K2 20WT/PK
5 D25 20RD
6 -
7 D21 20PK
8 F12 20DB/WT
9 T2 20TN/BK
10 Z234 20WT
11 T41 20BK/WT
12 F991 20OR/DB
C202 (AZC) - WHITE (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 C100 20YL/DB (RHD)
1 C32 20GY/DB (LHD)
2 C100 20YL/DB (LHD)
2 C32 20GY/DB (RHD)
3 C96 20WT/DB (RHD)
3 C33 20DB/RD (LHD)
4 C94 20WT/DG (RHD)
4 C95 20WT/BK (LHD)
5 C95 20WT/BK (RHD)
5 C94 20WT/DG (LHD)
6 C33 20DB/RD (RHD)
6 C96 20WT/DB (LHD)
7 C35 20DG/YL (RHD)
7 C102 20TN/BK (LHD)
8 C35 20DG/YL (LHD)
8 C102 20TN/BK (RHD)
9 C56 20RD/LG
10 -
11 C201 20LB/YL
12 G32 20BK/LB
C202 (AZC) - WHITE (A/C SIDE)
CAV CIRCUIT
1 C100 20YL/DB (RHD)
1 C32 20GY/DB (LHD)
2 C100 20YL/DB (LHD)
2 C32 20GY/DB (RHD)
3 C96 20WT/DB (RHD)
3 C33 20DB/RD (LHD)
4 C94 20WT/DG (RHD)
4 C95 20WT/BK (LHD)
5 C95 20WT/BK (RHD)
5 C94 20WT/DG (LHD)
6 C33 20DB/RD (RHD)
6 C96 20WT/DB (LHD)
7 C35 20DG/YL (RHD)
7 C102 20TN/BK (LHD)
8 C35 20DG/YL (LHD)
8 C102 20TN/BK (RHD)
9 C56 20RD/LG
10 -
11 C201 20LB/YL
12 G32 20BK/LB
C202 (MTC) - WHITE (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 -
2 C201 20LB/YL
3 G32 20BK/LB
4 -
5 C67 20RD/LB
6 -
7 -
8 -
9 -
10 C6 14LB
11 Z132 20BK/OR
12 F22 20WT/PK
13 C7 12BK/TN
14 C1 12DG
15 C4 16TN
16 C5 16LG
C202 (MTC) - WHITE (A/C SIDE)
CAV CIRCUIT
1 -
2 C101 20LB/YL
3 G32 20BK/LB
4 -
5 C67 20RD/LB
6 -
7 -
8 -
9 -
10 C6 14LB
11 Z132 20BK/OR
12 F22 20WT/PK
13 C7 12BK/TN
14 C1 12DG
15 C4 16TN
16 C5 16LG
C203 (AZC) - WHITE (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 Z118 12BK
2 C1 12DG
C203 (AZC) - WHITE (A/C SIDE)
CAV CIRCUIT
1 Z118 12BK
2 C1 12DG
C300 (LHD) - GRAY (RIGHT BODY SIDE)
CAV CIRCUIT
A P130 16DG/WT (EXCEPT BASE)
B Q13 16DB
C B40 12LB
D F9 14RD/BK (EXCEPT
BUILT-UP-EXPORT)
E P144 16BK/LG (EXCEPT BASE)
F A141 16DG/BK (GAS)
G -
H -
J -
K -
L Q23 16RD/WT
M -
1 D25 20YL/VT
2 V13 18BR/LG
3 V22 18BR/YL
4 P112 20YL/WT
5 P114 20YL/RD
6 P35 18OR/VT
7 P36 18PK/VT
8 L50 18WT/TN
9 B1 18YL/DB
10 B2 18YL
11 B3 18LG/DB
12 B4 18LG
13 -
14 -
15 -
16 P29 20BR/WT (EXCEPT BASE)
17 P86 20PK/BK (EXCEPT BASE)
18 E21 20OR/RD
19 K4 20BK/LB
20 K226 18LB/YL (DIESEL)
20 K226 20LB/YL (GAS)
21 L62 18BR/RD
22 L95 18DG/YL (BUILT-UP-EXPORT)
23 -
24 L1 18VT/BK
25 -
26 -
27 -
28 -
29 -
30 -
31 -
C300 (LHD) - GRAY (RIGHT BODY SIDE)
CAV CIRCUIT
32 -
33 -
34 -
35 -
36 -
38 -
39 -
40 -
BUILT-UP-EXPORT)
42 K107 20OR/YL (EXCEPT
BUILT-UP-EXPORT)
43 K125 18WT/DB (EXCEPT
BUILT-UP-EXPORT)
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 -
53 X57 18DG/WT (BASE)
53 X91 18WT/DG (EXCEPT BASE)
54 X51 18WT/DG (BASE)
54 X93 18DG/WT (EXCEPT BASE)
55 -
56 -
57 Z155 18BK/OR
58 -
59 -
60 -
C300 (LHD) - GRAY (LEFT BODY SIDE)
CAV CIRCUIT
A P130 16DG/WT (HEATED SEATS)
B Q13 16DB
C B40 14LB
D F9 14RD/BK (EXCEPT BASE))
E P144 16BK/VT (HEATED SEATS)
F A141 16DG/BK (EXCEPT DIESEL)
G -
H -
J -
K -
L Q23 16RD/WT
M -
1 D25 20YL/VT
2 V13 18BR/LG
3 V22 18BR/YL
4 P112 20YL/WT
5 P114 20YL/RD
6 P35 18OR/VT
7 P36 18PK/VT
8 L50 18WT/TN
9 B1 18YL/DB
10 B2 18YL
11 B3 18LG/DB
12 B4 18LG
13 -
14 -
15 -
16 P29 20BR/WT (HEATED SEATS)
17 P86 18PK/BK (HEATED SEATS)
18 E21 20OR/RD
19 K4 20BK/LB
20 K226 20LB/YL
21 L62 18BR/RD
22 L95 18DG/YL (BUILT-UP-EXPORT)
23 -
24 L1 18VT/BK
25 -
26 -
27 -
28 -
29 -
30 -
31 -
32 -
C300 (LHD) - GRAY (LEFT BODY SIDE)
CAV CIRCUIT
33 -
34 -
35 -
36 -
38 -
39 -
40 -
BUILT-UP-EXPORT)
42 K107 20OR/YL (EXCEPT
BUILT-UP-EXPORT)
43 K125 18OR/DG (EXCEPT
BUILT-UP-EXPORT)
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 -
53 X91 18WT/DG (PREMIUM)
53 X57 18WT/DG (BASE)
54 X51 18DG/WT (BASE)
54 X93 18DG/WT (PREMIUM)
55 -
56 -
57 Z155 18BK/OR (EXCEPT BASE)
58 -
59 -
60 -
C301 (RHD) - BLACK (LEFT BODY SIDE)
CAV CIRCUIT
A Q13 16DB
B Q23 16RD/WT
C F9 14RD/BK
D F60 16RD/WT
E Z9 16BK
F Z5 16BK/VT
G C15 12BK/WT
H A148 16LG/RD
J -
K -
L Q30 16TN
M P130 16DG/WT
1 L50 18W/TTN
2 F70 18PK
3 M2 18YL
4 M20 18YL/BK
5 P35 18 OR/VT
6 P36 18PK/VT
7 F30 14RD/TN
8 L7 18BK/YL
9 L95 18DG/YL
10 L63 18DG/RD
11 G80 20VT/YL
12 X80 18LB/BK
13 X82 18LB/RD
14 X85 18LG/DG
15 X87 18LG/RD
16 X93 18DG/WT
17 X91 18WT/DG
18 X84 18OR/GY
19 L62 20BR/RD
20 X86 18OR/RD
21 X81 18YL/BK
22 X83 18YL/RD
23 X56 18DB/PK
24 X51 18WT/DG
25 X57 18DG/WT
26 X52 18DB/WT
27 X58 18DB/OR
28 X54 18VT
29 X55 18BR/RD
30 X53 18DG/OR
31 X64 18BR/WT
32 D25 20YL/VT
C301 (RHD) - BLACK (LEFT BODY SIDE)
CAV CIRCUIT
33 -
34 G78 20TN/BK
35 -
36 -
37 E21 20OR/RD
38 G77 20TN/OR
39 G76 20TN/YL
40 L1 18VT/BK
41 G5 20DB/WT
42 P86 20PK/BK
43 P29 20BR/WT
44 G73 20LG/OR
45 C235 18WT/LB (CD)
46 X160 20YL (CD)
47 X40 20RD/WT (CD)
48 -
49 X112 20RD (CD)
50 X41 20RD/BK (CD)
51 Z4 20WT/BK (CD)
52 Z17 20BK (CD)
53 -
54 -
55 -
56 -
57 -
58 -
59 -
60 -
C301 (RHD) - BLACK (RIGHT BODY SIDE)
CAV CIRCUIT
A Q13 16DB
B Q23 16RD/WT
C F9 14RD/BK
D F60 16RD/WT
E Z9 16BK
F Z5 16BK/VT
G C15 12BK/WT
H A148 16LG/RD
J -
K -
L Q30 16TN
M P130 16DG/WT
1 L50 18WT/TN
2 F70 18PK
3 M2 18YL
4 M20 18YL/BK
5 P35 18OR/VT
6 P36 18PK/VT
7 F30 16RD/TN
8 L7 18BK/YL
9 L95 18DG/YL
10 L63 18DG/RD
11 G80 20VT/YL
12 X80 18LB/BK
13 X82 18LB/RD
14 X85 18LG/DG
15 X87 18LG/RD
16 X93 18DG/WT
17 X91 18WT/DG
18 X84 18OR/GY
19 L62 18BR/RD
20 X86 18OR/RD
21 X81 18YL/BK
22 X83 18YL/RD
23 X56 18DB/BK
24 X51 18WT/DG
25 X57 18DG/WT
26 X52 18DB/WT
27 X58 18DB/OR
28 X54 18VT
29 X55 18BR/RD
30 X53 18DG/OR
31 X64 18BR/WT
32 D25 20YL/VT
33 F22 20WT/PK
34 G78 20TN/BK
35 M1 18PK/RD
36 -
37 E21 20OR/RD
38 G77 20TN/OR
39 G76 20TN/YL
40 L1 18VT/BK
41 G5 20DB/WT
42 P86 20PK/BK
43 P29 20BR/WT
C301 (RHD) - BLACK (RIGHT BODY SIDE)
CAV CIRCUIT
44 G73 20LG/OR
45 C235 20WT/LB (CD)
46 X160 20YL (CD)
47 X40 20WT/RD (CD)
48 -
49 X112 20RD (CD)
50 X41 20WT/DG (CD)
51 Z4 20WT/BK (CD)
52 Z17 20BK (CD)
53 -
54 -
55 -
56 -
57 -
58 -
59 -
60 -
C302 - BLACK (BODY SIDE)
CAV CIRCUIT
1 P112 20YL/WT
2 P114 20YL/RD
3 D25 20YL/VT
4 Z243 12BK (RHD)
4 Z28 12BK (LHD)
5 E21 20OR/RD
6 Q13 16DB
7 Q23 16RD/WT
8 A146 12OR/WT
9 X55 18BR/RD (LHD BASE)
9 X85 18LG/DG (LHD PREMIUM)
9 X80 18LB/BK (RHD PREMIUM)
10 X82 18LB/RD (RHD PREMIUM)
10 X53 18DG/OR (LHD BASE)
10 X87 18LG/RD (LHD PREMIUM)
11 M1 18PK/RD (J APAN)
12 -
13 -
14 -
C302 - BLACK (FRONT DRIVER DOOR SIDE)
CAV CIRCUIT
1 P112 20YL/WT
2 P114 20YL/RD
3 D25 20YL/VT
4 Z1 12BK
5 E21 20OR/RD
6 Q13 16DB
7 Q23 16RD/WT
8 A146 12OR/WT
9 X85 18LG/DG (LHD PREMIUM)
9 X80 18LG/DG (RHD PREMIUM)
9 X55 18LG/DG (BASE)
10 X53 18LG/RD (BASE)
10 X82 18LG/RD (RHD PREMIUM)
10 X87 18LG/RD (LHD PREMIUM)
11 M1 18PK (J APAN)
12 -
13 -
14 -
C303 - WHITE (RIGHT BODY SIDE)
CAV CIRCUIT
1 X58 18DB/OR (BASE AUDIO)
1 X92 18TN/DG (PREMIUM AUDIO)
2 X52 18DB/WT (BASE AUDIO)
2 X90 18WT/VT (PREMIUM AUDIO)
3 E21 20OR/DB (RHD)
3 E20 20OR/DB (LHD)
4 P35 18OR/VT
5 P36 18PK/VT
6 -
7 -
8 Q13 16DB (RHD)
8 Q14 16GY (LHD)
9 Q24 16DG (LHD)
9 Q23 16RD/WT (RHD)
10 Z151 16BK (RHD)
10 Z28 16BK (LHD)
11 G76 18TN/YL (LHD)
11 G76 20TN/YL (RHD)
C303 - WHITE (REAR DOOR SIDE)
CAV CIRCUIT
1 X58 18TN/DG (BASE)
1 X55
1 X92 18TN/DG (PREMIUM)
2 X52 18WT/VT (BASE)
2 X90 18WT/VT (PREMIUM)
3 E21 20OR/RD
4 P35 18OR/VT
5 P36 18PK/VT
6 -
7 -
8 Q14 16GY
9 Q24 16DG
10 Z1 16BK
11 G76 18TN/YL
CAV CIRCUIT
1 P86 20PK/BK (RHD)
1 P86 18PK/BK (LHD)
2 P130 16DG/WT
3 D25 20YL/VT
4 F37 16RD/LB (RHD)
4 F37 16RD (LHD)
5 Z238 16BK (RHD)
5 Z243 16BK (LHD)
6 P29 20BR/WT
7 Z155 18BK/OR (RHD)
7 Z155 20BK/OR (LHD)
8 Z5 16BK/VT (RHD)
8 P144 16BK/VT (LHD)
9 -
10 -
C304 - BLACK (POWER SEAT SIDE)
CAV CIRCUIT
1 P86 20DG/YL (HEATED SEATS)
2 P130 16DG/WT (HEATED SEATS)
3 D25 20VT/YL (PREMIUM POWER
SEATS)
4 F35 16RD
5 Z1 16BK
7 Z2 20BK/OR (PREMIUM POWER SEATS)
8 Z5 16BK/VT (HEATED SEATS)
9 -
10 -
CAV CIRCUIT
1 P130 16DG/WT
2 Z238 16BK
3 F37 16RD/LB
4 P86 20PK/BK
5 P29 20BR/WT
6 P144 16BK/LG
C306 - BLACK (POWER SEAT SIDE)
CAV CIRCUIT
1 P130 16DG/WT (HEATED SEATS)
2 Z1 16BK
3 F37 16RD/LB
4 P86 20DG/YL (HEATED SEATS)
6 Z5 16BK/VT (HEATED SEATS)
C307 - WHITE (BODY SIDE)
CAV CIRCUIT
1 X93 18DG/WT (RHD)
1 X91 18WT/DG (LHD)
2 X93 18DG/WT (LHD)
2 X91 18WT/DG (RHD)
3 E20 20OR/DB (RHD)
3 E21 20OR/RD (LHD)
4 P35 18OR/VT
5 P36 18PK/VT
6 -
7 -
8 Q13 16DB (LHD)
8 Q14 16GY (RHD)
9 Q24 16DG (RHD)
9 Q23 16RD/TN (LHD)
10 Z243 16BK
11 G77 20TN/OR
C307 - WHITE (REAR DOOR SIDE)
CAV CIRCUIT
1 X57 18TN/DG (BASE)
1 X93 18TN/DG (PREMIUM)
2 X51 18WT/VT (BASE)
2 X91 18WT/VT (PREMIUM)
3 E21 20OR/RD
4 P35 18OR/VT
5 P36 18PK/VT
6 -
7 -
8 Q14 16GY
9 Q24 16DG
10 Z1 16BK
11 G76 18TN/YL
C308 - WHITE (LEFT BODY SIDE)
CAV CIRCUIT
1 G78 20TN/BK
2 P35 18PK/VT (RHD)
2 P35 18OR/VT (LHD)
3 P36 18OR/VT (RHD)
3 P36 18PK/VT (LHD)
4 V13 18BR/LG
5 V22 18BR/YL
6 F70 18PK
7 L50 18WT/TN
8 Z309 12BK
9 G80 20VT/YL
10 C15 12BK/WT
11 L7 18BK/YL
C308 - WHITE (LIFTGATE SIDE)
CAV CIRCUIT
1 G78 20TN/BK
2 P35 18OR/VT
3 P36 18PK/VT
4 V13 18BR/LG
5 V22 18BR/YL
6 F70 18PK
7 L50 18WT/TN
8 Z1 12BK
9 G80 18VT/YL
10 C15 12BK/WT
11 L7 18BK/YL
C309 - WHITE (OVERHEAD SIDE)
CAV CIRCUIT
1 D25 20YL/VT
2 M20 20YL/BK
3 M2 20YL/DG
4 P112 20BK/WT
5 P114 20BK/YL
6 L1 20BK/VT
7 G5 20DB/WT
8 X75 20GY/LG (ALARM)
9 -
10 F70 20PK
11 Q30 20BK/LB (AUTOWIPE)
11 Q30 16TN (SUNROOF)
12 Z150 20BK (EXCEPT SUNROOF)
12 Z150 16BK (SUNROOF)
13 -
14 Z155 20BK/OR
15 G73 20LG/OR
C309 - WHITE (LEFT BODY SIDE)
CAV CIRCUIT
1 D25 20YL/VT
2 M20 18YL/BK (RHD)
2 M20 20YL/BK (LHD)
3 M2 18YL (RHD)
3 M2 20YL/DG (LHD)
4 P112 20YL/WT
5 P114 20YL/RD
6 L1 20VT/BK
7 G5 20DB/WT
9 -
10 F70 20PK (LHD)
10 F70 18PK (RHD)
11 Q30 16TN
12 Z150 16BK
13 -
14 Z155 20BK/OR (EXCEPT LHD BASE)
14 Z155 18BK/OR (RHD/LHD BASE)
15 G73 20LG/OR
C310 (BUILT-UP-EXPORT) - LT.GRAY (TRAILER TOW SIDE)
CAV CIRCUIT
1 F9 14RD/BK
2 L62 20BR/RD
3 L1 18VT/BK
4 F30 14RD/TN
5 L7 18BK/YL
6 Z150 14RD/BK
7 B40 14LB
8 Z150 14BK
9 L50 18WT/TN
10 L63 20DG/RD
11 Z1 14BK
12 -
13 -
14 -
C310 (BUILT-UP-EXPORT) - LT.GRAY (BODY SIDE)
CAV CIRCUIT
1 F9 14RD/BK
2 L62 18BR/RD (LHD)
2 L62 20BR/RD (RHD)
3 L1 18VT/BK
4 F30 14RD/TN
5 L7 18BK/YL
6 L95 18DG/YL
7 B40 14LB
8 Z150 14BK
9 L50 16WT/TN (RHD)
9 L50 18WT/TN (LHD)
10 L63 20DG/RD
11 Z150 14BK
12 -
13 -
14 -
C310 (EXCEPT BUILT-UP-EXPORT) - LT. GREEN
(TRAILER TOW SIDE)
CAV CIRCUIT
1 F9 14RD/BK
2 L62 20BR/RD
3 L1 18VT/BK
4 F30 14RD/TN
5 L7 18BK/YL
6 Z150 14RD/BK
7 B40 14LB
8 Z150 14BK
9 L50 18WT/TN
10 L63 20DG/RD
C310 (EXCEPT BUILT-UP-EXPORT) - LT. GREEN
(LEFT BODY SIDE)
CAV CIRCUIT
1 F9 14RD/BK
2 L62 18BR/RD
3 L1 18VT/BK
4 F30 14RD/TN
5 L7 18BK/YL
6 Z150 14BK
7 B40 14LB
8 Z150 14BK
9 L50 18WT/TN
10 L63 20DG/RD
C311 - WHITE (LIFTGATE SIDE)
CAV CIRCUIT
1 L50 18WT/TN
2 Z1 18BK
C311 - WHITE (CHMSL SIDE)
CAV CIRCUIT
1 L50 18WT/TN
2 Z1 18BK
C312 - WHTE (LIFTGATE SIDE)
CAV CIRCUIT
1 Z1 18BK
2 L7 18BK/YL
3 P101 18OR/PK
4 F70 18PK
C312 - WHITE (LICENSE PLATE LAMP SIDE)
CAV CIRCUIT
1 Z1 18BK
2 L7 18BK/YL
3 P101 18OR/PK
4 F70 18PK
C313 - WHITE (FRONT DRIVER DOOR SIDE)
CAV CIRCUIT
1 P112 20YL/WT
2 P114 20YL/RD
C313 - WHITE (MUX J UMPER SIDE)
CAV CIRCUIT
1 P112 20YL/WT
2 P114 20YL/RD
C314 - LT. GRAY (BODY SIDE)
CAV CIRCUIT
1 D25 20YL/VT
2 A146 12OR/WT
3 P35 18OR/VT
4 P36 18PK/VT
5 Z28 12BK (LHD)
5 Z243 12BK (RHD)
6 Q14 16GY
7 Q24 16DG
8 E20 20OR/DB
9 X56 18DB/PK (BASE LHD)
9 X80 18LB/BK (PREMIUM LHD)
9 X85 18LG/DG (RHD)
10 X54 18VT (BASE)
10 X87 18LG/RD (RHD)
10 X82 18LB/RD (PREMIUM)
11 -
12 -
13 -
14 -
C314 - LT. GRAY (FRONT PASSENGER DOOR
SIDE)
CAV CIRCUIT
1 D25 20YL/VT
2 A146 12OR/WT
3 P35 18OR/VT
4 P36 18PK/VT
5 Z1 12BK
6 Q14 16GY
7 Q24 16DG
8 E20 20OR/DB
9 X80 18LB/BK (LHD PREMIUM)
9 X85 18LB/BK (RHD PREMIUM)
9 X56 18LB/BK (BASE)
10 X54 18LB/RD (BASE)
10 X87 18LB/RD (RHD PREMIUM)
10 X82 18LB/RD (LHD PREMIUM)
11 -
12 -
13 -
14 -
C315 - (OVERHEAD SIDE)
CAV CIRCUIT
1 Q30 16TN
2 -
3 Q43 20VT
4 Q41 20WT
5 -
6 -
7 Z150 16BK
8 -
C315 - (SUN ROOF MODULE SIDE)
CAV CIRCUIT
1 Q30 16DB
2 -
3 Q43 20VT
4 Q41 20WT
5 -
6 -
7 Z150 16BK
8 -
C316 (EXCEPT BUILT-UP-EXPORT) - (PEDAL
SIDE)
CAV CIRCUIT
1 Y153 16DB/RD
2 L1 18WT/BR
3 F72 16RD/YL
4 D25 20VT/YL
5 Y151 20LG/BR
6 Z155 20BK/OR
7 Y152 20LG/OR
8 Z151 16BK
C316 (EXCEPT BUILT-UP-EXPORT) - (BODY
SIDE)
CAV CIRCUIT
1 Y153 20DB/RD
2 L1 18VT/BK
3 F72 16RD/YL
4 D25 20YL/VT
5 Y151 20LG/BR
6 Z155 18BK/OR
7 Y152 20LG/OR
8 Z151 18BK
C317 - (OVERHEAD SIDE)
CAV CIRCUIT
1 Z155 20BK/OR
2 -
3 X75 20GY/LG
4 -
5 D25 20YL/VT
6 F70 20PK
C317 - (INTRUSION TRANSCEIVER MODULE
SIDE)
CAV CIRCUIT
1 Z155 20BK
2 -
3 X75 20GY/LG
4 -
5 D25 20YL/VT
6 F70 20PK
C318 - (LEFT BODY SIDE (LHD)/ RIGHT BODY
SIDE (RHD))
CAV CIRCUIT
1 R73 20LB/BR
2 R75 20LB/OR
C318 - (OVERLAY SIDE)
CAV CIRCUIT
1 R72 20LB/WT (RHD)
1 R73 20LB/BR (LHD)
2 R74 20LB/YL (RHD)
2 R75 20LB/OR (LHD)
C319 - (RIGHT BODY SIDE (LHD)/ LEFT BODY
SIDE (RHD))
CAV CIRCUIT
1 R72 20LB/WT (LHD)
2 R74 20LB/YL (LHD)
C319 - (OVERLAY SIDE)
CAV CIRCUIT
1 R73 20LB/BR (RHD)
1 R72 20LB/WT (LHD)
2 R75 20LB/OR (RHD)
2 R74 20LB/YL (LHD)
CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY
1 K944 20BR/DG CAMSHAFT POSITION SENSOR GROUND
2 K44 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
3 F15 18RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
CAMSHAFT POSITION SENSOR (GAS) - GRAY 3 WAY
1 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
3 K7 18OR 5 VOLT SUPPLY
CAPACITOR (4.0L) - BLACK 2 WAY
1 A142 16DG/OR (RHD) AUTO SHUT DOWN RELAY OUTPUT
1 A142 14DG/OR (LHD) AUTO SHUT DOWN RELAY OUTPUT
2 - -
CAPACITOR NO. 1 (4.7L) - BLACK 2 WAY
1 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
2 - -
CAPACITOR NO. 2 (4.7L) - BLACK 2 WAY
2 - -
CARGO LAMP - WHITE 3 WAY
1 F70 20PK FUSED B(+)
2 G73 20LG/OR LIFTGATE COURTESY DISABLE
3 M2 20YL/DG COURTESY LAMP DRIVER
CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY
1 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
2 Z309 18BK GROUND
CIGAR LIGHTER - RED 3 WAY
1 F30 16RD FUSED CIGAR LIGHTER RELAY OUTPUT
2 - -
3 Z300 16BK GROUND
CLOCKSPRING C1 - BLACK 4 WAY
1 X3 20GY/OR HORN RELAY CONTROL
2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
4 - -
CLOCKSPRING C2 - 4 WAY
3 R43 20BK/LB DRIVER SQUIB 1 LINE 1
4 R45 20DG/LB DRIVER SQUIB 1 LINE 2
CLOCKSPRING C3 - GRAY 6 WAY
6 - -
CLOCKSPRING C4 - BLACK 2 WAY
COIL ON PLUG NO. 1 (4.7L) - BLACK 3 WAY
1 K91 14TN/RD COIL DRIVER NO. 1
3 - -
1 K92 14TN/PK COIL DRIVER NO. 2
3 - -
1 K93 14TN/OR COIL DRIVER NO. 3
3 - -
1 K94 14TN/LG COIL DRIVER NO. 4
3 - -
1 K95 14TN/DG COIL DRIVER NO. 5
3 - -
1 K96 14TN/LB COIL DRIVER NO. 6
3 - -
1 K97 14BR COIL DRIVER NO. 7
3 - -
1 K98 14LB/RD COIL DRIVER NO. 8
3 - -
COIL RAIL (4.0L) - BLACK 4 WAY
COMPACT DISC CHANGER (PREMIUM RADIO) - BLACK 8 WAY
1 X40 20WT/RD AUDIO OUT RIGHT
2 C235 20WT/LB SHIELD
3 D25 20YL/VT PCI BUS
4 X112 20RD IGNITION SWITCH OUTPUT (RUN-ACC)
5 X41 20WT/DG AUDIO OUT LEFT
6 Z4 20WT/BK GROUND
7 Z17 20BK GROUND
8 X160 20YL B(+)
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY
2 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL
3 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT
SUPPLY
4 - -
6 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
7 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
8 - -
9 A20 12RD/DB FUSED B(+)
10 F20 18DB/PK FUSED IGNITION SWITCH OUTPUT (RUN)
11 D52 18LG/WT (DIESEL) CAN C BUS(+)
12 - -
13 B22 18DG/YL VEHICLE SPEED SENSOR SIGNAL
14 D51 18DG/WT (DIESEL) CAN C BUS(-)
15 - -
17 G9 18GY/BK BRAKE FLUID LEVEL SWITCH SENSE
19 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR SIGNAL
20 B4 18LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
21 Z231 18BK GROUND
22 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL
23 B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
24 A10 12RD/DG FUSED B(+)
COOLANT LEVEL SENSOR - LT. GRAY 2 WAY
1 G18 20PK/BK (EXCEPT LHD GAS) COOLANT LEVEL SWITCH SENSE
1 G18 18PK/BK (LHD GAS) COOLANT LEVEL SWITCH SENSE
2 Z307 20BK GROUND
CRANKCASE HEATER (DIESEL) - BLACK 2 WAY
1 Z18 20BR GROUND
CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 2 WAY
1 K924 20YL CRANKSHAFT POSITION SENSOR SIGNAL 2
2 K3 20BK CRANKSHAFT POSITION SENSOR SIGNAL 1
CRANKSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY
1 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
DATA LINK CONNECTOR - BLACK 16 WAY
1 - -
3 - -
5 Z306 20BK/LG GROUND
6 D32 20LG/DG SCI RECEIVE
7 D21 20PK SCI TRANSMIT
8 - -
10 - -
11 - -
12 - -
13 - -
14 D20 20LG SCI RECEIVE
15 - -
16 F33 20PK/RD FUSED B(+)
DIAGNOSTIC J UNCTION PORT - BLACK 16 WAY
1 D25 20YL/VT/BR PCI BUS (PCM/ECM TCM PDM CD SKIM)
2 D25 20YL/VT/DG (AZC) PCI BUS (AZC)
3 D25 20YL/VT/DB PCI BUS (RADIO)
4 D25 20YL/VT/OR PCI BUS (ACM)
5 D25 20YL/VT/RD PCI BUS (MIC)
6 D25 20YL/VT/WT PCI BUS (BCM)
7 D25 20YL/VT PCI BUS (DLC)
8 D25 20YL/VT/GY PCI BUS (DDM ABS MEM EVIC APM ITM RAIN
SENSOR)
9 - -
10 - -
11 D25 20YL/VT (DIESEL) PCI BUS (SHIFTER ASSEMBLY)
12 - -
13 - -
14 - -
15 - -
16 - -
DRIVER AIRBAG SQUIB 1 - BLACK 2 WAY
1 R43 20BK DRIVER SQUIB 1 LINE 1
2 R45 20BK DRIVER SQUIB 1 LINE 2
DRIVER AIRBAG SQUIB 2 - GREEN 2 WAY
DRIVER BLEND DOOR MOTOR/ACTUATOR (LHD) (AZC) - BLACK 2 WAY
A C95 20WT/BK (LHD) DRIVER BLEND DOOR DRIVER (B)
B C33 20DB/RD (LHD) DRIVER BLEND DOOR DRIVER (A)
DRIVER BLEND DOOR MOTOR/ACTUATOR (RHD) (AZC)- BLACK 2 WAY
A C33 20DB/RD (RHD) DRIVER BLEND DOOR DRIVER (A)
B C95 20WT/BK (RHD) DRIVER BLEND DOOR DRIVER (B)
DRIVER CURTAIN AIRBAG - BLACK 2 WAY
1 R73 20LB/BR DRIVER CURTAIN SQUIB LINE 2
2 R75 20LB/OR DRIVER CURTAIN SQUIB LINE 1
DRIVER CYLINDER LOCK SWITCH - GRAY 2 WAY
1 G73 20LG/OR DRIVER CYLINDER LOCK SWITCH SENSE
DRIVER DOOR LOCK MOTOR/AJ AR SWITCH - BLACK 4 WAY
1 G75 18TN/RD DRIVER DOOR AJ AR SWITCH SENSE
3 P34 18PK/BK DRIVER DOOR UNLOCK DRIVER
4 P35 18OR/BK DRIVER DOOR LOCK DRIVER
DRIVER DOOR MODULE C1 - WHITE 15 WAY
1 A146 12OR/WT FUSED B(+)
2 Q23 16RD/WT DRIVER REAR WINDOW DRIVER (DOWN)
3 Q13 16DB DRIVER REAR WINDOW DRIVER (UP)
5 P35 18OR/BK DRIVER DOOR LOCK DRIVER
6 - -
7 P34 18PK/BK DRIVER DOOR UNLOCK DRIVER
8 D30 20VT/YL (J APAN) DIAGNOSTIC OUT
10 G73 20LG/OR DRIVER CYLINDER LOCK SWITCH SENSE
11 G75 18TN/RD DRIVER DOOR AJ AR SWITCH SENSE
12 E21 20OR/RD DRIVER REAR DOOR SWITCH ILLUMINATION
13 Q11 16LB DRIVER WINDOW DRIVER (UP)
14 - -
15 Q21 16WT DRIVER WINDOW DRIVER (DOWN)
DRIVER DOOR MODULE C2 - BLACK 12 WAY
1 P95 20OR MIRROR HORIZONTAL DRIVER
2 C118 20BK/WT MIRROR HEATER GROUND
3 P64 20VT MIRROR VERTICAL POSITION SIGNAL
4 P69 20GY MIRROR SENSOR GROUND
5 P65 20DG MIRROR HORIZONTAL POSITION SIGNAL
6 C117 20BK MIRROR HEATER 12 VOLT SUPPLY
7 P91 20WT MIRROR COMMON DRIVER
8 P93 20RD MIRROR VERTICAL DRIVER
9 M21 20PK/DG COURTESY LAMP DRIVER
10 P110 20YL (BUILT-UP-EXPORT) FOLDING MIRROR RETURN
11 P99 20DB (BUILT-UP-EXPORT) FOLDING MIRROR FEED
12 L121 20BK/RD COURTESY LAMP GROUND
DRIVER DOOR MODULE C3 - BLACK 4 WAY
1 BK MEMORY SWITCH RETURN
2 BR MEMORY SWITCH MUX
3 OR MEMORY SET INDICATOR DRIVER
4 GY SWITCH ILLUMINATION DRIVER
DRIVER FRONT DOOR COURTESY LAMP - BLACK 2 WAY
DRIVER FRONT POWER WINDOW MOTOR - BLACK 2 WAY
1 Q21 16WT DRIVER WINDOW DRIVER (DOWN)
2 Q11 16LB DRIVER WINDOW DRIVER (UP)
DRIVER HEATED SEAT BACK (PREMIUM I/III) - 3 WAY
1 P88 16BK/BR HEATED SEAT DRIVER
2 Z6 16BK/YL GROUND
3 - -
DRIVER HEATED SEAT CUSHION (PREMIUM I/III) - 4 WAY
1 P131 16BK/OR DRIVER SEAT HEATER B(+) DRIVER
3 P135 20LB/BK DRIVER SEAT TEMPERATURE SENSOR INPUT
4 P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
DRIVER HEATED SEAT SWITCH - WHITE 6 WAY
1 P133 20TN/DG DRIVER SEAT HEATER SWITCH MUX
4 - -
5 Z300 20BK GROUND
DRIVER LUMBAR MOTOR (MIDLINE/PREMIUM) - BLACK 2 WAY
1 P105 16LG/DB LUMBAR FORWARD SWITCH SENSE
2 P104 16YL/RD LUMBAR REARWARD SWITCH SENSE
DRIVER LUMBAR SWITCH (MIDLINE/PREMIUM) - WHITE 6 WAY
1 - -
3 P105 16LG/DB (RHD) LUMBAR FORWARD SWITCH SENSE
3 P104 16YL/RD (LHD) LUMBAR REAR WARD SWITCH SENSE
4 P104 16YL/RD (RHD) LUMBAR REAR WARD SWITCH SENSE
4 P105 16LG/DB (LHD) LUMBAR FORWARD SWITCH SENSE
6 F35 16RD FUSED B(+)
DRIVER POWER MIRROR - BLACK 12 WAY
7 P114 20YL/RD AUTO DAY/NIGHT MIRROR(-)
10 P112 20YL/WT AUTO DAY/NIGHT MIRROR(+)
DRIVER POWER SEAT FRONT RISER MOTOR - RED 2 WAY
1 P119 16YL/RD (PREMIUM II/III) SEAT FRONT UP DRIVER
1 P19 16YL/LG (EXCEPT PREMIUM II/III) DRIVER SEAT FRONT UP DRIVER
2 P121 16RD/GY (PREMIUM II/III) SEAT FRONT DOWN DRIVER
2 P21 16RD/LG (EXCEPT PREMIUM II/III) DRIVER SEAT FRONT DOWN DRIVER
DRIVER POWER SEAT FRONT RISER MOTOR SENSOR (PREMIUM II/III) - 3 WAY
A P28 20BR/RD SEAT POSITION SENSOR GROUND
B P26 20BR FRONT RISER POSITION SIGNAL
C P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
DRIVER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY
1 P17 16RD/YL (EXCEPT PREMIUM II/III) DRIVER SEAT HORIZONTAL REARWARD DRIVER
1 P117 16RD/BR (PREMIUM II/III) SEAT HORIZONTAL REARWARD DRIVER
2 P15 16YL/LB (EXCEPT PREMIUM II/III) DRIVER SEAT HORIZONTAL FORWARD DRIVER
2 P115 16GY/LG (PREMIUM II/III) SEAT HORIZONTAL FORWARD DRIVER
DRIVER POWER SEAT HORIZONTAL MOTOR SENSOR (PREMIUM II/III) - BLACK 3 WAY
A P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
B P25 20VT/RD SEAT HORIZONTAL POSITION SIGNAL
C P28 20BR/RD SEAT POSITION SENSOR GROUND
DRIVER POWER SEAT REAR RISER MOTOR - RED 2 WAY
1 P11 16YL/WT (EXCEPT PREMIUM II/III) DRIVER SEAT REAR UP DRIVER
1 P111 16YL/DB (PREMIUM II/III) SEAT REAR UP DRIVER
2 P13 16RD/WT (EXCEPT PREMIUM
II/III)
DRIVER SEAT REAR DOWN DRIVER
2 P113 16RD/BK (PREMIUM II/III) SEAT REAR DOWN DRIVER
DRIVER POWER SEAT REAR RISER MOTOR SENSOR (PREMIUM II/III) - 3 WAY
A P28 20BR/RD SEAT POSITION SENSOR GROUND
B P27 20LB/RD REAR RISER POSITION SIGNAL
C P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
DRIVER POWER SEAT RECLINER MOTOR - BLACK 2 WAY
A P41 16GY/WT (MIDLINE/PREMIUM I) DRIVER SEAT RECLINER DOWN DRIVER
A P141 16GY/WT (PREMIUM II/III) SEAT RECLINER DOWN DRIVER
B P43 16GY/LB (MIDLINE/PREMIUM I) DRIVER SEAT RECLINER UP DRIVER
B P143 16GY/LB (PREMIUM II/III) SEAT RECLINER UP DRIVER
DRIVER POWER SEAT RECLINER MOTOR SENSOR (PREMIUM II/III) - BLACK 3 WAY
A P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
B P47 20LB RECLINER POSITION SIGNAL
C P28 20BR/RD SEAT POSITION SENSOR GROUND
DRIVER POWER SEAT SWITCH (EXCEPT MIDLINE/PREMIUM) - 12 WAY
A F35 16RD FUSED B(+)
B Z1 16BK GROUND
C - -
E P21 16RD/LG (LHD) DRIVER SEAT FRONT DOWN DRIVER
E P19 16YL/LG (RHD) DRIVER SEAT FRONT UP DRIVER
F - -
G - -
H - -
J P19 16YL/LG (LHD) DRIVER SEAT FRONT UP DRIVER
J P21 16RD/LG (RHD) DRIVER SEAT FRONT DOWN DRIVER
K P15 16YL/LB DRIVER SEAT HORIZONTAL FORWARD DRIVER
L P17 16RD/YL DRIVER SEAT HORIZONTAL REARWARD DRIVER
M P13 16RD/WT (LHD) DRIVER SEAT REAR DOWN DRIVER
M P11 16YL/WT (RHD) DRIVER SEAT REAR UP DRIVER
N P11 16YL/WT (LHD) DRIVER SEAT REAR UP DRIVER
N P13 16RD/WT (RHD) DRIVER SEAT REAR DOWN DRIVER
DRIVER POWER SEAT SWITCH (MIDLINE/PREMIUM) - GREEN 10 WAY
1 Z1 16BK GROUND
2 P43 16GY/LB (MIDLINE/PREMIUM I) DRIVER SEAT RECLINER UP DRIVER
2 P43 20GY/LB (PREMIUM II/III) RECLINER UP SWITCH SENSE
3 P17 16RD/YL (MIDLINE/PREMIUM I) DRIVER SEAT HORIZONTAL REARWARD DRIVER
3 P17 20RD/YL (PREMIUM II/III) DRIVER SEAT HORIZONTAL REARWARD SWITCH
SENSE
4 P41 16GY/WT (MIDLINE/PREMIUM I) DRIVER SEAT RECLINER DOWN DRIVER
4 P41 20GY/WT (PREMIUM II/III) RECLINER DOWN SWITCH SENSE
5 F35 16RD (MIDLINE/PREMIUM I) FUSED B(+)
5 P9 20RD/LB (PREMIUM II/III) SEAT SWITCH B(+) SUPPLY
6 P15 16YL/LB (MIDLINE/PREMIUM I) DRIVER SEAT HORIZONTAL FORWARD DRIVER
6 P15 20YL/LB (PREMIUM II/III) DRIVER SEAT HORIZONTAL FORWARD SWITCH
SENSE
7 P19 16YL/LG (MIDLINE/PREMIUM I) SEAT FRONT UP SWITCH SENSE
7 P21 20RD/LG (RHD PREMIUM II/III) SEAT FRONT DOWN SWITCH SENSE
7 P19 20YL/LG (PREMIUM II/III) SEAT FRONT UP SWITCH SENSE
8 P13 20RD/WT (RHD PREMIUM II/III) DRIVER SEAT REAR DOWN DRIVER
8 P11 20YL/WT (PREMIUM II/III) SEAT REAR UP SWITCH SENSE
8 P11 16YL/WT (MIDLINE/PREMIUM I) DRIVER SEAT REAR UP DRIVER
9 P13 20RD/WT (PREMIUM II/III) SEAT REAR DOWN SWITCH SENSE
9 P13 16RD/WT (MIDLINE/PREMIUM I) DRIVER SEAT REAR DOWN DRIVER
9 P11 20YL/WT (RHD PREMIUM II/III) DRIVER SEAT REAR UP DRIVER
10 P21 16RD/LG (MIDLINE/PREMIUM I) SEAT FRONT DOWN SWITCH SENSE
10 P21 20RD/LG (PREMIUM II/III) SEAT FRONT DOWN SWITCH SENSE
10 P19 20YL/LG (RHD PREMIUM II/III) SEAT FRONT UP SWITCH SENSE
DRIVER REAR POWER WINDOW MOTOR - BLACK 2 WAY
1 Q124 16DG/WT WINDOW DRIVER (DOWN)
2 Q114 16GY/WT WINDOW DRIVER (UP)
DRIVER REAR POWER WINDOW SWITCH - BLUE 6 WAY
1 Q14 16GY DRIVER REAR WINDOW DRIVER (UP)
3 E21 20OR/RD DRIVER REAR DOOR SWITCH ILLUMINATION
4 Q24 16DG DRIVER REAR WINDOW DRIVER (DOWN)
6 Z1 16BK GROUND
DRIVER SEAT BELT SWITCH - 2 WAY
1 R57 20DG DRIVER SEAT BELT SWITCH SENSE
2 R59 20LB DRIVER SEAT BELT SWITCH GROUND
DRIVER SIDE IMPACT SENSOR - BLACK 4 WAY
1 - -
2 - -
3 R133 20LB/DG DRIVER SIDE IMPACT SENSOR GROUND
4 R131 20LG/YL DRIVER SIDE IMPACT SENSOR SIGNAL
EGR SOLENOID (DIESEL) - BLACK 2 WAY
2 K35 20GY/YL EGR SOLENOID CONTROL
ELECTRIC BRAKE (EXCEPT BUILT-UP-EXPORT) - BLUE 4 WAY
1 Z151 14BK GROUND
3 B40 12LB TRAILER TOW BRAKE B(+)
4 F9 14RD/BK FUSED B(+)
ELECTRONIC SPEED CONTROL SERVO - BLACK 4 WAY
1 V36 20TN/RD (RHD/GAS) SPEED CONTROL VACUUM SOLENOID CONTROL
1 V36 18TN/RD (LHD GAS) SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 20LG/RD (RHD/GAS) SPEED CONTROL VENT SOLENOID CONTROL
2 V35 18LG/RD (LHD GAS) SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z307 20BK GROUND
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
1 Z108 14BK/DG GROUND
2 Z108 14BK/DG GROUND
3 K20 14DB GENERATOR FIELD CONTROL
6 D52 18DG/WT CAN C BUS(+)
8 K944 20BR/DG CAMSHAFT POSITION SENSOR GROUND
9 K44 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 Y53 20BK/YL BOOST PRESSURE SENSOR SIGNAL
12 K155 20YL/WT MASS AIR FLOW SENSOR SIGNAL
13 Y40 20DG/VT FUEL PRESSURE SENSOR SIGNAL
14 K22 20RD/DB ACCELERATOR PEDAL POSITION SENSOR 2 SIGNAL
15 K81 20DB/DG ACCELERATOR PEDAL POSITION SENSOR 1 SIGNAL
16 Y100 20BR/GY FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 F300 20RD/BK BATTERY SENSE (+)
20 Z11 20BK/WT BATTERY SENSE (-)
22 F991 20RD/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
24 K3 20BK CRANKSHAFT POSITION SENSOR SIGNAL 1
25 D51 18WT CAN C BUS(-)
26 - -
27 - -
28 - -
29 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT
30 G60 20BR/DB ENGINE OIL PRESSURE SENSOR SIGNAL
31 - -
32 K25 20VT/DG BATTERY TEMPERATURE SENSOR SIGNAL
33 - -
34 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR 1 GROUND
35 Y43 20WT/VT ACCELERATOR PEDAL POSITION SENSOR 1 5-VOLT
SUPPLY
36 C18 20DB A/C PRESSURE SENSOR SIGNAL
37 - -
38 V37 20RD/DG SPEED CONTROL SWITCH SIGNAL
39 K226 20DB/WT FUEL LEVEL SENSOR SIGNAL
40 K2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 20DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Y101 20 CRANKSHAFT POSITION SENSOR SHIELD
43 K924 20YL CRANKSHAFT POSITION SENSOR SIGNAL 2
44 - -
45 - -
46 - -
47 L50 20WT/DB PRIMARY BRAKE SWITCH SIGNAL
49 - -
51 - -
52 - -
53 - -
54 Z189 20BR MASS AIR FLOW SENSOR GROUND
56 K225 18BK ACCELERATOR PEDAL POSITION SENSOR 2 GROUND
57 - -
58 K4 20BK/LB WATER IN FUEL SENSOR GROUND
59 K900 18GY INTAKE PORT SWIRL ACTUATOR SIGNAL
60 K7 20RD/WT FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20DB/YL AUTO SHUT DOWN RELAY CONTROL
62 - -
63 - -
64 - -
65 - -
66 - -
67 K173 20GY HYDRAULIC RADIATOR FAN SOLENOID CONTROL
68 - -
69 C13 20DB/RD A/C COMPRESSOR CLUTCH RELAY CONTROL
70 - -
71 - -
72 K236 20GY/PK GLOW PLUG RELAY NO. 2 CONTROL
73 - -
74 T752 20DG/RD ENGINE STARTER MOTOR RELAY CONTROL
75 K132 20BR/BK VISCOUS/CABIN HEATER RELAY CONTROL
76 Y42 20BR/BK WASTEGATE SOLENOID CONTROL
77 K152 20WT GLOW PLUG RELAY NO. 1 CONTROL
78 - -
79 - -
80 K46 20DB/BK FUEL PRESSURE SOLENOID CONTROL
83 - -
84 - -
85 - -
86 - -
87 - -
88 - -
89 K35 20GY/YL EGR SOLENOID CONTROL
90 - -
91 - -
92 - -
93 - -
94 G123 20DG/WT WATER IN FUEL SENSOR SIGNAL
95 - -
96 - -
97 - -
98 - -
99 - -
100 - -
101 - -
102 - -
103 - -
104 - -
105 - -
106 - -
107 - -
108 - -
109 - -
110 - -
111 - -
112 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
113 - -
114 - -
115 K14 14BK/YL FUEL INJ ECTOR NO. 4 CONTROL
116 K63 14BK COMMON INJ ECTOR DRIVER
117 - -
118 K11 14BK/DB FUEL INJ ECTOR NO. 1 CONTROL
119 K38 14BK/DG FUEL INJ ECTOR NO. 5 CONTROL
120 K12 14BK/VT FUEL INJ ECTOR NO. 2 CONTROL
121 K13 14BK/RD FUEL INJ ECTOR NO. 3 CONTROL
ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY
2 K2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR (GAS) - BLACK 2 WAY
2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
2 G60 20BR/DB ENGINE OIL PRESSURE SENSOR SIGNAL
ENGINE OIL PRESSURE SENSOR (GAS) - BLACK 3 WAY
1 K6 18VT/BK 5 VOLT SUPPLY
2 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY
1 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 K52 18PK/BK (RHD) DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
2 K52 20PK/BK (LHD) DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
FRONT POWER OUTLET - RED 3 WAY
1 F85 16VT (RHD) FUSED B(+)
1 F85 16VT/WT (LHD) FUSED B(+)
2 - -
3 Z300 16BK GROUND
FRONT WASHER PUMP - WHITE 2 WAY
2 Z141 20BK GROUND
FRONT WIPER MOTOR - BLACK 6 WAY
1 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 V55 16TN/RD WIPER PARK SWITCH SENSE
3 - -
4 Z141 16BK GROUND
5 V3 16BR/WT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
6 V4 16RD/YL WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
FUEL INJ ECTOR NO. 1 (DIESEL) - BLACK 2 WAY
1 K11 14BK/DB FUEL INJ ECTOR NO. 1 CONTROL
FUEL INJ ECTOR NO. 1 (GAS) - BLACK 2 WAY
1 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
2 F42 18DG/LG FUSED AUTO SHUT DOWN RELAY OUTPUT
1 K12 14BK/VT FUEL INJ ECTOR NO. 2 CONTROL
1 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
1 K13 14BK/RD FUEL INJ ECTOR NO. 3 CONTROL
1 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
1 K14 14BK/YL FUEL INJ ECTOR NO. 4 CONTROL
1 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
1 K38 14BK/DG FUEL INJ ECTOR NO. 5 CONTROL
1 K38 18GY FUEL INJ ECTOR NO. 5 DRIVER
1 K58 18BR/DB FUEL INJ ECTOR NO. 6 DRIVER
FUEL INJ ECTOR NO. 7 (4.7L) - BLACK 2 WAY
1 K26 18VT FUEL INJ ECTOR NO. 7 DRIVER
FUEL INJ ECTOR NO. 8 (4.7L) - BLACK 2 WAY
1 K28 18GY/LB FUEL INJ ECTOR NO. 8 DRIVER
FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
1 Y100 20BR/GY FUEL PRESSURE SENSOR GROUND
2 Y40 20DG/VT FUEL PRESSURE SENSOR SIGNAL
3 K7 20RD/WT FUEL PRESSURE SENSOR 5 VOLT SUPPLY
FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY
FUEL PUMP MODULE (GAS) - BLACK 6 WAY
1 A141 16DG/BK FUEL PUMP RELAY OUTPUT
2 - -
3 K226 20LB/YL FUEL LEVEL SENSOR SIGNAL
5 - -
6 Z150 16BK GROUND
FUEL TANK MODULE (DIESEL) - BLACK 6 WAY
1 - -
2 - -
5 - -
6 - -
GENERATOR (DIESEL) - LT. GRAY 2 WAY
1 F15 14DB/WT FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K20 14DB GENERATOR FIELD CONTROL
GENERATOR (GAS) - BLACK 2 WAY
1 K125 18WT/DB GENERATOR SOURCE
2 K20 18DG GENERATOR FIELD DRIVER
GLOVE BOX LAMP - BLACK 2 WAY
1 F70 20PK/BK FUSED B(+)
2 M20 20BR/OR COURTESY LAMP LOAD SHED
HEADLAMP LEVELING SWITCH (BUILT-UP-EXPORT) - WHITE 3 WAY
1 Z234 20BK GROUND
2 L7 18BK/YL PARK LAMP RELAY OUTPUT
3 L13 20BR/YL HEADLAMP ADJ UST SIGNAL
HOOD AJ AR SWITCH (BUILT-UP-EXPORT) - BLACK 2 WAY
1 G70 20BR/TN HOOD AJ AR SWITCH SENSE
2 Z141 20BK (DIESEL) GROUND
2 Z161 20BK (GAS) GROUND
HORN NO. 1 - BLACK 2 WAY
1 Z307 18BK GROUND
2 X2 18DG/RD HORN RELAY OUTPUT
HORN NO. 2 - BLACK 2 WAY
1 Z307 18BK GROUND
2 X2 18DG/RD HORN RELAY OUTPUT
HYDRAULIC COOLING MODULE - BLACK 3 WAY
1 F15 18DB/WT (DIESEL) FUSED AUTO SHUT DOWN RELAY OUTPUT
1 F142 18OR/DG (GAS) FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K173 18LG (DIESEL) HYDRAULIC RADIATOR FAN RELAY CONTROL
2 K173 18LG (GAS) RADIATOR FAN RELAY CONTROL
3 Z500 18BK GROUND
IDLE AIR CONTROL MOTOR - BLACK 4 WAY
1 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
2 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
3 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
4 K39 18GY/BK IDLE AIR CONTROL NO. 1 DRIVER
IGNITION SWITCH C1 - WHITE 6 WAY
1 A41 12YL IGNITION SWITCH OUTPUT (START)
2 A2 12PK/BK FUSED B(+)
3 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
4 A1 12RD FUSED B(+)
5 A31 12RD/BK IGNITION SWITCH OUTPUT (RUN-ACC)
6 A21 12DB IGNITION SWITCH OUTPUT (RUN-START)
IGNITION SWITCH C2 - BLACK 2 WAY
1 G26 20LB KEY-IN IGNITION SWITCH SENSE
2 Z234 20BK GROUND
INPUT SPEED SENSOR (4.7L) - BLACK 2 WAY
1 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
2 T13 18DB/BK SPEED SENSOR GROUND
INSTRUMENT CLUSTER - WHITE 12 WAY
1 L61 20TN/LG LEFT TURN SIGNAL
2 L60 20TN RIGHT TURN SIGNAL
3 - -
4 - -
5 G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER
7 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
9 Z300 20BK GROUND
10 D25 20YL/VT/RD PCI BUS
12 - -
INTAKE AIR TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY
2 K21 20DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
INTAKE AIR TEMPERATURE SENSOR (GAS) - GRAY 2 WAY
2 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
INTAKE PORT SWIRL ACTUATOR (DIESEL) - BLACK 3 WAY
1 Z18 18BK GROUND
3 K900 18GY INTAKE PORT SWIRL ACTUATOR SIGNAL
INTRUSION TRANSCEIVER MODULE (BUILT-UP-EXPORT) - BLACK 6 WAY
1 Z155 20BK GROUND
2 - -
3 X75 20GY/LG SIREN SIGNAL CONTROL
4 - -
J UNCTION BLOCK BODY CONTROL MODULE - BLACK 26 WAY
1 L308 PARK LAMP RELAY CONTROL
2 L26 FOG LAMP RELAY CONTROL
3 Q29 ACCESSORY DELAY RELAY CONTROL
4 L307 LOW BEAM RELAY CONTROL
5 G5 FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 X4 HORN RELAY CONTROL
7 V16 WIPER HIGH/LOW RELAY CONTROL
8 G80 LIFTGATE FLIP-UP AJ AR SWITCH SENSE
9 L11 HIGH BEAM RELAY CONTROL
10 L91 HAZARD SWITCH SENSE
11 C80 REAR WINDOW DEFOGGER RELAY CONTROL
12 Z2 GROUND
13 L96 (BUILT-UP-EXPORT) REAR FOG LAMP RELAY CONTROL
14 L7 PARK LAMP RELAY OUTPUT
15 Z1 GROUND
16 M2 COURTESY LAMP DRIVER
17 - -
18 - -
19 M20 COURTESY LAMP LOAD SHED
20 V55 WIPER PARK SWITCH SENSE
21 G78 LIFTGATE AJ AR SWITCH SENSE
22 G10 SEAT BELT SWITCH SENSE
23 G77 LEFT REAR DOOR AJ AR SWITCH SENSE
24 G73 LIFTGATE COURTESY DISABLE
25 V23 FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
26 M1 FUSED B(+)
J UNCTION BLOCK C1 - BLACK 52 WAY
1 Q30 16TN ACCESSORY DELAY RELAY OUTPUT
2 L63 18DG/RD LEFT TURN SIGNAL
3 - -
4 - -
5 L95 18DG/YL (BUILT-UP-EXPORT) REAR FOG LAMP RELAY OUTPUT
6 - -
7 - -
8 - -
9 G73 20LG/OR LIFTGATE COURTESY DISABLE
10 G77 20TN/OR LEFT REAR DOOR AJ AR SWITCH SENSE
12 - -
13 - -
14 - -
15 F37 16RD (LHD EXCEPT BASE) FUSED B(+)
15 F37 16RD/LB (RHD) FUSED B(+)
16 M2 18YL (RHD) COURTESY LAMP DRIVER
16 M2 20YL/DG (LHD) COURTESY LAMP DRIVER
17 - -
18 - -
19 - -
20 - -
21 - -
22 F22 20WT/PK (RHD) FUSED IGNITION SWITCH OUTPUT (RUN)
23 - -
24 G80 20VT/YL LIFTGATE FLIP-UP AJ AR SWITCH SENSE
25 G78 20TN/BK LIFTGATE AJ AR SWITCH SENSE
26 M20 18YL/BK (RHD) COURTESY LAMP LOAD SHED
26 M20 20YL/BK (LHD) COURTESY LAMP LOAD SHED
27 - -
28 - -
29 - -
31 - -
32 M1 18PK/RD (RHD) FUSED B(+)
33 - -
34 - -
35 F9 14RD/BK FUSED B(+)
37 - -
38 - -
39 - -
40 - -
41 F30 14RD/TN (LHD) CIGAR LIGHTER RELAY OUTPUT
41 F30 16RD/TN (RHD) CIGAR LIGHTER RELAY OUTPUT
42 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
49 - -
50 C15 12BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
51 - -
52 - -
J UNCTION BLOCK C2 (LHD) - BLACK 52 WAY
2 - -
3 L39 20LB FOG LAMP RELAY OUTPUT
4 - -
6 - -
7 - -
9 V6 16DB (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
10 L62 18BR/RD RIGHT TURN SIGNAL
11 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
13 - -
14 - -
15 V16 22VT WIPER HIGH/LOW RELAY CONTROL
16 - -
17 - -
18 - -
19 - -
22 - -
23 - -
24 F37 16RD/LB (EXCEPT BASE) FUSED B(+)
27 F45 20YL/RD FUSED IGNITION SWITCH OUTPUT (START)
29 - -
30 - -
31 F72 16RD/YL FUSED B(+)
32 M1 20PK/RD FUSED B(+)
33 V55 16TN/RD (GAS) WIPER PARK SWITCH SENSE
34 - -
35 - -
37 - -
38 L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
39 L43 18VT FUSED LEFT LOW BEAM OUTPUT
40 - -
41 - -
44 - -
46 - -
48 - -
49 L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
50 L33 18RD FUSED LEFT HIGH BEAM OUTPUT
51 - -
52 F60 14RD/WT (EXCEPT BASE) FUSED B(+)
J UNCTION BLOCK C2 (RHD) - BLACK 52 WAY
1 X3 22BK/RD HORN RELAY CONTROL
2 - -
4 - -
6 - -
7 - -
9 V6 16DB (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
11 F991 20OR/DB (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-START)
13 - -
14 - -
15 V16 22VT -
16 - -
17 - -
18 - -
19 - -
22 - -
23 - -
24 F37 16RD/LB FUSED B(+)
25 F22 18WT/TN FUSED IGNITION SWITCH OUTPUT (RUN)
29 - -
30 - -
31 - -
33 V55 16TN/RD (GAS) WIPER PARK SWITCH SENSE
34 - -
35 - -
37 - -
38 L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
39 L43 18VT FUSED LEFT LOW BEAM OUTPUT
40 - -
41 - -
43 F12 20DB/WT (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-START)
44 - -
46 - -
48 - -
49 L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
50 L33 18RD FUSED LEFT HIGH BEAM OUTPUT
51 - -
52 F60 16RD/WT FUSED B(+)
J UNCTION BLOCK C3 - BLACK 52 WAY
2 - -
4 L302 20LB/YL RIGHT TURN SWITCH SENSE
6 L91 20DB/PK HAZARD SWITCH SENSE
7 - -
8 L305 20LB/WT LEFT TURN SWITCH SENSE
9 - -
10 L309 20PK/LG HIGH BEAM RELAY CONTROL
11 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
13 - -
14 F85 16VT/WT FUSED B(+)
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 A31 12RD/BK IGNITION SWITCH OUTPUT (RUN-ACC)
26 - -
27 A41 12YL IGNITION SWITCH OUTPUT (START)
28 F14 20LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
29 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
31 Z234 20BK GROUND
33 X12 16WT/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
35 M1 20PK (AZC) FUSED B(+)
36 A21 12DB IGNITION SWITCH OUTPUT (RUN-START)
37 - -
40 F30 16RD FUSED CIGAR LIGHTER RELAY OUTPUT
42 - -
43 V23 20BR/PK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
46 - -
47 - -
49 - -
J UNCTION BLOCK C4 - WHITE 2 WAY
1 A148 10PK/WT FUSED B(+)
J UNCTION BLOCK C5 - WHITE 3 WAY
1 A145 10WT/RD FUSED B(+)
2 A149 12RD/TN FUSED B(+)
3 A147 10RD/GY FUSED B(+)
KNOCK SENSOR - BLACK 4 WAY
2 K42 18DB/LG KNOCK SENSOR NO. 1 SIGNAL
4 K142 18GY/BK KNOCK SENSOR NO. 2 SIGNAL
LEAK DETECTION PUMP (EXCEPT BUILT-UP-EXPORT) - 4 WAY
1 - -
2 K125 18OR/DG GENERATOR SOURCE
3 K106 20WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
4 K107 20OR/YL LEAK DETECTION PUMP SWITCH SENSE
LEFT COURTESY LAMP - BLACK 2 WAY
LEFT DOOR HANDLE COURTESY LAMP - WHITE 3 WAY
2 M20 20YL/BK COURTESY LAMP LOAD SHED
LEFT FOG LAMP - BLACK 2 WAY
2 Z141 20BK (DIESEL/4.7L RHD) GROUND
2 Z141 18BK (EXCEPT DIESEL/4.7L RHD) GROUND
LEFT FRONT DOOR SPEAKER - WHITE 3 WAY
1 X55 18LG/DG (BASE) LEFT FRONT DOOR SPEAKER (-)
1 X85 18LB/BK (RHD PREMIUM) LEFT FRONT DOOR SPEAKER (-)
1 X85 18LG/DG (LHD PREMIUM) LEFT FRONT DOOR SPEAKER (-)
2 - -
3 X53 18LG/RD (BASE) LEFT FRONT DOOR SPEAKER (+)
3 X87 18LB/RD (RHD PREMIUM) LEFT FRONT DOOR SPEAKER (+)
3 X87 18LG/RD (LHD PREMIUM) LEFT FRONT DOOR SPEAKER (+)
LEFT FRONT IMPACT SENSOR - BLACK 4 WAY
1 - -
2 - -
3 R47 18DB/LB LEFT FRONT IMPACT SENSOR GROUND
4 R49 18LB LEFT FRONT IMPACT SENSOR SIGNAL
LEFT FRONT PARK LAMP - WHITE 2 WAY
1 Z1 18BK GROUND
2 L7 20BK/PK PARK LAMP RELAY OUTPUT
LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY
1 L7 20BK/PK PARK LAMP RELAY CONTROL
2 Z1 18BK GROUND
LEFT FRONT SIDE MARKER LAMP (EXCEPT BUILT-UP-EXPORT) - WHITE 2 WAY
LEFT FRONT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - WHITE 2 WAY
2 Z1 18BK GROUND
LEFT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY
1 B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL
LEFT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY
1 Z1 18BK GROUND
2 L114 18VT/DB HEADLAMP ADJ UST SIGNAL
LEFT HIGH BEAM HEADLAMP - BLACK 2 WAY
A Z1 18BK GROUND
B L33 18RD FUSED LEFT HIGH BEAM OUTPUT
LEFT INSTRUMENT PANEL SPEAKER - WHITE 2 WAY
1 X83 18YL/RD LEFT INSTRUMENT PANEL SPEAKER (+)
2 X81 18YL/BK LEFT INSTRUMENT PANEL SPEAKER (-)
LEFT LIFTGATE AJ AR SWITCH - BLACK 2 WAY
1 Z1 20BK GROUND
LEFT LOW BEAM HEADLAMP - GRAY 2 WAY
A Z1 18BK GROUND
B L43 18VT FUSED LEFT LOW BEAM OUTPUT
LEFT MULTI-FUNCTION SWITCH - WHITE 11 WAY
1 L27 20WT/TN FOG LAMP SWITCH SENSE
2 Z234 20BK GROUND
3 - -
4 L80 20WT/DG HEADLAMP SWITCH RETURN
5 L309 20PK/LG HIGH BEAM RELAY CONTROL
6 L40 20BR HIGH BEAM SWITCH SENSE
7 L302 20LB/YL RIGHT TURN SWITCH SENSE
8 L305 20LB/WT LEFT TURN SWITCH SENSE
9 L91 20DB/PK HAZARD SWITCH SENSE
10 E19 20RD PANEL LAMPS DIMMER SIGNAL
11 G52 20YL HEADLAMP SWITCH MUX
LEFT REAR DOOR LOCK MOTOR/AJ AR SWITCH - BLACK 4 WAY
1 G77 18TN/YL LEFT REAR DOOR AJ AR SWITCH SENSE
2 Z1 18BK GROUND
3 P36 18PK/VT DOOR UNLOCK DRIVER
4 P35 18OR/VT DOOR LOCK DRIVER
LEFT REAR DOOR SPEAKER - WHITE 3 WAY
1 X51 18WT/VT (BASE) LEFT REAR DOOR SPEAKER (+)
1 X91 18WT/VT (PREMIUM) LEFT REAR DOOR SPEAKER (+)
2 - -
3 X57 18TN/DG (BASE) LEFT REAR DOOR SPEAKER (-)
3 X93 18TN/DG (PREMIUM) LEFT REAR DOOR SPEAKER (-)
LEFT REAR LAMP ASSEMBLY - BLACK 6 WAY
1 L1 18VT/BK BACK-UP LAMP FEED
5 Z150 18BK GROUND
LEFT REAR WHEEL SPEED SENSOR - GRAY 2 WAY
1 B4 18LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
2 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR SIGNAL
LEFT REMOTE RADIO SWITCH - BLACK 2 WAY
LEFT SIDE REPEATER LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY
1 L61 18LG (DIESEL) LEFT TURN SIGNAL
1 L61 18TN/LG (GAS) LEFT TURN SIGNAL
2 Z161 18BK GROUND
LEFT VISOR/VANITY LAMP - BLACK 2 WAY
LICENSE LAMP NO. 1 - BLACK 2 WAY
2 Z1 18BK GROUND
LICENSE LAMP NO. 2 - BLACK 2 WAY
2 Z1 18BK GROUND
LIFTGATE FLIP-UP AJ AR SWITCH - GRAY 2 WAY
1 Z1 20BK GROUND
LIFTGATE FLIP-UP PUSH BUTTON SWITCH - BLACK 2 WAY
1 P101 18OR/PK LIFTGATE FLIP-UP SWITCH OUTPUT
LIFTGATE FLIP-UP RELEASE SOLENOID - BLACK 2 WAY
1 Z1 18BK GROUND
2 P100 18OR/BR LIFTGATE GLASS LIMIT SWITCH OUTPUT
LIFTGATE POWER LOCK MOTOR - BLACK 4 WAY
3 P101 18OR/PK LIFTGATE FLIP-UP SWITCH OUTPUT
4 P100 18OR/BR LIFTGATE GLASS LIMIT SWITCH OUTPUT
LINE PRESSURE SENSOR (4.7L) - BLACK 4 WAY
1 Z114 14BK/LB GROUND
2 T138 14GY/LB 5 VOLT SUPPLY
3 T130 14VT/TN LINE PRESSURE SENSOR SIGNAL
4 - -
MANIFOLD ABSOLUTE PRESSURE SENSOR (4.0L) - BLACK 3 WAY
2 K1 18DG/RD MAP SENSOR SIGNAL
MANIFOLD ABSOLUTE PRESSURE SENSOR (4.7L) - BLACK 3 WAY
MANUAL TEMPERATURE CONTROL C1 (MTC) - WHITE 11 WAY
3 C67 20RD/LB BLEND AIR DOOR POSITION CONTROL
8 C4 16TN BLOWER MOTOR LOW DRIVER
9 C5 16LG BLOWER MOTOR M1 DRIVER
10 C6 14LB BLOWER MOTOR M2 DRIVER
11 - -
MANUAL TEMPERATURE CONTROL C2 (MTC) - WHITE 2 WAY
1 Z118 12BK GROUND
2 C7 12BK/TN BLOWER MOTOR HIGH DRIVER
MASS AIR FLOW SENSOR (DIESEL) - BLACK 5 WAY
1 - -
3 Z189 20BR MASS AIR FLOW SENSOR GROUND
5 K155 20YL/WT MASS AIR FLOW SENSOR SIGNAL
MODE DOOR MOTOR/ACTUATOR (AZC) - BLACK 2 WAY
A C102 20TN/BK (LHD) MODE DOOR DRIVER (B)
A C35 20DG/YL (RHD) MODE DOOR DRIVER (A)
B C35 20DG/YL (LHD) MODE DOOR DRIVER (A)
B C102 20TN/BK (RHD) MODE DOOR DRIVER (B)
NEEDLE MOVEMENT SENSOR (DIESEL) - BLACK 2 WAY
1 K67 18BR/BK NEEDLE MOVEMENT SENSOR SIGNAL
2 K68 18LG/YL NEEDLE MOVEMENT SENSOR GROUND
OUTPUT SPEED SENSOR (4.0L) - GRAY 2 WAY
2 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
OUTPUT SPEED SENSOR (4.7L) - BLACK 2 WAY
OVERHEAD MAP/COURTESY LAMP - WHITE 3 WAY
OXYGEN SENSOR 1/1 UPSTREAM - 4 WAY
1 F142 18OR/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
4 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
OXYGEN SENSOR 1/2 DOWNSTREAM - 4 WAY
1 F142 18OR/DG (4.0L
BUILT-UP-EXPORT)
FUSED AUTO SHUT DOWN RELAY OUTPUT
1 K200 18VT/OR (EXCEPT 4.0L
BUILT-UP-EXPORT)
OXYGEN SENSOR DOWNSTREAM RELAY OUTPUT
2 K299 18BR/WT (4.0L
BUILT-UP-EXPORT)
OXYGEN SENSOR 1/2 HEATER CONTROL
2 Z186 18BK (EXCEPT 4.0L
BUILT-UP-EXPORT)
GROUND
4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
OXYGEN SENSOR 2/1 UPSTREAM - 4 WAY
1 F142 18OR/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K299 18BR/WT OXYGEN SENSOR 2/1 HEATER CONTROL
4 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
OXYGEN SENSOR 2/2 DOWNSTREAM - 4 WAY
1 K200 18VT/OR (4.0L) OXYGEN SENSOR DOWNSTREAM RELAY OUTPUT
1 K200 18BR/WT (4.7L) OXYGEN SENSOR DOWNSTREAM RELAY OUTPUT
2 Z186 18BK GROUND
4 K341 18TN/WT (4.0L) OXYGEN SENSOR 2/2 SIGNAL
4 K341 18PK/WT (4.7L) OXYGEN SENSOR 2/2 SIGNAL
PARK/NEUTRAL POSITION SWITCH (4.0L) - BLACK 3 WAY
PARK/NEUTRAL POSITION SWITCH (DIESEL) - BLACK 3 WAY
2 T41 18BR/YL PARK/NEUTRAL POSITION SWITCH SENSE (T41)
3 F22 18WT/TN FUSED IGNITION SWITCH OUTPUT (RUN)
PASSENGER AIRBAG - YELLOW 4 WAY
1 R42 20BK/YL PASSENGER SQUIB 1 LINE 1
2 R44 20DG/YL PASSENGER SQUIB 1 LINE 2
3 R64 20TN/YL PASSENGER SQUIB 2 LINE 1
4 R62 20OR/YL PASSENGER SQUIB 2 LINE 2
PASSENGER BLEND DOOR MOTOR/ACTUATOR (LHD) (AZC) - BLACK 2 WAY
A C96 20WT/DB (LHD) PASSENGER BLEND DOOR DRIVER (B)
B C94 20WT/DG (LHD) PASSENGER BLEND DOOR DRIVER (A)
PASSENGER BLEND DOOR MOTOR/ACTUATOR (RHD) (AZC) - BLACK 2 WAY
A C94 20WT/DG (RHD) PASSENGER BLEND DOOR DRIVER (A)
B C96 20WT/DB (RHD) PASSENGER BLEND DOOR DRIVER (B)
PASSENGER CURTAIN AIRBAG - BLACK 2 WAY
1 R72 20LB/WT PASSENGER CURTAIN SQUIB LINE 2
2 R74 20LB/YL PASSENGER CURTAIN SQUIB LINE 1
PASSENGER DOOR LOCK MOTOR/AJ AR SWITCH - BLACK 4 WAY
1 G74 18TN/RD PASSENGER DOOR AJ AR SWITCH SENSE
2 Z1 18BK GROUND
PASSENGER DOOR MODULE C1 - WHITE 15 WAY
2 Q24 16DG PASSENGER REAR WINDOW DRIVER (DOWN)
3 Q14 16GY PASSENGER REAR WINDOW DRIVER (UP)
4 Z1 12BK GROUND
6 - -
8 - -
10 - -
11 G74 18TN/RD PASSENGER DOOR AJ AR SWITCH SENSE
12 E20 20OR/DB PASSENGER REAR DOOR SWITCH ILLUMINATION
13 Q12 16BR PASSENGER WINDOW DRIVER (UP)
14 - -
15 Q22 16VT PASSENGER WINDOW DRIVER (DOWN)
PASSENGER DOOR MODULE C2 - BLACK 12 WAY
PASSENGER FRONT DOOR COURTESY LAMP - BLACK 2 WAY
PASSENGER FRONT POWER WINDOW MOTOR - BLACK 2 WAY
1 Q22 16VT PASSENGER WINDOW DRIVER (DOWN)
2 Q12 16BR PASSENGER WINDOW DRIVER (UP)
PASSENGER HEATED SEAT BACK (PREMIUM I/III) - 3 WAY
2 Z5 16BK/VT GROUND
3 - -
PASSENGER HEATED SEAT CUSHION (PREMIUM I/III) - 4 WAY
1 P130 16DG/WT PASSENGER SEAT HEATER B(+) DRIVER
3 P86 20DG/YL PASSENGER SEAT TEMPERATURE SENSOR INPUT
PASSENGER HEATED SEAT SWITCH - BLACK 6 WAY
1 P134 20TN/LG PASSENGER SEAT HEATER SWITCH MUX
4 - -
5 Z300 20BK GROUND
PASSENGER LUMBAR MOTOR (MIDLINE/PREMIUM) - BLACK 2 WAY
1 P105 16LG/DG LUMBAR FORWARD SWITCH SENSE
2 P104 16YL/RD LUMBAR REARWARD SWITCH SENSE
PASSENGER LUMBAR SWITCH (MIDLINE/PREMIUM) - WHITE 6 WAY
1 - -
2 Z1 16BK GROUND
3 P104 16YL/RD (RHD) LUMBAR REARWARD SWITCH SENSE
3 P105 16LG/DB (LHD) LUMBAR FORWARD SWITCH SENSE
4 P105 16LG/DB (RHD) LUMBAR FORWARD SWITCH SENSE
4 P104 16YL/RD (LHD) LUMBAR REARWARD SWITCH SENSE
5 Z1 16BK GROUND
PASSENGER POWER MIRROR - BLACK 12 WAY
7 - -
10 - -
PASSENGER POWER SEAT FRONT RISER MOTOR - RED 2 WAY
1 P18 16YL/LG PASSENGER SEAT FRONT UP DRIVER
2 P20 16RD/LG PASSENGER SEAT FRONT DOWN DRIVER
PASSENGER POWER SEAT HORIZONTAL MOTOR - RED 2 WAY
1 P16 16RD/YL PASSENGER SEAT HORIZONTAL REARWARD DRIVER
2 P14 16YL/LB PASSENGER SEAT HORIZONTAL FORWARD DRIVER
PASSENGER POWER SEAT REAR RISER MOTOR - RED 2 WAY
1 P10 16YL/WT PASSENGER SEAT REAR UP DRIVER
2 P12 16RD/WT PASSENGER SEAT REAR DOWN DRIVER
PASSENGER POWER SEAT RECLINER MOTOR (MIDLINE/PREMIUM) - BLACK 2 WAY
A P42 16BR/WT PASSENGER SEAT RECLINER DOWN DRIVER
B P44 16GY/LB PASSENGER SEAT RECLINER UP DRIVER
PASSENGER POWER SEAT SWITCH (MIDLINE/PREMIUM) - GREEN 10 WAY
1 Z1 16BK GROUND
2 P44 16GY/LB PASSENGER SEAT RECLINER UP DRIVER
3 P16 16RD/YL PASSENGER SEAT HORIZONTAL REARWARD DRIVER
4 P42 16BR/WT PASSENGER SEAT RECLINER DOWN DRIVER
6 P14 16YL/LB PASSENGER SEAT HORIZONTAL FORWARD DRIVER
7 P18 16YL/LG (RHD) PASSENGER SEAT FRONT UP DRIVER
7 P20 16RD/LG (LHD) PASSENGER SEAT FRONT DOWN DRIVER
8 P10 16YL/WT (RHD) PASSENGER SEAT REAR UP DRIVER
8 P12 16RD/WT (LHD) PASSENGER SEAT REAR DOWN DRIVER
9 P12 16RD/WT (RHD) PASSENGER SEAT REAR DOWN DRIVER
9 P10 16YL/WT (LHD) PASSENGER SEAT REAR UP DRIVER
10 P20 16RD/LG (RHD) PASSENGER SEAT FRONT DOWN DRIVER
10 P18 16YL/LG (LHD) PASSENGER SEAT FRONT UP DRIVER
PASSENGER REAR POWER WINDOW MOTOR - BLACK 2 WAY
PASSENGER REAR POWER WINDOW SWITCH - BLUE 6 WAY
1 Q14 16GY PASSENGER REAR WINDOW DRIVER (UP)
3 E21 20OR/RD PASSENGER REAR DOOR SWITCH ILLUMINATION
4 Q24 16DG PASSENGER REAR WINDOW DRIVER (DOWN)
6 Z1 16BK GROUND
PASSENGER SEAT BELT SWITCH - 2 WAY
1 R58 20GY PASSENGER SEAT BELT SWITCH SENSE
2 R60 20VT PASSENGER SEAT BELT SWITCH GROUND
PASSENGER SIDE IMPACT SENSOR - BLACK 4 WAY
1 - -
2 - -
3 R134 20LB/BR PASSENGER SIDE IMPACT SENSOR GROUND
4 R132 20LG/VT PASSENGER SIDE IMPACT SENSOR SIGNAL
POWER AMPLIFIER C1 (PREMIUM RADIO) - WHITE 18 WAY
3 Z9 16BK GROUND
4 - -
5 X58 18DB/OR RIGHT REAR SPEAKER (-)
6 X57 18DG/WT LEFT REAR SPEAKER (-)
7 X56 18DB/PK RIGHT FRONT SPEAKER (-)
8 X55 18BR/RD LEFT FRONT SPEAKER (-)
9 - -
11 Z9 16BK GROUND
12 - -
13 X64 18BR/WT ENABLE SIGNAL TO AMPLIFIER
14 - -
15 X52 18DB/WT RIGHT REAR SPEAKER (+)
16 X51 18WT/DG LEFT REAR SPEAKER (+)
17 X54 18VT RIGHT FRONT SPEAKER (+)
18 X53 18DG/OR LEFT FRONT SPEAKER (+)
POWER AMPLIFIER C2 (PREMIUM RADIO) - WHITE 12 WAY
1 X90 18WT/VT RIGHT REAR DOOR SPEAKER (+)
2 X92 18TN/DG RIGHT REAR DOOR SPEAKER (-)
3 X85 18LG/DG LEFT FRONT DOOR SPEAKER (-)
4 X83 18YL/RD LEFT INSTRUMENT PANEL SPEAKER (+)
5 X84 18OR/GY RIGHT INSTRUMENT PANEL SPEAKER (-)
6 X93 18DG/WT LEFT REAR DOOR SPEAKER (+)
7 X91 18WT/DG LEFT REAR DOOR SPEAKER (-)
8 X87 18LG/RD LEFT FRONT DOOR SPEAKER (+)
9 X80 18LB/BK RIGHT FRONT DOOR SPEAKER (-)
10 X82 18LB/RD RIGHT FRONT DOOR SPEAKER (+)
11 X81 18YL/BK LEFT INSTRUMENT PANEL SPEAKER (-)
12 X86 18OR/RD RIGHT INSTRUMENT PANEL SPEAKER (+)
POWER CONNECTOR - WHITE 2 WAY
1 F85 16VT/WT FUSED B(+)
2 Z234 16BK GROUND
POWERTRAIN CONTROL MODULE C1 (GAS) - BLACK 32 WAY
3 K94 14TN/LG (4.7L) COIL DRIVER NO. 4
5 K96 14TN/LB (4.7L) COIL DRIVER NO. 6
9 K98 14LB/RD (4.7L) COIL DRIVER NO. 8
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 - -
13 - -
14 K77 18LG/BK TRANSFER CASE POSITION SENSOR INPUT
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
18 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
19 K39 18GY/BK IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 K95 14TN/DG (4.7L) COIL DRIVER NO. 5
22 A7 14RD/BK FUSED B(+)
23 K22 18OR/RD THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 K241 18LG/RD (EXCEPT 4.0L
BUILT-UP-EXPORT)
OXYGEN SENSOR 2/1 SIGNAL
28 - -
29 K341 18TN/WT (4.0L EXCEPT
BUILT-UP-EXPORT)
OXYGEN SENSOR 2/2 SIGNAL
29 K341 18PK/WT (4.7L) OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z82 14BK/WT GROUND
32 Z81 14BK/TN GROUND
POWERTRAIN CONTROL MODULE C2 (GAS) - WHITE 32 WAY
1 T54 18VT (4.0L) TRANSMISSION TEMPERATURE SENSOR SIGNAL
2 K26 18VT (4.7L) FUEL INJ ECTOR NO. 7 DRIVER
3 - -
4 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
6 K38 18GY FUEL INJ ECTOR NO. 5 DRIVER
7 K97 14BR (4.7L) COIL DRIVER NO. 7
8 K88 18PK (4.0L) GOVERNOR PRESSURE SOLENOID CONTROL
10 K20 18DG GENERATOR FIELD DRIVER
11 T20 18LB (4.0L) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
12 K58 18BR/DB FUEL INJ ECTOR NO. 6 DRIVER
13 K28 18GY/LB (4.7L) FUEL INJ ECTOR NO. 8 DRIVER
14 - -
15 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
17 K173 18LG RADIATOR FAN RELAY CONTROL
18 - -
19 C18 18DB A/C PRESSURE SIGNAL
20 - -
21 T60 18BR (4.0L) 3-4 SHIFT SOLENOID CONTROL
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
25 T13 18DB/BK (4.0L) SPEED SENSOR GROUND
26 - -
28 T14 18LG/WT (4.0L) OUTPUT SPEED SENSOR SIGNAL
29 T25 18LG/RD (4.0L) GOVERNOR PRESSURE SENSOR SIGNAL
30 K30 18PK/YL (4.0L) TRANSMISSION CONTROL RELAY CONTROL
32 - -
POWERTRAIN CONTROL MODULE C3 (GAS) - GRAY 32 WAY
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2 - -
3 K51 18DB/YL AUTO SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6 - -
7 K42 18DB/LG (4.7L HIGH OUTPUT) KNOCK SENSOR NO. 1 SIGNAL
8 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
9 K512 18RD/YL (EXCEPT 4.0L
BUILT-UP-EXPORT)
OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
BUILT-UP-EXPORT)
LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18OR/DG SPEED CONTROL SUPPLY
13 T10 18YL/DG (4.7L RHD) TORQUE MANAGEMENT REQUEST SENSE
13 T6 18OR/WT (4.0L LHD) OVERDRIVE OFF SWITCH SENSE
13 T10 18DG/LG (4.7L LHD) TORQUE MANAGEMENT REQUEST SENSE
13 T6 18OR/BK (4.0L RHD) OVERDRIVE OFF SWITCH SENSE
14 K107 18OR/PK (EXCEPT
BUILT-UP-EXPORT)
LEAK DETECTION PUMP SWITCH SENSE
15 K25 18VT/LG BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT OXYGEN SENSOR 1/2 HEATER CONTROL
17 - -
18 K142 18GY/BK (4.7L HIGH OUTPUT) KNOCK SENSOR NO. 2 SIGNAL
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
21 - -
22 - -
23 - -
25 K125 18WT/DB GENERATOR SOURCE
28 - -
29 D32 18LG (LHD) SCI RECEIVE
29 D32 18LG/DG (RHD) SCI RECEIVE
31 - -
RADIATOR FAN MOTOR - BLACK 2 WAY
1 C23 12DG RADIATOR FAN RELAY OUTPUT
2 Z4 12BK/PK GROUND
RADIATOR FAN RELAY - BLACK 4 WAY
1 Z1 20BK GROUND
2 C24 20DB/PK RADIATOR FAN RELAY CONTROL
3 C23 12DG RADIATOR FAN RELAY OUTPUT
4 A16 12GY FUSED B(+)
RADIO C1 - GRAY 22 WAY
2 X12 16WT/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
4 - -
5 - -
6 - -
7 X54 18VT RIGHT FRONT SPEAKER (+)
8 X56 18DB/PK RIGHT FRONT SPEAKER (-)
9 X55 18BR/RD LEFT FRONT SPEAKER (-)
10 X53 18DG/OR LEFT FRONT SPEAKER (+)
11 Z9 16BK GROUND
13 X64 18BR/WT ENABLE SIGNAL TO AMPLIFIER
14 D25 20YL/VT/DB PCI BUS
15 - -
16 - -
17 - -
18 X51 18WT/DG LEFT REAR SPEAKER (+)
19 X57 18DG/WT LEFT REAR SPEAKER (-)
20 X58 18DB/OR RIGHT REAR SPEAKER (-)
21 X52 18DB/WT RIGHT REAR SPEAKER (+)
22 Z9 16BK GROUND
RADIO C2 - GRAY 10 WAY
1 X40 20WT/RD AUDIO OUT RIGHT
2 Z4 20WT/BK GROUND
3 Z5 20BK/LB SHIELD
4 - -
5 X112 20RD IGNITION SWITCH OUTPUT (RUN-ACC)
6 X41 20WT/DG AUDIO OUT LEFT
7 Z17 20BK GROUND
8 - -
9 - -
10 X160 20YL FUSED B(+)
RAIN SENSOR (AUTOWIPE) - BLACK 6 WAY
1 - -
2 D25 20BK/PK PCI BUS
3 - -
5 Q30 20BK/LB ACCESSORY DELAY RELAY OUTPUT
6 - -
REAR POWER OUTLET - BLACK 3 WAY
1 A148 16LG/RD FUSED B(+)
2 - -
3 Z151 16BK GROUND
REAR WASHER PUMP - BLACK 2 WAY
1 Z141 18BK GROUND
2 V20 18BK/WT REAR WASHER PUMP MOTOR CONTROL
REAR WIPER MOTOR - BLACK 6 WAY
1 Z1 18BK GROUND
2 V13 18BR/LG REAR WIPER MOTOR CONTROL
4 V22 18BR/YL REAR WIPER MOTOR DELAY CONTROL
5 F70 18BK FUSED B(+)
6 - -
RECIRCULATION DOOR MOTOR/ACTUATOR (AZC) - BLACK 2 WAY
A C32 20GY/DB (LHD) RECIRCULATION DOOR DRIVER (A)
A C100 20YL/DB (RHD) RECIRCULATION DOOR DRIVER (B)
B C100 20YL/DB (LHD) RECIRCULATION DOOR DRIVER (B)
B C32 20GY/DB (RHD) RECIRCULATION DOOR DRIVER (A)
RED BRAKE WARNING INDICATOR SWITCH - GRAY 2 WAY
1 Z231 18BK GROUND
2 G9 18GY/BK RED BRAKE WARNING INDICATOR DRIVER
REMOTE KEYLESS MODULE (J APAN) - BLUE 6 WAY
1 K25 20RD/GY ANTENNA SIGNAL
2 K25 20RD/GY ANTENNA SIGNAL
4 Z1 18BK GROUND
5 D30 20VT/YL DIAGNOSTIC OUT
6 D30 20VT/YL DIAGNOSTIC OUT
RIGHT COURTESY LAMP - BLACK 2 WAY
RIGHT DOOR HANDLE COURTESY LAMP - WHITE 3 WAY
RIGHT FOG LAMP - BLACK 2 WAY
2 Z142 18BK GROUND
RIGHT FRONT DOOR SPEAKER - WHITE 3 WAY
1 X56 18LB/BK (BASE) RIGHT FRONT DOOR SPEAKER (-)
1 X80 18LG/DG (RHD PREMIUM) RIGHT FRONT DOOR SPEAKER (-)
1 X80 18LB/BK (LHD PREMIUM) RIGHT FRONT DOOR SPEAKER (-)
2 - -
3 X54 18LB/RD (BASE) RIGHT FRONT DOOR SPEAKER (+)
3 X82 18LG/RD (RHD PREMIUM) RIGHT FRONT DOOR SPEAKER (+)
3 X82 18LB/RD (LHD PREMIUM) RIGHT FRONT DOOR SPEAKER (+)
RIGHT FRONT IMPACT SENSOR - BLACK 4 WAY
1 - -
2 - -
3 R46 18BR/LB RIGHT FRONT IMPACT SENSOR GROUND
4 R48 18TN RIGHT FRONT IMPACT SENSOR SIGNAL
RIGHT FRONT PARK LAMP - WHITE 2 WAY
1 Z1 18BK GROUND
RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY
2 Z1 18BK GROUND
RIGHT FRONT SIDE MARKER LAMP (EXCEPT BUILT-UP-EXPORT) - WHITE 2 WAY
RIGHT FRONT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - WHITE 2 WAY
2 Z1 18BK GROUND
RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY
1 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
RIGHT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY
1 Z1 18BK GROUND
2 L114 18VT/DB HEADLAMP ADJ UST SIGNAL
RIGHT HIGH BEAM HEADLAMP - BLACK 2 WAY
A Z1 18BK GROUND
B L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
RIGHT INSTRUMENT PANEL SPEAKER - WHITE 2 WAY
1 X86 18OR/RD RIGHT INSTRUMENT PANEL SPEAKER (+)
2 X84 18OR/BK RIGHT INSTRUMENT PANEL SPEAKER (-)
RIGHT LIFTGATE AJ AR SWITCH - BLACK 2 WAY
1 Z1 20BK GROUND
RIGHT LOW BEAM HEADLAMP - GRAY 2 WAY
A Z1 18BK GROUND
B L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
RIGHT MULTI-FUNCTION SWITCH - WHITE 10 WAY
1 V23 20BR/PK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 V20 18BK/WT REAR WASHER PUMP MOTOR CONTROL
4 - -
5 V13 18BR/LG REAR WIPER MOTOR CONTROL
6 V22 18BR/YL REAR WIPER MOTOR DELAY CONTROL
7 V9 20WT/BK WINDSHIELD WIPER SWITCH RETURN
8 V52 20DG/RD WINDSHIELD WIPER SWITCH MUX
9 V48 20RD/GY WIPER HIGH CONTROL
10 - -
RIGHT REAR DOOR LOCK MOTOR/AJ AR SWITCH - BLACK 4 WAY
1 G76 18TN/YL RIGHT REAR DOOR AJ AR SWITCH SENSE
2 Z1 18BK GROUND
RIGHT REAR DOOR SPEAKER - WHITE 3 WAY
1 X52 18WT/VT (BASE) RIGHT REAR DOOR SPEAKER (+)
1 X90 18WT/VT (PREMIUM) RIGHT REAR DOOR SPEAKER (+)
2 - -
3 X58 18TN/DG (BASE) RIGHT REAR DOOR SPEAKER (-)
3 X92 18TN/DG (PREMIUM) RIGHT REAR DOOR SPEAKER (-)
RIGHT REAR LAMP ASSEMBLY - BLACK 6 WAY
5 Z151 18BK GROUND
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
1 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL
RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY
RIGHT SIDE REPEATER LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY
2 Z142 18BK GROUND
RIGHT VISOR/VANITY LAMP - BLACK 2 WAY
SEAT BELT SWITCH - WHITE 2 WAY
1 G10 20LG/RD SEAT BELT SWITCH SENSE
2 Z1 20BK GROUND
SEAT MODULE C1 (PREMIUM) - BLACK 20 WAY
1 P15 20YL/LB (PREMIUM II/III) SEAT HORIZONTAL FORWARD SWITCH SENSE
2 - -
3 P11 20YL/WT(PREMIUM II/III) SEAT REAR UP SWITCH SENSE
4 P43 20GY/LB (PREMIUM II/III) RECLINER UP SWITCH SENSE
5 P19 20YL/LG (PREMIUM II/III) SEAT FRONT UP SWITCH SENSE
6 P86 20DG/YL (PREMIUM I/III) PASSENGER SEAT TEMPERATURE SENSOR INPUT
7 P27 20LB/RD (PREMIUM II/III) REAR RISER POSITION SIGNAL
8 P25 20VT/RD (PREMIUM II/III) SEAT HORIZONTAL POSITION SIGNAL
9 P135 20LB/BK (PREMIUM I/III) DRIVER SEAT TEMPERATURE SENSOR INPUT
10 P28 20BR/RD (PREMIUM II/III) SEAT POSITION SENSOR GROUND
11 P41 20GY/WT (PREMIUM II/III) RECLINER DOWN SWITCH SENSE
12 P17 20RD/YL (PREMIUM II/III) SEAT HORIZONTAL REARWARD SWITCH SENSE
13 - -
14 P21 20RD/LG (PREMIUM II/III) SEAT FRONT DOWN SWITCH SENSE
15 P13 20RD/WT (PREMIUM II/III) SEAT REAR DOWN SWITCH SENSE
16 P47 20LB (PREMIUM II/III) RECLINER POSITION SIGNAL
17 P26 20BR (PREMIUM II/III) FRONT RISER POSITION SIGNAL
SEAT MODULE C2 (PREMIUM) - ORANGE 20 WAY
2 P131 16BK/OR (PREMIUM I/III) DRIVER SEAT HEATER B(+) DRIVER
3 Z1 16BK GROUND
4 P119 16YL/RD (PREMIUM II/III) SEAT FRONT UP DRIVER
5 P121 16RD/GY (PREMIUM II/III) SEAT FRONT DOWN DRIVER
6 P111 16YL/DB (PREMIUM II/III) SEAT REAR UP DRIVER
7 P113 16RD/BK (PREMIUM II/III) SEAT REAR DOWN DRIVER
8 - -
9 P115 16GY/LG (PREMIUM II/III) SEAT HORIZONTAL FORWARD DRIVER
11 P130 16DG/WT (PREMIUM I/III) PASSENGER SEAT HEATER B(+) DRIVER
12 Z1 16BK GROUND
13 - -
14 P9 20RD/LB (PREMIUM II/III) SEAT SWITCH B(+) SUPPLY
15 Z6 16BK/YL (PREMIUM I/III) GROUND
16 Z5 16BK/VT (PREMIUM I/III) GROUND
17 - -
18 P141 16GY/WT (PREMIUM II/III) SEAT RECLINER DOWN DRIVER
19 P143 16GY/LB (PREMIUM II/III) SEAT RECLINER UP DRIVER
20 P117 16RD/BR (PREMIUM II/III) SEAT HORIZONTAL REARWARD DRIVER
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY
4 - -
5 D25 20YL/VT/BK PCI BUS
6 - -
SHIFTER ASSEMBLY (C201 DIESEL) - WHITE 12 WAY
1 - -
2 - -
3 - -
5 D25 20RD PCI BUS
6 - -
9 T2 20TN/BK BACK-UP LAMP RELAY CONTROL
10 Z234 20WT GROUND
SHIFTER ASSEMBLY (GAS) - WHITE 6 WAY
2 Z234 18BK GROUND
3 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
4 Z300 18BK GROUND
SHIFTER ASSEMBLY C1 (DIESEL) - BLACK 12 WAY
4 T2 20TN/BK BACK-UP LAMP RELAY CONTROL
5 D25 20OR PCI BUS
6 W0 20DB/WT SHIFTER C1 SENSE
7 W1 20VT/WT SHIFTER C2 SENSE
8 W2 20VT SHIFTER C3 SENSE
9 W3 20BK SHIFTER C4 SENSE
10 W4 20PK/OR SHIFTER C5 SENSE
11 Z234 20WT GROUND
12 Z234 20WT GROUND
SHIFTER ASSEMBLY C2 (DIESEL) - 6 WAY
1 - -
2 - -
6 Y1 20DB/PK PARK LOCKOUT SOLENOID CONTROL
SIREN (BUILT-UP-EXPORT) - 3 WAY
1 Z141 18BK GROUND
2 X75 18GY/LB (DIESEL) SIREN SIGNAL CONTROL
2 X75 18GY/LG (GAS) SIREN SIGNAL CONTROL
SPEED CONTROL SWITCH NO. 1 - BLACK 4 WAY
1 - -
4 - -
SPEED CONTROL SWITCH NO. 2 - BLACK 4 WAY
1 - -
4 - -
SUNROOF CONTROL MODULE - 8 WAY
A Q46 20OR/WT SUNROOF MOTOR POSITION SENSOR SIGNAL
B Q41 20WT SUNROOF OPEN
C Q43 20VT SUNROOF VENT
D Z1 16BK GROUND
E - -
F Q30 16DB ACCESSORY DELAY RELAY OUTPUT
G Q5 16RD SUNROOF MOTOR B(+)
H Q6 16OR SUNROOF MOTOR B(-)
SUNROOF MOTOR C1 - WHITE 2 WAY
1 Q5 16RD SUNROOF MOTOR B(+)
2 Q6 16OR SUNROOF MOTOR B(-)
SUNROOF MOTOR C2 - BLACK 3 WAY
1 Z1 20BK GROUND
2 Q46 20OR/WT SUNROOF MOTOR POSITION SENSOR SIGNAL
3 - -
SUNROOF SWITCH - GRAY 5 WAY
1 Q43 20VT SUNROOF VENT
2 - -
3 Z150 20BK GROUND
4 - -
5 Q41 20WT SUNROOF OPEN
TEMPERATURE VALVE ACTUATOR (MTC) - BLACK 6 WAY
5 - -
6 - -
8 C67 20RD/LB BLEND AIR DOOR POSITION CONTROL
9 - -
THROTTLE POSITION SENSOR (4.0L) - BLACK 3 WAY
THROTTLE POSITION SENSOR (4.7L) - 3 WAY
TRAILER TOW BRAKE LAMP RELAY - BLACK 5 WAY
30 (3) F9 14RD/BK FUSED B(+)
85 (2) L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
86 (1) Z150 18BK GROUND
87 (5) L95 14DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A
(4)
L94 14OR/WT TRAILER TOW BRAKE LAMP RELAY OUTPUT
TRAILER TOW CIRCUIT BREAKER - BLACK 2 WAY
A F30 14RD/WT FUSED CIGAR LIGHTER RELAY OUTPUT
B F30 14RD/TN CIGAR LIGHTER RELAY OUTPUT
TRAILER TOW CONNECTOR - BLACK 10 WAY
1 - -
4 F30 14RD/WT FUSED CIGAR LIGHTER RELAY OUTPUT
6 - -
7 B40 14LB TRAILER TOW BRAKE B(+)
8 Z150 14BK GROUND
9 Z150 14BK GROUND
TRAILER TOW LEFT TURN RELAY - BLACK 5 WAY
30 (3) L63 16DG/RD LEFT TURN SIGNAL
85 (2) L63 14DG/RD LEFT TURN SIGNAL
86 (1) Z150 18BK GROUND
87 (5) L94 14OR/WT TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A (4) L95 14DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
TRAILER TOW RIGHT TURN RELAY - BLACK 5 WAY
30 (3) L62 14BR/RD RIGHT TURN SIGNAL
85 (2) L62 20BR/RD RIGHT TURN SIGNAL
86 (1) Z150 18BK GROUND
87 (5) L94 14OR/WT TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A (4) L95 14DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
TRANSFER CASE POSITION SENSOR - BLACK 2 WAY
1 K77 20BR/WT (DIESEL) TRANSFER CASE POSITION SENSOR SIGNAL
1 K77 18LG/BK (GAS) TRANSFER CASE POSITION SENSOR INPUT
2 K4 20BK/LB (DIESEL) SENSOR GROUND
2 K4 18BK/LB (GAS) SENSOR GROUND
TRANSMISSION CONTROL MODULE (4.7L) - BLACK 60 WAY
1 T1 18LG/BK TRS T1 SENSE
2 T2 18TN/BK TRS T2 SENSE
3 T3 18VT TRS T3 SENSE
4 - -
5 - -
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
15 K30 18PK/YL TRANSMISSION CONTROL RELAY CONTROL
16 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
18 T118 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
19 T119 18WT/DB 2C SOLENOID CONTROL
20 T120 18LG LR SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
30 T130 14VT/TN LINE PRESSURE SENSOR SIGNAL
31 - -
32 - -
33 - -
34 - -
35 - -
37 Z113 14BK/WT GROUND
38 T138 14GY/LB 5 VOLT SUPPLY
39 Z112 14BK/YL GROUND
40 T140 18VT/LG MS SOLENOID CONTROL
41 T41 18WT TRS T41 SENSE
42 T42 18VT/WT TRS T42 SENSE
44 - -
45 - -
46 D20 18LG SCI RECEIVE
47 T147 18LB 2C PRESSURE SWITCH SENSE
48 T48 18DB 4C PRESSURE SWITCH SENSE
49 T6 18VT/WT OVERDRIVE OFF SWITCH SENSE
50 T150 18BR/LB LR PRESSURE SWITCH SENSE
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z114 14BK/LG GROUND
54 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 T59 18PK UNDERDRIVE SOLENOID CONTROL
56 A30 14RD/WT FUSED B(+)
57 Z12 14BK/TN GROUND
58 - -
59 T159 18DG/WT 4C SOLENOID CONTROL
60 T60 18BR OVERDRIVE SOLENOID CONTROL
TRANSMISSION CONTROL MODULE C1 (DIESEL) - BLACK 18 WAY
2 - -
3 W4 20PK/OR SHIFTER C5 SENSE
4 Y1 20DB/PK PARK LOCKOUT SOLENOID CONTROL
5 - -
6 - -
8 - -
9 - -
10 - -
23 - -
24 - -
25 W0 20DB/WT SHIFTER C1 SENSE
26 W1 20VT/WT SHIFTER C2 SENSE
27 W2 20VT SHIFTER C3 SENSE
28 W3 20BK SHIFTER C4 SENSE
30 Z234 20WT GROUND
TRANSMISSION CONTROL MODULE C2 (DIESEL) - BLACK 14 WAY
12 T52 18RD/BK N2 INPUT SPEED SENSOR
13 T39 18GY/LB SENSOR SUPPLY VOLTAGE
14 T60 18BR 1-2/4-5 SOLENOID CONTROL
15 T159 18DG/WT 3-4 SOLENOID CONTROL
16 T119 18WT/DB 2-3 SOLENOID CONTROL
17 T120 18LG TCC SOLENOID CONTROL
33 T13 18DB/BK SENSOR GROUND
34 T54 18VT TEMP SENSOR - P/N SWITCH
35 T14 18LG/WT N3 INPUT SPEED SENSOR
36 T591 18YL/DB MODULATION PRESSURE SOLENOID CONTROL
37 T118 18YL/DB SHIFT PRESSURE SOLENOID CONTROL
38 T16 18RD SOLENOID SUPPLY VOLTAGE
H1 D52 18LG/WT CAN C BUS(+)
L2 D51 18DG/WT CAN C BUS(-)
TRANSMISSION SOLENOID (4.0L) - BLACK 8 WAY
1 T15 18LG FUSED TRANSMISSION CONTROL RELAY OUTPUT
4 T25 18LG/RD GOVERNOR PRESSURE SENSOR SIGNAL
5 K88 18PK GOVERNOR PRESSURE SOLENOID CONTROL
6 T60 18BR 3-4 SHIFT SOLENOID CONTROL
7 T20 18LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL
TRANSMISSION SOLENOID ASSEMBLY (DIESEL) - BLACK 13 WAY
1 T14 18LG/WT N3 INPUT SPED SENSOR
2 T591 18YL/DB MODULATION PRESSURE SOLENOID CONTROL
3 T52 18RD/BK N2 INPUT SPEED SENSOR
4 T54 18VT TEMP SENSOR - P/N SWITCH
5 - -
6 T16 18RD SOLENOID SUPPLY VOLTAGE
7 T39 18GY/LB SENSOR SUPPLY VOLTAGE
8 T119 18WT/DB 2-3 SOLENOID CONTROL
9 T159 18DG/WT 3-4 SOLENOID CONTROL
10 T118 18YL/DB SHIFT PRESSURE SOLENOID CONTROL
11 T120 18LG TCC SOLENOID CONTROL
12 T13 18DB/BK SENSOR GROUND
13 T60 18BR 1-2/4-5 SOLENOID CONTROL
TRANSMISSION SOLENOID/TRS ASSEMBLY (4.7L) - GRAY 23 WAY
2 T120 18LG LR SOLENOID CONTROL
4 T141 18WT TRS T41 SENSE
5 T42 18VT/WT TRS T42 SENSE
7 T60 18BR OVERDRIVE SOLENOID CONTROL
8 T3 18VT TRS T3 SENSE
9 T1 18LG/BK TRS T1 SENSE
11 T48 18DB 4C PRESSURE SWITCH SENSE
12 T118 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
13 T2 18TN/BK TRS T2 SENSE
14 T150 18BR/LB LR PRESSURE SWITCH SENSE
15 T147 18LB 2C PRESSURE SWITCH SENSE
16 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
17 T59 18PK UNDERDRIVE SOLENOID CONTROL
18 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
19 T159 18DG/WT 4C SOLENOID CONTROL
20 T119 18WT/DB 2C SOLENOID CONTROL
21 T140 18VT/LG MS SOLENOID CONTROL
UNDERHOOD LAMP - BLACK 2 WAY
1 Z141 20BK GROUND
VEHICLE INFORMATION CENTER - BLACK 6 WAY
1 - -
6 - -
VISCOUS/CABIN HEATER (DIESEL) - BLACK 2 WAY
1 A82 16PK/LG VISCOUS/CABIN HEATER RELAY OUTPUT
2 Z18 16BK GROUND
WASHER FLUID LEVEL SWITCH - GRAY 2 WAY
1 V11 20BK/TN WASHER FLUID SWITCH SENSE
2 Z141 20BK GROUND
WASTEGATE SOLENOID (DIESEL) - 2 WAY
1 F15 18DB/WT FUSED AUTO SHUT DOWN RELAY OUTPUT
2 Y42 18OR/DB WASTEGATE SOLENOID CONTROL
WATER IN FUEL SENSOR (DIESEL) - BLACK 3 WAY
2 G123 20DG/WT WATER IN FUEL SENSOR SIGNAL
8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng con-
nector, ground, and spl i ce l ocati ons i n the vehi cl e.
Connector, ground, and spl i ce i ndexes are provi ded.
Use the wi ri ng di agrams i n each secti on for connec-
tor, ground, and spl i ce i denti fi cati on. Refer to the
appropri ate i ndex for the proper fi gure number. For
i tems that are not shown i n thi s secti on N/S i s pl aced
i n the Fi g. col umn.
CONNECTORS
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
A/C Compressor Clutch BK At A/C Compressor 9, 13
A/C Pressure Transducer BK Right Front of Engine Compartment 3, 4, 5
Accelerator Pedal Position
Sensor (Diesel)
BK Rear of Engine Compartment Near
Fuel/Water Seperator
7
Adjustable Pedals Module
(Except Built-up Export)
GN Above Drivers Control Pedals N/S
Adjustable Pedals Motor/
Sensor Assembly (Except
Built-up Export)
Above Drivers Control Pedals N/S
Adjustable Pedals Switch WT Drivers Lower Kick Panel 21
Airbag Control Module (ORC)
C1
YL Below Center Floor Console, Near
Park Brake
19, 20, 21, 22
Airbag Control Module (ORC)
C2
YL Below Center Floor Console, Near
Park Brake
19, 20, 21, 22
Ambient Temperature Sensor BK On Radiator Center Support 5
Antenna Module (Built-up-
export)
WT Above Right Quarter Window N/S
Ash Receiver Lamp BK Below Cigarette Lighter 19, 20
Automatic Day/Night Mirror BK In Front of Rear View Mirror N/S
Automatic Headlamp Light
Sensor/VTSS LED
BK Near Left Instrument Panel Speaker 19, 20
Automatic Zone Control
Module - C1 (AZC)
WT Left Side of HVAC Housing N/S
Automatic Zone Control
Module - C2 (AZC)
WT Left Side of HVAC Housing N/S
Battery Temperature Sensor BK Below Battery Tray 4, 5
Blower Motor BK Behind Right Hand Side of
Instrument Panel
N/S
WJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Blower Motor Controller (AZC) BK Behind Right Hand Side of
Instrument Panel
N/S
Blower Motor Resistor Block
(MTC)
BK Behind Right Hand Side of
Instrument Panel
N/S
Body Control Module - C1 GY Lower Left Side of Instrument Panel 21, 22
Body Control Module-C2 -LHD WT Lower Left Side of Instrument Panel 21
Body Control Module-C2 -
RHD
GY Lower Left Side of Instrument Panel 22
Boost Pressure Sensor
(Diesel)
BK Top Front of Engine N/S
Brake Lamp Switch GY Brake Pedal Arm 31
C100 BK Right Front Engine Compartment 2, 5
C101 (4.0L RHD) LTGY Rear of Engine Compartment 15
C101 (4.7L RHD) BK Rear of Engine Compartment N/S
C102 (Diesel) BK Left Rear Engine Compartment 4, 7
C102 (Gas) BK Right Rear Engine Compartment 5, 10, 11, 14, 15, 18
C103 (Diesel) LTGY Rear of Engine 4, 7
C103 (Gas) GY Right Rear Engine Compartment 5, 10 11, 14, 15
C104 LTGY Right Rear Engine Compartment 14 18
C105 (Diesel) GY Right Rear Engine Compartment 4, 7, 8
C106 (Diesel) GY Lower Right Instrument Panel N/S
C106 (Gas RHD) GY Lower Right Instrument Panel N/S
C107 (Diesel) GY Left Rear Engine Compartment 4
C107 (LHD) BK Passenger Side Near Kick Panel 3, 30, 35
C107 (RHD) GY Passenger Side Near Kick Panel 3, 31
C108 BK Left Cowl 3, 4
C109 BK Near Transfer Case switch 12
C110 (Diesel) GY Top of Engine Near Glow Plugs 4, 7
C111 BK Left Front Frame Near Windshield
Washer Pump
1, 3, 4
C112 BK Right Front Frame Near Horns 1, 5
C113 (Diesel) LTGY Rear of Engine 7, 8
C200 - LHD GY Passenger Side Near Kick Panel 19, 21, 35
C200 - RHD BK Passenger Side Near Kick Panel 20, 22
C201) WT Below Center Floor Console, Near
Park Brake
19, 20, 21, 22
C202 WT HVAC Unit, Right Side of Instrument
Panel
19, 20, 21, 22
C203 (AZC) WT HVAC Unit, Right Side of Instrument
Panel
19, 20, 21, 22
C300 (LHD) GY Near Junction Block 30, 33
C301 (RHD) BK Near Junction Block 31
C302 BK At Driver Door 24, 25, 30, 31
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION WJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
C303 WT Right Rear Door 29, 34, 36
C304 BK Under Driver Seat 33, 36
C306 BK Under Passenger Seat 34, 35
C307 WT Left Rear Door 28, 33 35
C308 WT Top of Liftgate 37, 38
C309 WT Left Rear Quarter Pillar 37
C310 (Built-Up-Export) LT GY Above Left Quarter Wheel Housing 37, 39
C310 (Except Built-Up-Export) LT GN Above Left Quarter Wheel Housing 39
C311 WT Top of Liftgate 38
C312 Center of Liftgate 38
C313 WT In Driver Door 24, 25
C314 LT GY At Passenger Door 26, 27, 31
C315 To Rear of Right Quarter Window 32
C318 At C Post 33, 36
(Diesel)
BK Top of Engine N/S
(Gas)
GY Right Side of Engine 10, 11, 14, 15
Capacitor (4.0L) BK Right Rear of Engine 10
Capacitor NO. 1 (4.7L) BK Right Side of Engine 14, 15
Capacitor NO. 2 (4.7L) BK Left Side of Engine 13
Cargo Lamp WT In Headliner Near Liftgate N/S
Center High Mounted Stop
Lamp
BK Top of Liftgate N/S
Cigar Lighter RD Center of Instrument Panel 19, 20
Clockspring - C1 BK At Steering Column 23
Clockspring - C2 At Steering Column 23
Clockspring - C3 GY At Steering Column 23
Clockspring - C4 BK At Steering Column N/S
Coil On Plug NO. 1 (4.7L) BK Left Side of Engine Near Fuel
Injector No.1
13
Coil On Plug NO. 2 (4.7L) BK Right Side of Engine Near Fuel
Injector No.2
14, 15
Injector No.3
13
Injector No.4
14, 15
Injector No.5
13
Injector No.6
14, 15
Injector No.7
13
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Injector No.8
14, 15
Coil Rail (4.0L) BK Right Rear of Engine 10, 11
Compact Disc Changer BK Near Radio N/S
Compact Disc Changer BK Right Rear Quarter Panel 37
Controller Antilock Brake BK Left Front Engine Compartment 3, 4
Coolant Level Sensor LT GY Right Rear of Engine 5
Crankcase Heater (Diesel) BK Near T/O for G105 8
(Diesel)
BK Rear of Engine Near Transmission
Bell Housing
N/S
(Gas)
BK Rear of Engine Near Transmission
Bell Housing
10, 11, 14, 15, 17
Data Link Connector BK Under Lower Drivers Side of
Instrument Panel
20, 21, 22
Diagnostic Junction Port BK At Steering Column 23
Driver Airbag Squib 1 BK In Steering Wheel N/S
Driver Airbag Squib 2 BK In Steering Wheel N/S
Driver Blend Door Motor/
Actuator (AZC)
BK On HVAC Housing N/S
Driver Cylinder Lock Switch GY In Driver Door 24, 25
Driver Door Lock Motor/Ajar
Switch
BK In Driver Door 24, 25
Driver Door Module - C1 WT In Driver Door 24, 25
Driver Door Module - C2 BK In Driver Door N/S
Driver Door Module - C3 BK In Driver Door N/S
Driver Front Door Courtesy
Lamp
BK In Driver Door N/S
Driver Front Power Window
Motor
BK In Driver Door 24, 25
Driver Heated Seat Back
(Premium I/III)
GN At Driver Seat N/S
Driver Heated Seat Cushion
(Premium I/III)
BK At Driver Seat N/S
Driver Heated Seat Switch WT Center of Instrument Panel 19 20, 21
Driver Lumbar Motor
(Midline/Premium)
Driver Lumbar Switch
(Midline/Premium)
WT At Driver Seat N/S
Driver Power Mirror BK At Driver Door N/S
Driver Power Seat Front Riser
Motor
RD At Driver Seat N/S
Driver Power Seat Front Riser
Motor Sensor (Premium II/III)
Driver Power Seat Horizontal
Motor
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Driver Power Seat Horizontal
Driver Power Seat Rear Riser
Motor
RD At Driver Seat N/S
Driver Power Seat Rear Riser
Driver Power Seat Recliner
Motor
Driver Power Seat Recliner
Driver Power Seat Switch
(Midline/Premium)
GN At Driver Seat N/S
Driver Rear Power Window
Motor
BK In Left Rear Door 28
Driver Rear Power Window
Switch
BL In Left Rear Door 28
Driver Seat Belt Switch At Switch N/S
EGR Solenoid (Diesel) BK Left Front Fender 7, 8
Electric Brake BL Near Junction Block N/S
Electronic Speed Control Servo BK Right Front of Engine Compartment 5
Engine Control Module C1
(Diesel)
BK Left Front of Engine 7, 8
Engine Control Module C2
(Diesel)
BK Left Front of Engine 7, 8
Engine Coolant Temperature
Sensor (Diesel)
Engine Coolant Temperature
Sensor (GAS)
BK Front of Engine 9, 13
Engine Oil Pressure Sensor BK Side of Engine 10, 11, 13
EVAP/Purge Solenoid BK Left Front Fender Near Controller
Antilock Brake
3
Front Power Outlet RD Center of Instrument Panel 19, 20
Front Washer Pump WT Left Front of Engine Compartment 3, 4
Front Wiper Motor BK Left Side of Cowl 3, 4
Fuel Injector No.1 BK At Injector 7, 9, 13
Fuel Injector No.2 BK At Injector 7, 9, 14, 15
Fuel Injector No.4 BK At Injector 7, 9, 14, 15
Fuel Injector No.5 BK At Injector 9, 13
Fuel Injector No.7 (4.7L) BK At Injector 13
Fuel Injector No.8 (4.7L) BK At Injector 14, 15
Fuel Pressure Sensor (Diesel) BK Right Front of Engine N/S
Fuel Pressure Solenoid
(Diesel)
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Fuel Pump Module (Gas) BK Near Fuel Tank 33, 35
Fuel Tank Module Diesel) BK Near Fuel Tank 33, 35
Generator (Diesel) LTGY At Generator 8
Generator (Gas) BK At Generator N/S
Glove Box Lamp BK Inside Glove Box 19, 20, 22
Headlamp Leveling Switch
(Built-Up-Export)
WT Driver Side of Instrument Panel 20
Hood Ajar Switch BK Left Side of Engine Compartment 3, 4
Horn No.1 BK Right Front Fascia 5
Horn No.2 BK Right Front Fascia 5
Hydraulic Cooling Module BK Right Front of Engine Compartment 5
Idle Air Control Motor BK Left Side of Engine Near Throttle
Body
13
Ignition Switch - C1 WT On Steering Column 23
Ignition Switch - C2 BK On Steering Column 23
Input Speed Sensor (4.7L) BK Left Side of Transmission 16
Instrument Cluster WT At Instrument Cluster 19, 20
Intake Air Temperature Sensor
(Gas)
GY Left Side of Engine 9, 13
Intake Air Temperature Sensor
(Diesel)
BK Near T/O for Crankcase Heater 8
Intake Port Swirl Actuator
(Diesel)
BK Right Rear of Engine Compartment N/S
Intrusion Transceiver Module
(Built-up-Export)
BK In The Overhead N/S
Junction Block - C1 BK At Junction Block 30, 31, 33
Junction Block - C2 BK At Junction Block 30, 31
Junction Block - C3 BK At Junction Block 21, 22, 30
Junction Block - C4 WT At Junction Block 30, 31
Junction Block - C5 WT At Junction Block 30, 31
Knock Sensor (4.7L High
Output)
BK Right Rear Side of Engine, Near
Coil on Plug No.8
N/S
Leak Detection Pump (Except
Built-Up-Export)
Left Front Wheel Opening 3
Left Courtesy Lamp BK Left Side of Instrument Panel 21 22, 23
Left Curtain Airbag BK Near Left C Pillar 37
Left Door Handle Courtesy
Lamp
BK At Lamp N/S
Left Fog Lamp BK At Lamp 3, 4
Left Front Door Speaker WT In Left Front Door 24, 27
Left Front Impact Sensor BK Left Front Frame Near Windshield
Washer Pump
3, 4
Left Front Park Lamp WT At Lamp N/S
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Left Front Park/Turn Signal
Lamp (Except Built-Up-Export)
BK At Lamp N/S
Left Front Side Marker Lamp
(Except Built-Up-Export)
WT At Lamp N/S
Left Front Turn Signal Lamp
(Built-Up-Export)
WT At Lamp N/S
Left Front Wheel Speed
Sensor
GY At Left Front Wheel Opening 4
Left Headlamp Leveling Motor
(Built-Up-Export)
BK At Motor N/S
Left High Beam Headlamp BK At Lamp N/S
Left Instrument Panel Speaker WT At Speaker 19, 20
Left Liftgate Ajar Switch BK In Liftgate 38
Left Low Beam Headlamp GY At Lamp N/S
Left Multi-Function Switch WT On Steering Column 23
Left Rear Door Lock Motor/Ajar
Switch
BK In Left Rear Door 28
Left Rear Door Speaker WT In Left Rear Door 28
Left Rear Lamp Assembly BK At Lamp Assembly 37
Left Rear Wheel Speed Sensor GY Near Left Rear Wheel 33, 35
Left Remote Radio Switch BK At Switch in Steering Wheel N/S
Left Side Impact Sensor BK Left Body N/S
Left Side Repeater Lamp
(Built-Up-Export)
BK On Left Front Fender 3, 4
Left Visor/Vanity Lamp BK At Lamp N/S
License Lamp No.1 BK At Lamp N/S
License Lamp No.2 BK At Lamp N/S
Liftgate Flip-Up Ajar Switch GY In Liftgate 38
Liftgate Flip-Up Push Button
Switch
BK In Liftgate N/S
Liftgate Flip-Up Release
Solenoid
BK In Liftgate 38
Liftgate Lock Motor BK In Liftgate 38
Line Pressure Sensor (4.7L) BK Rear of Transmission N/S
Manifold Absolute Pressure
Sensor (4.0L)
BK At Throttle Body 9
Manifold Absolute Pressure
Sensor (4.7L)
BK Right Side of Engine 13
Manual Temperature Control -
C1 (MTC)
WT Center of Instrument Panel N/S
Manual Temperature Control -
C2 (MTC)
WT Center of Instrument Panel N/S
Mass Air Flow sensor (Diesel) BK Near T/O for G105 8
Mode Door Motor/Actuator
(AZC)
BK Right Center of Instrument Panel N/S
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Output Speed Sensor (4.0L) GY Left Side of Transmission 12
Output Speed Sensor (4.7L) BK Left Side of Transmission 16
Overhead Map/Courtesy Lamp WT At Overhead Console N/S
Oxygen Sensor 1/1 Upstream
(4.0L)
GY Left Side of Engine at Exhaust 9, 12
Oxygen Sensor 1/1 Upstream
(4.7L)
GY Left Side of Engine at Exhaust 17
Oxygen Sensor 1/2
Downstream (4.0L)
BK Rear of Transmission 9, 12
Oxygen Sensor 1/2
Downstream (4.7L)
BK Rear of Transmission 17
Oxygen Sensor 2/1 Upstream Rear of Transmission N/S
Oxygen Sensor 2/2
Downstream
Rear of Transmission N/S
Park Brake Switch Center Console Area, Near Airbag
Control Module
20, 21, 22
Park/Neutral Position Switch
(4.0L)
BK Left Side of Transmission 12
Park/Neutral Position Switch
(Diesel)
BK Left Side of Transmission N/S
Passenger Airbag YL Passenger Side of Instrument Panel 19, 20
Passenger Blend Door
Motor/Actuator (AZC)
BK Passenger Side of Instrument Panel N/S
Passenger Door Lock
Motor/Ajar Switch
BK In Passenger Door 26, 27
Passenger Door Module - C1 WT In Passenger Door 26, 27
Passenger Door Module - C2 BK In Passenger Door N/S
Passenger Front Door
Courtesy Lamp
BK In Passenger Door N/S
Passenger Front Power
Window Motor
BK In Passenger Door 26, 27
Passenger Heated Seat Back
(Premium I/III)
GN At Passenger Seat N/S
Passenger Heated Seat
Cushion (Premium I/III)
BK At Passenger Seat N/S
Passenger Heated Seat Switch BK Center of Instrument Panel 19, 20, 21
Passenger Lumbar Motor
(Midline/Premium)
Passenger Lumbar Switch
(Midline/Premium)
WT At Passenger Seat N/S
Passenger Power Mirror BK In Passenger Door N/S
Passenger Power Seat Front
Riser Motor
RD At Passenger Seat N/S
Passenger Power Seat
Horizontal Motor
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Passenger Power Seat Rear
Riser Motor
Passenger Power Seat
Recliner Motor (Midline/
Premium)
Passenger Power Seat Switch
(Midline/Premium)
GN At Passenger Seat N/S
Passenger Rear Power
Window Motor
BK In Right Rear Door 29
Passenger Rear Power
Window Switch
BL In Right Rear Door 29
Passenger Seat Belt Switch t Switch N/S
Power Amplifier - C1 WT Under Rear Seat 34, 36
Power Amplifier - C2 WT Under Rear Seat 34, 36
Power Connector WT Center of Instrument Panel 21, 22
Powertrain Control Module -
C1 (Gas)
BK Rear of Engine Compartment 5, 10, 11, 14, 15, 18
C2 (Gas)
WT Rear of Engine Compartment 5, 10, 11, 14, 15, 18
C3 (Gas)
WT Rear of Engine Compartment N/S
Radiator Fan Motor BK At Radiator 5
Radiator Fan Relay BK Right Side of Engine Compartment 5
Radio - C1 GY Center of Instrument Panel 19, 20
Radio - C2 BK Center of Instrument Panel 19, 20
Rain Sensor BK Front Center Overhead N/S
Rear Power Outlet RD Right Rear Quarter Panel 37
Rear Washer Pump BK Left Front of Engine Compartment 3, 4
Rear Window Defogger BK Right Upper Coner of Liftgate 38
Rear Wiper Motor BK In Liftgate 38
Recirculation Door Motor/
Actuator (AZC)
BK Center of Instrument Panel N/S
Red Brake Warning Indicator
Switch
GY At Master Cylinder 4
Remote Keyless Module
(Japan)
BL In Driver Door 25
Right Courtesy Lamp BK At Lamp 20 21, 22
Right Curtain Airbag BK Near Right C Pillar 37
Right Door Handle Courtesy
Lamp
BK At Lamp N/S
Right Fog Lamp BK At Right Front Fascia 5
Right Front Door Speaker WT In Right Front Door 25, 26
Right Front Impact Sensor BK Near Right Verticle Radiator Support N/S
Right Front Park Lamp WT At Lamp N/S
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Right Front Park/Turn Signal
Lamp (Except Built-Up-Export)
BK At Lamp N/S
Right Front Side Marker Lamp
(Except Built-Up-Export)
WT At Lamp N/S
Right Front Turn Signal Lamp
(Built-Up-Export)
WT At Lamp N/S
Right Front Wheel Speed
Sensor
GY In Right Front Wheel Opening N/S
Right Headlamp Leveling
Motor (Built-Up-Export)
BK At Motor N/S
Right High Beam Headlamp BK At Lamp N/S
Right Instrument Panel
Speaker
WT At Speaker 19, 20
Right Liftgate Ajar Switch BK In Liftgate 38
Right Low Beam Headlamp GY At Lamp N/S
Right Multi-Function Switch WT On Steering Column 23
Right Rear Door Lock
Motor/Ajar Switch
BK In Right Rear Door 29
Right Rear Door Speaker WT In Right Rear Door 29
Right Rear Lamp Assembly BK At Lamp Assembly 37
Right Rear Wheel Speed
Sensor
BK Near Right Rear Wheel 33, 35
Right Remote Radio Switch BK At Switch in Steering Wheel N/S
Right Side Repeater Lamp
(Built-Up-Export)
BK On Right Front Fender 5
Right Visor/Vanity Lamp BK At Lamp N/S
Seat Belt Switch WT At Driver Seat N/S
Seat Module - C1 (Premium) BK Under Driver Seat N/S
Seat Module - C2 (Premium) OR Under Driver Seat N/S
Sentry Key Immobilizer Module BK On Steering Column 23
Shifter Assembly (Gas) WT Between Front Seats 23
Shifter Assembly C1 (Diesel) Between Front Seats N/S
Shifter Assembly C2 (Diesel) Between Front Seats N/S
Siren (Built-up-export) Left Front Fender 3, 4
Speed Control Switch NO. 1 BK On Steering Wheel N/S
Speed Control Switch NO. 2 BK On Steering Wheel N/S
Sunroof Control Module At Sunroof 32
Sunroof Motor C1 WT At Sunroof N/S
Sunroof Motor C2 BK In Overhead N/S
Sunroof Switch GY At Switch N/S
Temperature Valve Actuator
(MTC)
BK On HVAC Housing N/S
Throttle Position Sensor (4.0L) BK Left Side of Engine 9
Throttle Position Sensor (4.7L) WT Left Side of Engine 13
CONNECTOR NAME/
NUMBER
COLOR LOCATION FIG.
Trailer Tow Brake Lamp Relay BK Left Quarter Panel N/S
Trailer Tow Circuit Breaker BK Left Quarter Panel N/S
Trailer Tow Connector BK In Rear Bumper 39
Trailer Tow Left Turn Relay BK Left Quarter Panel N/S
Trailer Tow Right Turn Relay BK Left Quarter Panel N/S
Transfer Case Position Sensor BK On Transfer Case 7
Transmission Control Module
(4.7L)
BK Rear of Engine Compartment 14, 15, 18
C1 (Diesel)
BK Right Rear Side of Engine
Compartment
N/S
C2 (Diesel)
BK Right Rear Side of Engine
Compartment
8
Transmission Solenoid (4.0L
Gas)
BK Left Side of Transmission 12
Transmission Solenoid
Assembly (Diesel)
BK On Transmission 8
Transmission Solenoid/TRS
Assembly (4.7L)
GY Left Side of Transmission 16
Underhood Lamp BK At Lamp 6
Vehicle Information Center BK In Overhead Console N/S
Viscous/Cabin Heater (Diesel) BK Left Rear of Engine Compartment N/S
Washer Fluid Level Switch GY Left Front of Engine Compartment 3, 4
Wastegate Solenoid (Diesel) Near Power Distribution Center N/S
Water In Fuel Sensor (Diesel) BK Left Rear of Engine Compartment N/S
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 (4.0L and Diesel) Near Starter N/S
G100 (4.7L) Near Intake Plenum N/S
G101 Near Battery 2
G102 Right Side of Engine 14, 15
G103 Right Side of Engine 7, 8, 10, 11, 14, 15
G104 (4.0L) Right Rear of Engine 10, 11
G104 (4.7L) Left Side of Engine 13
G105 Right Side of Engine 8
G106 Left Side of Engine Compartment 3, 4
G107 Left Side of Engine Compartment 3, 4
G108 Near Power Distribution Center 5
G200 Near Airbag Control Module 19, 20, 21, 22
G201 Near Airbag Control Module 19, 20, 21, 22
G300 Near Right Front Seat 34, 36
G301 Near Left Front Seat 33, 35
SPLICES
SPLICE
NUMBER
LOCATION FIG.
S100 Near T/O for Power Distribution Center Eyelet 2
S102 (4.0L) Near T/O for G103 10, 11
102 (4.7L) Near T/O for Fuel Injector No. 1 13
S102 (Diesel) Near T/O for C110 7, 8
S103 (4.7L) Near T/O for Engine Oil Pressure Sensor 13
S104 (4.0L) Near T/O for A/C Compressor Clutch N/S
S104 (4.7L) Near T/O for Oxygen Sensor 2/2 Downstream N/S
S105 (4.0L) Near T/O for Capacitor 10 11
S105 (4.7L) Near T/O for Fuel Injector NO. 7 13
S106 (4.0L) In T/O for Oxygen Sensors 11, 12
S106 (4.7L) Near T/O for C103 14
S106 (4.7L) RHD Near T/O for Fuel Injector No.4 15
S107 (4.0L) Near T/O for Fuel Injector No.5 9
S109 (4.7L) Near T/O for Coil On Plug No. 6 14, 15
S110 (4.0L
Except
Built-Up-Export)
Near T/O for Oxygen Sensor N/S
S111 (4.7L) In T/O for Oxygen Sensor N/S
S111 (4.0L
Except
Built-Up-Export)
Near T/O for Oxygen Sensor N/S
S112 (4.0L) Near T/O for C102, C103 and C104 10, 11
S112 (4.7L) Near T/O for Coil On Plug No.8 15
S112 (Diesel) Near T/O for Accelerator Pedal Position Sensor N/S
S113 (4.7L) Near T/O for Transmission Control Module 15, 18
S114 (4.0L) Near T/O for Transmission Control Module 18
S115 (4.0L) Near T/O for Transmission Control Module 18
S116 (4.0L) Near Powertrain Control Module C1 and C2 18
S116 (4.7L) LHD Near T/O for C102, C103 and C104 14
S116 (4.7L) RHD In T/O for Powertrain Control Module 15
S117 (4.7L) LHD Neat T/O for C102, C103 and C104 14
S118 (4.7L) Near T/O for Coil On PlugNo.4 14, 15
S118 (Diesel) Near T/O for Fuel Sender Unit N/S
S119 (4.7L) LHD In T/O for Crankshaft Position Sensor 18
S119 (4.7L) RHD In T/O for Powertrain Control Module 15
S120 (4.7L) Near T/O for Powertrain Control Module 15, 18
S121 (4.7L) Near T/O for Idle Air Control Motor 13
SPLICE
NUMBER
LOCATION FIG.
S122 (4.0L) Near T/O for G103 10, 11
S122 (4.7L) LHD Near T/O for Input Speed Sensor 15
S122 (4.7L) RHD Near T/O for Powertrain Control Module 16
S122 (Diesel) Near T/O for Generator N/S
S123 (4.0L) Near T/O for Capacitor 10, 11
S124 (4.7L) In Trough Near T/O for Capacitor No.2 13
S125 (Diesel) In T/O for C103 and C105 Left Rear of Engine Compartment N/S
S125 (Gas) Near T/O for Powertrain Control Module - C3 N/S
S126 (4.0L) LHD Near T/O for Battery Temperature Sensor N/S
S126 (4.0L) RHD In Trough Near T/O for Powertrain Control Module - C3 N/S
S127 (LHD) Gas In Trough Near T/O for Powertrain Control Module - C3 N/S
S127 (RHD) Gas In T/O for Power Distribution Center 5
S127 (Diesel) Near T/O for Power Distribution Center 4
S128 (Diesel) In T/O for C102 Left Rear of Engine Compartment N/S
S128 (LHD) Gas In Trough Near T/O for Powertrain Control Module - C3 N/S
S128 (RHD) Gas In T/O for C102 5
S130 (LHD) Gas In T/O for C102 N/S
S130 (RHD) Gas In T/O for Controller Antilock Brake 3
S130 (Diesel) In T/O for Controller Anti-Lock Brake 4
S131 In Trough Near T/O for Power Distribution Center 5
S132 (Diesel) Near T/O for EGR Solenoid N/S
S132 (Gas) Near T/O for Battery Temperature Sensor 5
S133 (Diesel) In Trough Near T/O for EGR Solenoid N/S
S133 (Gas) Near T/O for Battery Temperature Sensor 5
S134 (Diesel) In Trough Near T/O for G106/G107 4
S134 (Gas) In Trough Near T/O for Controller Anti-Lock Brake 3
S135 (Diesel) Near T/O for Engine Control Module C1 7, 8
S137 (Diesel) In Trough Near T/O for Coolant Level Sensor N/S
S140 (Gas) Near T/O for Controller Antilock Brake N/S
S141 (Gas) Near T/O for Controller Antilock Brake 3
S142 (Diesel) In Trough Near T/O for Coolant Level Sensor N/S
S142 Gas In T/O for C102 5
S143 (Diesel) In Trough Near T/O for Hood Ajar Switch 4
S143 (Gas,
Built-Up-Export)
LHD
In Trough Near T/O for Controller Antilock Brake 3
S143 Gas RHD Near T/O for Evap/Purge Solenoid N/S
SPLICE
NUMBER
LOCATION FIG.
S147 (Diesel) In T/O for Controller Anti-Lock Brake 4
S151 In Headlamp Assembly N/S
S158 4.7L RHD Near T/O for Fuel Injector No. 1 13
S159 In T/O for C101 N/S
S160 (4.7L High
Output)
In T/O for C102 N/S
S162 (Diesel) In T/O for Wastegate Solenoid 4, 8
S163 Near T/O for Leak Detection Pump 3
S165 (Diesel) Near T/O for Left Front Wheel Speed Sensor 4
S168 Near T/O for Intake Air Temperature Sensor 7, 8
S169 Near T/O for Engine Control Module C1 7, 8
S170 Near T/O for Engine Control Module C2 7, 8
S171 Near T/O for C113 7
S174 Near Washer Fluid Level Switch Connector 3
S176 Near T/O for Intake Air Temperature Sensor 7
S200 In Trough Near T/O for Passenger Heated Seat Switch 21
S200 (RHD) Upper Center Instrument Panel 22
S201 In Trough Near T/O for Front Power Outlet 21
S201 (RHD) Near T/O for Power Connector 22
S202 In Trough Near T/O for Passenger Heated Seat Switch 21
S203 In Trough Near T/O for Cigar Lighter 21
S203 (RHD) Lower Center Instrument Panel 22
S204 In Trough Near T/O for Power Connector 21
S204 (RHD) Right Center Instrument Panel 22
S205 Near T/O for Adjustable Pedal Switch 21
S206 Near T/O for Adjustable Pedals Switch N/S
S207 In Trough Near T/O for Radio Connectors 21
S208 In Trough Near T/O for Radio Connectors 21
S209 In Trough Near T/O for Left Courtesy Lamp 21
SPLICE
NUMBER
LOCATION FIG.
S211 In Trough Near T/O for Left Courtesy Lamp N/S
S211 (RHD) Right Side of Instrument Panel 22
S212 (RHD) Right Center Instrument Panel 22
S213 Near T/O for Cruise Switch No.1 N/S
S214 Near T/O for Cruise Switch No.1 N/S
S215 Near T/O for Horn Switch N/S
S216 Near T/O for Remote Radio Switch No.2 N/S
S217 In Trough Near T/O for Power Connector 21
S221 Right Center of Instrument Panel 21
S221 (RHD) Left Center of Instrument Panel 22
S222 (RHD) Near T/O for Front Power Outlet 22
S223 Near T/O for Adjustable Pedals Switch 21
S223 (RHD) Lower Left Side of Instrument Panel 22
S224 (RHD) Upper Center of Instrument Panel 22
S300 Near T/O for G304 33
S301 In T/O for C304 33
S302 In Sill Trough Near T/O for C307 33, 35
S304 In Sill Trough Near T/O for C307 35
S305 In Sill Trough Near T/O for C307 N/S
S308 Between T/Os for C310 and Left Rear Lamp Assembly 36, 37
S309 Between T/Os for C310 and Left Rear Lamp Assembly 37
S310 Between T/Os for C310 and Left Rear Lamp Assembly 35, 37
S311 Near T/O for Left Rear Lamp Assembly 37
S314 Near T/O for C314 N/S
S315 (Gas) In Center Spline Near T/O for G301 35
S316 (Gas) Near T/O for Junction Block C2, C4, C5 N/S
S317 Between Troughs Near T/O for C314 N/S
S318 Between Troughs Near T/O for C314 N/S
S319 In Trough Near T/O for C304 33
S324 In T/O for C200 34
SPLICE
NUMBER
LOCATION FIG.
S326 Near T/O for C200 34, 35
S327 Near T/O for c307 34, 35
S328 In Sill Trough Near T/O for G300 34
S329 In Sill Trough Near T/O for G300 34
S333 Near T/O for Power Amplifiers 36
S334 In T/O for Power Amplifier - C2 34
S336 Near T/O for Driver Power Window Motor 24, 25
S338 Near T/O for Passenger Power Window Motor 26, 27
S339 Near T/O for Passenger Power Window Motor 26 27
S340 In T/O for Passenger Door Module - C1 26, 27
S345 Near T/O for Sunroof Switch 32
S346 Near T/O for Left Visor/Vanity Lamp 32
S347 Near T/O for Left Visor/Vanity Lamp 32
S348 Near T/O for Automatic Day/Night Mirror 32
S349 Near T/O for Automatic Day/Night Mirror 32
S351 Near T/O for Seat Belt Switch N/S
S352 Near T/O for Seat Belt Switch N/S
S353 Near T/O for Driver Lumbar Switch N/S
S355 Near T/O for C304 and C306 N/S
S356 In T/O for Left Rear Door Lock Motor/Ajar Switch 28
S357 In T/O for Right Rear Door Lock Motor/Ajar Switch 29
S358 Near Left B Pillar Sill Trough 35
S362 In T/O for C200 34
S363 In T/O for C200 34
S364 Near B Pillar Sill Trough 36
S365
Japan
Near T/O for Remote Keyless Entry Module 24, 25
S366 Near T/O for Junction Block C1 N/S
S367 (RHD) Near T/O for C310 N/S
S368 Near T/O for Power Amplifier - C1 34
S369 Near T/O for Left Visor Vanity Lamp N/S
S370 Near T/O for Sunroof Module 32
S400 Near Rear Window Defogger Ground Connector 38
S401 Near Rear Window Defogger Ground Connector 38
S402 Near T/O for Liftgate Flip-Up Ajar Switch 38
SPLICE
NUMBER
LOCATION FIG.
S403 Near T/O for Rear Wiper Motor 38
S404 Near T/O for Liftgate Lock Motor 38
S405 In T/O for Rear Wiper Motor 38
S406 (Except
Built-Up-Export)
In T/O for Trailer Tow Right Turn Relay N/S
S407 (Except
Built-Up-Export)
Near T/O for Trailer Tow Left Turn Relay N/S
S408 Near T/O for Trailer Tow Circuit Breaker N/S
S410 In T/O for Trailer Tow Connector 39
S411 Near T/O for License Lamp No.1 N/S
Fig. 1 ENGINE COMPARTMENT (FRONT CLIP)
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Fig. 6 UNDERHOOD LAMP
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Fig. 12 TRANSMISSION 4.0 LITER ENGINE
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Fig. 16 TRANSMISSION 4.7 LITER ENGINE LEFT SIDE
Fig. 17 TRANSMISSION 4.7 LITER ENGINE RIGHT SIDE
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Fig. 23 STEERING COLUMN
Fig. 24 DRIVER DOOR LHD
Fig. 25 DRIVER DOOR RHD
Fig. 26 PASSENGER DOOR LHD
Fig. 27 PASSENGER DOOR RHD
Fig. 28 LEFT REAR DOOR
Fig. 29 RIGHT REAR DOOR
Fig. 30 KICK PANEL AREA LHD
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Fig. 32 ROOF AREA
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Fig. 37 BODY QUARTER PANELS
Fig. 38 LIFTGATE
Fig. 39 TRAILER TOW
8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS . . . . . . . . . 2
CIGAR LIGHTER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CIGAR LIGHTER OUTLET DOOR SPRING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IOD FUSE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
JUNCTION BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER DISTRIBUTION CENTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DISASSEMBLY
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER OUTLET
DESCRIPTION - FRONT POWER OUTLET . . . . 12
OPERATION - FRONT POWER OUTLET . . . . . . 12
DIAGNOSIS AND TESTING - POWER OUTLET . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
POWER OUTLET RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - POWER OUTLET
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
IOD WIRE HARNESS CONNECTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUSE COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR POWER OUTLET
DESCRIPTION - REAR POWER OUTLET . . . . . 16
OPERATION - REAR POWER OUTLET . . . . . . . 17
DIAGNOSIS AND TESTING - REAR POWER
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
POWER DISTRIBUTION
DESCRIPTION
Thi s group covers the vari ous standard and
opti onal power di stri buti on components used on thi s
model . The power di stri buti on system for thi s vehi cl e
consi sts of the fol l owi ng components:
Power Di stri buti on Center (PDC)
Juncti on Bl ock (JB)
Power Outl ets
The power di stri buti on system al so i ncorporates
vari ous types of ci rcui t control and protecti on fea-
tures, i ncl udi ng:
Automati c resetti ng ci rcui t breakers
Bl ade-type fuses
Bus bars
Cartri dge fuses
Ci rcui t spl i ce bl ocks
Fl ashers
Fusi bl e l i nks
Standard and Mi cro-Rel ays
Fol l owi ng are general descri pti ons of the major
components i n the power di stri buti on system. See the
owners manual i n the vehi cl e gl ove box for more
i nformati on on the features and use of al l of the
power di stri buti on system components. Refer to Wi r-
i ng Di agrams for compl ete ci rcui t di agrams.
OPERATION
The power di stri buti on system for thi s vehi cl e i s
desi gned to provi de safe, rel i abl e, and central i zed di s-
tri buti on poi nts for the el ectri cal current requi red to
operate al l of the standard and opti onal factory-i n-
stal l ed el ectri cal and el ectroni c powertrai n, chassi s,
safety, securi ty, comfort and conveni ence systems. At
the same ti me, the power di stri buti on system was
desi gned to provi de ready access to these el ectri cal
di stri buti on poi nts for the vehi cl e techni ci an to use
when conducti ng di agnosi s and repai r of faul ty ci r-
cui ts. The power di stri buti on system can al so prove
useful for the sourci ng of addi ti onal el ectri cal ci rcui ts
that may be requi red to provi de the el ectri cal current
needed to operate accessori es that the vehi cl e owner
may choose to have i nstal l ed i n the aftermarket.
NOTE: DO NOT ATTEMPT TO SWAP POWER DIS-
TRIBUTION CENTERS FROM ONE VEHICLE TO
ANOTHER. MOST OF THESE ASSEMBLIES ARE
VEHICLE FEATURE SPECIFIC AND THEREFORE
NOT INTERCHANGEABLE. ALWAYS USE THE COR-
RECT PART NUMBERED ASSEMBLY WHEN DIAG-
NOSING OR REPLACING A POWER DISTRIBUTION
CENTER.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
DESCRIPTION
A ci gar l i ghter outl et i s standard equi pment on
thi s model . On model s equi pped wi th the opti onal
Smokers Package, the ci gar l i ghter knob and heati ng
el ement are i ncl uded. On model s wi thout the Smok-
ers Package, the ci gar l i ghter outl et i s equi pped wi th
a snap fi t pl asti c cap and i s treated as an extra
accessory power outl et. The ci gar l i ghter outl et i s
i nstal l ed i n the i nstrument panel center l ower bezel ,
whi ch i s l ocated near the bottom of the i nstrument
panel center stack area, bel ow the heater and ai r
condi ti oner control s. The ci gar l i ghter outl et i s
secured by a snap fi t wi thi n the center l ower bezel .
The ci gar l i ghter outl et, pl asti c cap and the knob
and heati ng el ement uni t are avai l abl e for servi ce
repl acement. These components cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
OPERATION
The ci gar l i ghter consi sts of two major components:
a knob and heati ng el ement uni t, and the ci gar
l i ghter base or outl et shel l . The receptacl e shel l i s
connected to ground, and an i nsul ated contact i n the
bottom of the shel l i s connected to battery current.
The ci gar l i ghter recei ves battery vol tage from a fuse
i n the juncti on bl ock when the i gni ti on swi tch i s i n
the Accessory or On posi ti ons.
The ci gar l i ghter knob and heati ng el ement are
encased wi thi n a spri ng-l oaded housi ng, whi ch al so
features a sl i di ng protecti ve heat shi el d. When the
knob and heati ng el ement are i nserted i n the outl et
shel l , the heati ng el ement resi stor coi l i s grounded
through i ts housi ng to the outl et shel l . I f the ci gar
l i ghter knob i s pushed i nward, the heat shi el d sl i des
up toward the knob exposi ng the heati ng el ement,
and the heati ng el ement extends from the housi ng
toward the i nsul ated contact i n the bottom of the
outl et shel l .
Two smal l spri ng-cl i p retai ners are l ocated on
ei ther si de of the i nsul ated contact i nsi de the bottom
of the outl et shel l . These cl i ps engage and hol d the
heati ng el ement agai nst the i nsul ated contact l ong
enough for the resi stor coi l to heat up. When the
heati ng el ement i s engaged wi th the contact, battery
current can fl ow through the resi stor coi l to ground,
causi ng the resi stor coi l to heat.
When the resi stor coi l becomes suffi ci entl y heated,
excess heat radi ates from the heati ng el ement caus-
i ng the spri ng-cl i ps to expand. Once the spri ng-cl i ps
expand far enough to rel ease the heati ng el ement,
the spri ng-l oaded housi ng forces the knob and heat-
i ng el ement to pop back outward to thei r rel axed
posi ti on. When the ci gar l i ghter knob and el ement
are pul l ed out of the outl et shel l , the protecti ve heat
shi el d sl i des downward on the housi ng so that the
heati ng el ement i s recessed and shi el ded around i ts
ci rcumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For compl ete ci rcui t di agrams, refer to Horn/Ci-
gar Lighter/Power Outlet i n Wi ri ng Di agrams.
fuse.
Check for battery vol tage at the fused B(+) fuse i n
Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTION WJ
POWER DISTRIBUTION (Continued)
the juncti on bl ock. I f OK, go to Step 3. I f not OK,
repai r the open or short as requi red.
(3) Remove the ci gar l i ghter knob and el ement
from the ci gar l i ghter outl et shel l . Check for conti nu-
i ty between the i nsi de ci rcumference of the ci gar
l i ghter outl et shel l and a good ground. there shoul d
be conti nui ty. I f OK, go to Step 4. I f not OK, go to
Step 5.
Check for battery vol tage at the i nsul ated contact
l ocated at the back of the ci gar l i ghter outl et shel l . I f
OK, repl ace the faul ty ci gar l i ghter knob and el e-
ment. I f not OK, go to Step 5.
Remove the i nstrument panel center l ower bezel .
i ty of the ci gar l i ghter wi re harness connector and a
Step 6. I f not OK, repai r the open ground ci rcui t to
ground as requi red.
(6) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the Accessory or On posi ti ons.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the ci gar l i ghter wi re harness connector. I f
OK, repl ace the faul ty ci gar l i ghter outl et. I f not OK,
repai r the open fused B(+) ci rcui t to the juncti on
bl ock fuse as requi red.
DOOR SPRING
REMOVAL
cabl e.
(2) Remove the i nstrument panel center l ower
bezel from the I .P. Refer to Body for the procedure.
(3) Remove the ci gar l i ghter outl et door spri ng
from i ts l ocati ng hol es (Fi g. 1).
INSTALLATION
(1) I nstal l the ci gar outl et door spri ng i n i ts l ocat-
i ng hol es.
(2) I nstal l the i nstrument panel center l ower bezel
on the I .P. Refer to Body for the procedure.
IOD FUSE
DESCRIPTION
Draw (I OD) fuse (Fi g. 2) that i s removed from i ts
cavi ty i n the Power Di stri buti on Center (PDC) when
the vehi cl e i s shi pped from the factory. Deal er per-
sonnel are to remove the I OD fuse from the storage
l ocati on and i nstal l i t i nto PDC fuse cavi ty 15 as part
Fig. 1 Cigar Lighter Outlet Door Spring
1 - CIGAR LIGHTER OUTLET
2 - CIGAR LIGHTER OUTLET DOOR SPRING
Fig. 2 Ignition-Off Draw Fuse
2 - IGNITION-OFF DRAW FUSE
3 - IOD FUSE STORAGE CAVITY
CIGAR LIGHTER OUTLET (Continued)
of the preparati on procedures performed just pri or to
new vehi cl e del i very.
The PDC has a mol ded pl asti c cover that can be
removed to provi de servi ce access to al l of the fuses
and rel ays i n the PDC. An i ntegral l atch and hi nges
are mol ded i nto the PDC cover for easy removal . A
fuse l ayout map i s i ntegral to the undersi de of the
PDC cover to ensure proper fuse and rel ay i denti fi ca-
ti on. The I OD fuse i s a 50 ampere maxi -type car-
tri dge fuse and, when removed, i t i s stored i n a spare
fuse cavi ty wi thi n the PDC.
OPERATION
The term i gni ti on-off draw i denti fi es a normal con-
di ti on where power i s bei ng drai ned from the battery
wi th the i gni ti on swi tch i n the Off posi ti on. The I OD
fuse feeds the memory and sl eep mode functi ons for
some of the el ectroni c modul es i n the vehi cl e as wel l
as vari ous other accessori es that requi re battery cur-
rent when the i gni ti on swi tch i s i n the Off posi ti on,
i ncl udi ng the cl ock. The onl y reason the I OD fuse i s
removed i s to reduce the normal I OD of the vehi cl e
el ectri cal system duri ng new vehi cl e transportati on
and pre-del i very storage to reduce battery depl eti on,
whi l e sti l l al l owi ng vehi cl e operati on so that the
vehi cl e can be l oaded, unl oaded and moved as needed
by both vehi cl e transportati on company and deal er
personnel .
The I OD fuse i s removed from PDC fuse cavi ty 15
when the vehi cl e i s shi pped from the assembl y pl ant.
Deal er personnel must i nstal l the I OD fuse when the
vehi cl e i s bei ng prepared for del i very i n order to
restore ful l el ectri cal system operati on. Once the
vehi cl e i s prepared for del i very, the I OD functi on of
thi s fuse becomes transparent and the fuse that has
been assi gned the I OD desi gnati on becomes onl y
another Fused B(+) ci rcui t fuse. The I OD fuse serves
no useful purpose to the deal er techni ci an i n the ser-
vi ce or di agnosi s of any vehi cl e system or condi ti on,
other than the same purpose as that of any other
standard ci rcui t protecti on devi ce.
The I OD fuse can be used by the vehi cl e owner as
a conveni ent means of reduci ng battery depl eti on
when a vehi cl e i s to be stored for peri ods not to
exceed about thi rty days. However, i t must be
remembered that removi ng the I OD fuse wi l l not
el i mi nate I OD, but onl y reduce thi s normal condi ti on.
I f a vehi cl e wi l l be stored for more than about thi rty
days, the battery negati ve cabl e shoul d be di scon-
nected to el i mi nate normal I OD; and, the battery
shoul d be tested and recharged at regul ar i nterval s
duri ng the vehi cl e storage peri od to prevent the bat-
tery from becomi ng di scharged or damaged. Refer to
Battery System for addi ti onal servi ce i nformati on.
REMOVAL
The I gni ti on-Off Draw (I OD) fuses normal i nstal l a-
ti on l ocati on i s cavi ty 15 i n the power di stri buti on
center. When the vehi cl e i s shi pped from the assem-
bl y pl ant the fuse i s removed to mai ntai n proper bat-
tery vol tage duri ng vehi cl e storage (i n some cases).
Deal er personnel must i nstal l the I OD fuse when the
vehi cl e i s bei ng prepared for customer del i very i n
order to restore ful l el ectri cal system operati on.
(2) Unl atch and open the cover of the power di stri -
buti on center.
(3) Remove the I OD fuse from fuse cavity 15 of
the power di stri buti on center (Fi g. 2).
(4) Store the removed I OD fuse by i nstal l i ng i t i n
the unused fuse storage cavity 11 of the PDC (Fi g.
2).
(5) Cl ose and l atch the power di stri buti on center
cover.
INSTALLATION
(1) Be certai n the i gni ti on swi tch i s i n the Off posi -
ti on.
(2) Unl atch and open the cover of the power di stri -
buti on center.
(3) Remove the stored I OD fuse from fuse storage
cavity 11 of the power di stri buti on center.
(4) Use a thumb to press the I OD fuse fi rml y down
i nto power di stri buti on center fuse cavity 15.
(5) Cl ose and l atch the power di stri buti on center
cover.
IOD FUSE (Continued)
J UNCTION BLOCK
DESCRIPTION
An el ectri cal Juncti on Bl ock (JB) i s conceal ed
beneath the dri ver si de of the i nstrument panel i n
the passenger compartment of the vehi cl e (Fi g. 3).
The JB combi nes the functi ons previ ousl y provi ded
by a separate fusebl ock modul e and rel ay center. The
JB serves to si mpl i fy and central i ze numerous el ec-
tri cal components, as wel l as to di stri bute el ectri cal
current to many of the accessory systems i n the vehi -
cl e. I t al so el i mi nates the need for numerous spl i ce
connecti ons. The JB houses up to thi rty-three bl ade-
type mi ni fuses, up to two bl ade-type automati c
resetti ng ci rcui t breakers, the el ectroni c combi nati on
fl asher, the Dayti me Runni ng Lamp (DRL) modul e
(Canada onl y) and up to twel ve I nternati onal Stan-
dards Organi zati on (I SO) rel ays (three standard-type
and ni ne mi cro-type). The JB al so i ncorporates an
i ntegral connector and mounti ng for the Body Con-
trol Modul e (BCM). The BCM i s secured wi th four
screws di rectl y to the dash panel si de of the JB.
Refer to Body Control Module i n El ectroni c Con-
trol Modul es for addi ti onal i nformati on coveri ng the
BCM.
The mol ded pl asti c JB housi ng has i ntegral mounts
that are secured wi th two screws and two snap
retai ners to the i nstrument panel steeri ng col umn
support bracket behi nd the i nstrument panel steer-
i ng col umn openi ng cover. The JB i s conceal ed above
the mol ded pl asti c i nstrument panel fuse cover. I nte-
gral l atches mol ded i nto the fuse cover secure i t the
JB, the BCM and the 16-way data l i nk connector tab
of the i nstrument panel steeri ng col umn support
bracket. The fuse cover can be pul l ed downward to
di sengage the l atches and provi de servi ce access to
al l of the fuses, rel ays and wi re harness connectors of
the JB. The fuse cover has a fuse pul l er and spare
fuses secured to i ts upper surface. Refer to Instru-
ment Panel Fuse Cover i n Body for addi ti onal ser-
vi ce i nformati on.
The JB uni t cannot be repai red and i s onl y ser-
vi ced as an assembl y. I f any i nternal ci rcui t or the JB
housi ng i s faul ty or damaged, the enti re JB uni t
must be repl aced. The BCM i s avai l abl e for separate
servi ce repl acement.
OPERATION
Al l of the ci rcui ts enteri ng and l eavi ng the Junc-
ti on Bl ock (JB) do so through up to fi ve wi re harness
connectors, whi ch are connected to the JB through
i ntegral connector receptacl es mol ded i nto the JB
housi ng. I nternal connecti on of al l of the JB ci rcui ts
i s accompl i shed by a pri nted ci rcui t board. There are
al so two separate wi re harness connecti ons to con-
nector receptacl es that are i ntegral to the BCM.
Refer to J unction Block i n Wi ri ng Di agrams for
addi ti onal i nformati on and the l ocati on of compl ete
JB ci rcui t di agrams.
REMOVAL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
cabl e.
(2) Remove the fuse cover from the bottom of the
Juncti on Bl ock (JB).
from the i nstrument panel . Refer to Steering Col-
umn Opening Cover i n Body for the l ocati on of
steeri ng col umn openi ng cover removal procedures.
Fig. 3 Junction Block Location
1 - REAR LATCHES
2 - JUNCTION BLOCK AND BODY CONTROL MODULE UNIT
3 - INSTRUMENT PANEL FUSE COVER
4 - SIDE LATCH
5 - FRONT LATCHES
(4) Reach behi nd the JB to di sconnect the two
i nstrument panel wi re harness connectors from the
Body Control Modul e (BCM) connector receptacl es
l ocated near the bottom of the JB (Fi g. 4).
(5) Reach behi nd the JB to remove the screw that
secures the i nstrument panel wi re harness bul khead
connector to the connector receptacl e l ocated near the
top of the JB and di sconnect the connector.
(6) Di sconnect the fused B(+) and the I OD wi re
harness connectors from the connector receptacl es
l ocated near the bottom of the JB (Fi g. 5).
(7) Remove the screws that secure the ri ght and
l eft body wi re harness bul khead connectors to the
connector receptacl es l ocated near the center of the
JB and di sconnect the connectors.
(8) Remove the two screws that secure the JB to
the i nstrument panel steeri ng col umn support
bracket (Fi g. 6).
(9) To di sengage the two snap cl i ps that secure the
top of the JB to the i nstrument panel steeri ng col -
umn support bracket, grasp the bottom of the junc-
ti on bl ock fi rml y wi th both hands and pul l i t
downward sharpl y.
(10) Remove the JB from the i nstrument panel
steeri ng col umn support bracket.
INSTALLATION
NOTE: If the Junction Block (JB) is being replaced
with a new unit, be certain to transfer each of the
optional fuses, circuit breakers and relays from the
faulty JB to the proper cavities of the replacement
JB. Refer to Junction Block in Wiring Diagrams for
the location of complete circuit diagrams and cavity
assignments for the JB. The Body Control Module
(BCM) must also be transferred to the new JB.
Refer to Body Control Module in Electronic Control
Modules for the location of the BCM removal and
installation procedures.
(1) Posi ti on the JB i nto i ts mounti ng l ocati on on the
i nstrument panel steeri ng col umn support bracket.
(2) Al i gn the snap cl i ps at the top of the JB wi th
the mounti ng hol es i n the i nstrument panel steeri ng
col umn support bracket.
(3) Grasp the bottom of the JB fi rml y wi th both
hands and push i t upward sharpl y to engage the two
snap cl i ps that secure the top of the JB to the i nstru-
ment panel steeri ng col umn support bracket.
(4) I nstal l and ti ghten the two screws that secure the
JB to the i nstrument panel steeri ng col umn support
bracket. Ti ghten the screws to 2.2 Nm (20 i n. l bs.).
Fig. 4 Junction Block Connections
1 - SCREW
2 - JUNCTION BLOCK
3 - BULKHEAD CONNECTOR
1 - SNAP CLIPS
2 - SCREW
3 - CONNECTOR
4 - LEFT BODY WIRE HARNESS
5 - IOD CONNECTOR
6 - FUSED B+ CONNECTOR
8 - SCREW
9 - CONNECTOR
10 - JUNCTION BLOCK
J UNCTION BLOCK (Continued)
(5) Reconnect the ri ght and l eft body wi re harness
bul khead connectors to the connector receptacl es
l ocated near the center of the JB.
ri ght and l eft body wi re harness bul khead connectors
to the connector receptacl es l ocated near the center
of the JB. Ti ghten the screws to 2.2 Nm (20 i n. l bs.).
(7) Reconnect the fused B(+) and the I OD wi re
harness connectors to the connector receptacl es
l ocated near the bottom of the JB.
(8) Reach behi nd the JB to reconnect the i nstru-
ment panel wi re harness bul khead connector to the
connector receptacl e l ocated near the top of the JB.
i nstrument panel wi re harness bul khead connector to
the connector receptacl e l ocated near the top of the
JB. Ti ghten the screw to 2.2 Nm (20 i n. l bs.).
(10) Reach behi nd the JB to reconnect the two
i nstrument panel wi re harness connectors to the BCM
connector receptacl es l ocated near the bottom of the JB.
the i nstrument panel . Refer to Steering Column
Opening Cover i n Body for the l ocati on of the steer-
i ng col umn openi ng cover i nstal l ati on procedures.
(12) I nstal l the fuse cover onto the bottom of the JB.
POWER DISTRIBUTION
CENTER
DESCRIPTION
Al l of the el ectri cal current di stri buted throughout
thi s vehi cl e i s di rected through the standard equi p-
ment Power Di stri buti on Center (PDC) (Fi g. 7). The
mol ded pl asti c PDC housi ng i s l ocated i n the ri ght
front corner of the engi ne compartment, between the
battery and the ri ght front i nner fender shi el d. The
PDC houses up to fi fteen maxi -type cartri dge fuses,
whi ch repl ace al l i n-l i ne fusi bl e l i nks. The PDC al so
houses up to thi rteen bl ade-type mi ni fuses, and up
to ten I nternati onal Standards Organi zati on (I SO)
rel ays (two standard-type and ei ght mi cro-type).
The PDC housi ng i s secured i n the engi ne compart-
ment at three poi nts. I ntegral mounts on both si des of
the PDC housi ng engage and l atch to stanchi ons that
are i ntegral to the mol ded pl asti c battery support. The
PDC i s i ntegral to the ri ght headl amp and dash wi re
harness, whi ch exi ts from the bottom of the PDC hous-
i ng. The PDC housi ng has a mol ded pl asti c cover that
i ncl udes two i ntegral l atches at the front and pi vot
hooks at the back that snap over a hi nge pi n on the
rear of the PDC housi ng. The PDC cover i s easi l y
opened or removed for servi ce access and has a conve-
ni ent fuse and rel ay l ayout map i ntegral to the i nsi de
surface of the cover to ensure proper component i denti -
fi cati on. A fuse pul l er i s al so stored on the i nsi de of the
PDC cover.
The PDC cover, the PDC housi ng l ower cover, the
PDC rel ay wedges, the PDC rel ay cassettes and the
PDC B(+) termi nal stud modul e are avai l abl e for ser-
vi ce repl acement. The PDC mai n housi ng uni t, the
fuse wedges and the bus bars cannot be repai red and
Fig. 6 Junction Block
1 - SCREW (2)
2 - DRIVER SIDE COURTESY LAMP
3 - JUNCTION BLOCK
4 - 16 WAY DATA LINK CONNECTOR
Fig. 7 Power Distribution Center Location
1 - RIGHT FENDER
2 - BATTERY
4 - COVER
J UNCTION BLOCK (Continued)
are onl y servi ced as a uni t wi th the ri ght headl amp
and dash wi re harness. I f the PDC mai n housi ng
uni t, fuse wedges or the bus bars are faul ty or dam-
aged, the ri ght headl amp and dash wi re harness uni t
must be repl aced.
OPERATION
Al l of the current from the battery and the generator
output enters the PDC through two cabl es and a si ngl e
two-hol ed eyel et that i s secured wi th nuts to the two
PDC B(+) termi nal studs just i nsi de the front end of the
PDC housi ng. The PDC cover i s unl atched and opened
to access the battery and generator output connecti on
B(+) termi nal studs, the fuses or the rel ays. I nternal
connecti on of al l of the PDC ci rcui ts i s accompl i shed by
an i ntri cate combi nati on of hard wi ri ng and bus bars.
Refer to Power Distribution i n Wi ri ng Di agrams for
the l ocati on of compl ete PDC ci rcui t di agrams.
REMOVAL
The Power Di stri buti on Center (PDC) mai n housi ng
uni t, the PDC fuse wedges and the PDC bus bars can-
not be repai red and are onl y servi ced as a uni t wi th the
ri ght headl amp and dash wi re harness. I f the PDC
mai n housi ng uni t, the fuse wedges or the bus bars are
faul ty or damaged, the enti re PDC and ri ght headl amp
and dash wi re harness uni t must be repl aced.
(1) Di sconnect and i sol ate the battery negati ve cabl e.
(2) Di sconnect each of the ri ght headl amp and
dash wi re harness connectors. Refer to Connector
Locations i n Wi ri ng Di agrams for the l ocati on of
more i nformati on on the ri ght headl amp and dash
wi re harness connector l ocati ons.
(3) Remove al l of the fasteners that secure each of
the ri ght headl amp and dash wi re harness ground
eyel ets to the vehi cl e body and chassi s components.
Refer to Connector Locations i n Wi ri ng Di agrams
for the l ocati on of more i nformati on on the ground
eyel et l ocati ons.
(4) Di sengage each of the retai ners that secure the
ri ght headl amp and dash wi re harness to the vehi cl e
body and chassi s components. Refer to Connector
wi re harness retai ner l ocati ons.
(5) Unl atch and open the PDC cover.
(6) Remove the two nuts that secure the two-hol ed
eyel et of the battery wi re harness PDC take outs to
the PDC B(+) termi nal studs (Fi g. 8).
(7) Remove the battery wi re harness PDC take out
eyel et from the B(+) termi nal studs.
(8) Di sengage the l atches on the PDC housi ng
mounts from the tabs on the PDC mounti ng stan-
chi ons of the battery support, and pul l the PDC
housi ng upward to di sengage the mounts from the
stanchi ons (Fi g. 9).
Fig. 8 Power Distribution Center Connections
1 - PDC COVER
2 - NUT (2)
3 - EYELET
4 - B(+) TERMINAL STUDS
Fig. 9 Power Distribution Center Remove/Install
2 - MOUNTS
3 - STANCHIONS (3)
4 - BATTERY SUPPORT
POWER DISTRIBUTION CENTER (Continued)
(9) Remove the PDC and the ri ght headl amp and
dash wi re harness from the engi ne compartment as a
uni t.
DISASSEMBLY
POWER DISTRIBUTION CENTER DISASSEMBLY
PDC HOUSING LOWER COVER REMOVAL
The Power Di stri buti on Center (PDC) cover, the
PDC housi ng l ower cover, the PDC rel ay wedges, the
PDC rel ay cassettes and the PDC B(+) termi nal stud
modul e are avai l abl e for servi ce repl acement. The
PDC cover can be si mpl y unl atched and removed
from the PDC housi ng wi thout the PDC bei ng
removed or di sassembl ed. Servi ce of the remai ni ng
PDC components requi res that the PDC be removed
from i ts mounti ng and di sassembl ed. Refer to Wiring
Repair i n Wi ri ng Di agrams for the l ocati on of the
wi ri ng repai r procedures.
(1) Remove the battery from the battery support.
Refer to Battery System for the l ocati on of the bat-
tery removal procedures.
(2) Unl atch and remove the cover from the PDC.
(3) Remove the two nuts that secure the two-hol ed
eyel et of the battery wi re harness PDC take out to
the B(+) termi nal studs near the front of the PDC.
(4) Remove the battery wi re harness PDC take out
eyel et from the two PDC B(+) termi nal studs.
(5) Di sengage the l atches on the PDC housi ng
mounts from the tabs on the PDC mounti ng stan-
chi ons on the battery support, and pul l the PDC
housi ng upward to di sengage the mounts from the
stanchi ons.
(6) Where the ri ght headl amp and dash wi re har-
ness exi ts the PDC, remove the tape that secures the
wi re harness to the trough formati on on the PDC
housi ng l ower cover.
fl at-bl aded tool , gentl y pry the l atches on each si de
and the front of the PDC housi ng that secure the
housi ng l ower cover to the PDC and remove the
housi ng l ower cover (Fi g. 10).
PDC B+ TERMINAL MODULE REMOVAL
(1) Remove the PDC housi ng l ower cover.
(2) From the top of the PDC housi ng, use a smal l
screwdri ver or a termi nal pi ck tool (Speci al Tool Ki t
6680) to rel ease the two l atches that secure the B(+)
termi nal modul e i n the PDC.
(3) Gentl y and evenl y press the two B(+) termi nal
studs down through the bus bar i n the PDC.
(4) From the bottom of the PDC housi ng, remove
the B(+) termi nal modul e from the PDC.
PDC RELAY WEDGE REMOVAL
(1) Remove the PDC housi ng l ower cover.
(2) Remove each of the rel ays from the PDC rel ay
wedge to be removed.
(3) From the bottom of the PDC housi ng, use a
smal l screwdri ver or a termi nal pi ck tool (Speci al
Fig. 10 PDC Housing Lower Cover Remove/Install -
Typical
1 - TROUGH FORMATION
2 - LATCHES (5)
3 - PDC HOUSING LOWER COVER
4 - WIRE HARNESS
Tool Ki t 6680) to rel ease the two l atches (yel l ow) that
secure the rel ay wedge to the PDC rel ay cassette.
(4) From the top of the PDC housi ng, remove the
rel ay wedge from the PDC rel ay cassette (Fi g. 11).
PDC RELAY CASSETTE REMOVAL
(1) Remove the rel ay wedge from the PDC rel ay
cassette to be removed.
NOTE: It may be necessary to remove relay cas-
settes that are not being serviced from the PDC
housing in order to obtain sufficient clearance to
access the faulty relay cassette. The same service
procedure is repeated as necessary to remove each
of the interfering relay wedges and relay cassettes
from the PDC housing.
(2) From the top of the PDC housi ng, use a smal l
screwdri ver or a termi nal pi ck tool (Speci al Tool Ki t
6680) to rel ease the two l atches that secure the rel ay
cassette i n the PDC (Fi g. 12).
(3) Gentl y and evenl y press the rel ay cassette
down through the PDC housi ng.
(4) From the bottom of the PDC housi ng, remove
the rel ay cassette from the PDC (Fi g. 13).
Fig. 11 PDC Relay Wedge Remove/Install - Typical
1 - RELAY WEDGE (TYPICAL)
2 - PDC HOUSING
Fig. 12 PDC Relay Cassette Latches - Typical
1 - LATCHES
2 - FROM SPECIAL TOOL KIT 6680
3 - PDC RELAY CASSETTES (TYPICAL)
Fig. 13 PDC Relay - Typical
1 - PDC HOUSING
2 - PDC RELAY CASSETTE (TYPICAL)
3 - LATCHES
CAUTION: Do not remove the wiring and terminals
from the terminal cavities of the faulty PDC relay
cassette at this time. Refer to the Assembly proce-
dure that follows for the proper procedures for
transferring the wiring and terminals to the replace-
ment PDC relay cassette.
ASSEMBLY
POWER DISTRIBUTION CENTER ASSEMBLY
PDC B(+) TERMINAL MODULE INSTALLATION
(1) From the bottom of the PDC housi ng, al i gn and
i nsert the B(+) termi nal modul e i nto the PDC.
i nsert the two studs of the PDC B(+) termi nal mod-
ul e through the bus bar i n the PDC.
(3) From the bottom of the PDC housi ng, press the
B(+) termi nal modul e gentl y and evenl y i nto the PDC
unti l both of the l atches are ful l y engaged.
(4) I nstal l the PDC housi ng l ower cover.
RELAY WEDGE INSTALLATION
(1) From the top of the PDC housi ng, al i gn and
i nsert the PDC rel ay wedge l atch arms i nto the cor-
rect cavi ti es i n the rel ay cassette.
(2) Gentl y and evenl y press the PDC rel ay wedge
down i nto the rel ay cassette unti l both of the l atches
are ful l y engaged.
(3) I nstal l each of the removed rel ays i nto the
proper cavi ti es of the PDC rel ay wedge.
(4) I nstal l the PDC housi ng l ower cover.
RELAY CASSETTE INSTALLATION
(1) Move the faul ty PDC rel ay cassette wi th i ts
wi ri ng away from the bottom of the PDC housi ng far
enough to al l ow the repl acement rel ay cassette to be
i nstal l ed i nto the PDC.
(2) Usi ng the faul ty rel ay cassette as a gui de, be
certai n that the repl acement rel ay cassette i s cor-
rectl y ori ented before i nstal l i ng i t i nto the PDC hous-
i ng.
i nsert the repl acement rel ay cassette i nto the PDC.
Press the rel ay cassette up i nto the PDC unti l both
of the l atches are ful l y engaged.
CAUTION: Proper care must be taken to be certain
that the wiring and terminals from the faulty PDC
relay cassette are installed in the correct terminal
cavities of the replacement relay cassette. To pre-
vent mistakes it is recommended that the wiring
and terminals be removed from the faulty relay cas-
sette one cavity at a time, repaired or spliced as
necessary, then installed securely into the correct
cavity of the replacement relay cassette. If you are
not absolutely certain into which cavity a terminal
should be installed, refer to Power Distribution in
the index of this service manual for the location of
complete circuit diagrams covering the PDC.
(4) Whi l e pul l i ng gentl y on the wi re from the bot-
tom of the faul ty PDC rel ay cassette, use a termi nal
pi ck tool (Speci al Tool Ki t 6680) from the top of the
rel ay cassette to rel ease the l atch that secures the
termi nal i n the rel ay cassette termi nal cavi ty (Fi g.
14).
(5) From the bottom of the faul ty PDC rel ay cas-
sette, remove the wi re and termi nal from the rel ay
cassette termi nal cavi ty.
(6) Make al l necessary repai rs and spl i ces to the
wi re for the removed termi nal . Refer to Wiring
i nsert the removed wi re and termi nal i nto the correct
termi nal cavi ty of the repl acement rel ay cassette.
Push the wi re and termi nal up i nto the rel ay cassette
termi nal cavi ty unti l i t i s ful l y engaged by the l atch.
(8) Repeat Step 4, Step 5, Step 6 and Step 7 one
wi re and termi nal at a ti me unti l each of the wi res
and termi nal s have been transferred from the faul ty
PDC rel ay cassette i nto the repl acement rel ay cas-
sette.
(9) I nstal l the PDC rel ay wedge i nto the repl ace-
ment PDC rel ay cassette.
Fig. 14 PDC Relay Cassette Terminal Remove/Install
- Typical
1 - TERMINAL CAVITIES (TYPICAL)
2 - PDC RELAY CASSETTE (TYPICAL)
3 - TERMINAL LATCHES (TYPICAL)
4 - FROM SPECIAL TOOL KIT 6680
PDC LOWER COVER INSTALLATION
(1) Al i gn the PDC housi ng l ower cover on the bot-
tom of the PDC.
(2) Evenl y press the l ower cover i nto pl ace unti l
l atches are ful l y engaged.
(3) Where the ri ght headl amp and dash harness
enters the PDC, tape the harness securel y to the
trough formati on on the PDC l ower cover.
(4) I nstal l the PDC i n i ts mounti ng l ocati on on the
battery support.
(5) I nstal l the battery wi re harness over the two
PDC B+ termi nal studs. Torque the nuts to 11.3 Nm
(100 i n. l bs.).
(6) I nstal l the battery. Refer to Battery System for
the procedure.
(7) I nstal l the PDC cover.
INSTALLATION
The Power Di stri buti on Center (PDC) mai n hous-
i ng uni t, the PDC fuse wedges and the PDC bus bars
cannot be repai red and are onl y servi ced as a uni t
wi th the ri ght headl amp and dash wi re harness. I f
the PDC mai n housi ng uni t, the fuse wedges or the
bus bars are faul ty or damaged, the enti re PDC and
ri ght headl amp and dash wi re harness uni t must be
repl aced.
(1) Posi ti on the PDC and the ri ght headl amp and
dash wi re harness uni t i n the engi ne compartment.
(2) Engage the PDC housi ng mounts wi th the
stanchi ons of the battery support and push the uni t
downward unti l the mount l atches ful l y engage the
mounti ng tabs on the stanchi ons.
(3) I nstal l the two-hol ed eyel et of the battery wi re
harness PDC take outs onto the two PDC B(+) termi -
nal studs.
(4) I nstal l and ti ghten the nuts that secure the
eyel et of the battery wi re harness PDC take outs to
the B(+) termi nal studs. Ti ghten the nuts to 11.3
Nm (100 i n. l bs.).
(5) Engage each of the retai ners that secure the
ri ght headl amp and dash wi re harness to the vehi cl e
body and chassi s components. Refer to Connector
wi re harness retai ner l ocati ons.
(6) I nstal l al l of the fasteners that secure each of
the ri ght headl amp and dash wi re harness ground
eyel ets to the vehi cl e body and chassi s components.
Refer to Connector Locations i n Wi ri ng Di agrams
for the l ocati on of more i nformati on on the ground
eyel et l ocati ons.
(7) Reconnect each of the ri ght headl amp and dash
wi re harness connectors. Refer to Connector Loca-
tions i n Wi ri ng Di agrams for the l ocati on of more
i nformati on on the ri ght headl amp and dash wi re
harness connector l ocati ons. For connectors secured
wi th screws, ti ghten the screws to 4.3 Nm (38 i n.
l bs.).
POWER OUTLET
DESCRIPTION - FRONT POWER OUTLET
An accessory power outl et i s standard equi pment
on thi s model . The power outl et i s i nstal l ed i n the
i nstrument panel center l ower bezel , whi ch i s l ocated
near the bottom of the i nstrument panel center stack
area, bel ow the heater and ai r condi ti oner control s.
The power outl et base i s secured by a snap fi t wi thi n
the center l ower bezel . A hi nged door wi th an over-
center spri ng fl i ps cl osed to conceal and protect the
power outl et base when the power outl et i s not bei ng
used, and fl i ps open bel ow the center l ower bezel
whi l e the power outl et i s i n use.
The power outl et receptacl e uni t and the power
outl et door are each avai l abl e for servi ce repl ace-
ment.
OPERATION - FRONT POWER OUTLET
The power outl et base or receptacl e shel l i s con-
nected to ground, and an i nsul ated contact i n the
The power outl et recei ves battery vol tage from a fuse
i n the juncti on bl ock at al l ti mes.
Whi l e the power outl et i s very si mi l ar to a ci gar
l i ghter base uni t, i t does not i ncl ude the two smal l
spri ng-cl i p retai ners i nsi de the bottom of the recepta-
cl e shel l that are used to secure the ci gar l i ghter
heati ng el ement to the i nsul ated contact.
For compl ete ci rcui t di agrams, refer to Horn/Ci-
gar Lighter/Power Outlet i n Wi ri ng Di agrams.
WARNING: REFER TO RESTRAINTS BEFORE
PERSONAL INJURY.
fuse.
repai r the open fused B(+) ci rcui t to the Power Di s-
tri buti on Center (PDC) fuse as requi red.
(3) Open the power outl et door. Check for conti nu-
i ty between the i nsi de ci rcumference of the power
outl et receptacl e and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 4. I f not OK, go to Step
5.
(4) Check for battery vol tage at the i nsul ated con-
tact l ocated at the back of the power outl et recepta-
cl e. I f not OK, go to Step 5.
cabl e. Remove the i nstrument panel center l ower
bezel . Check for conti nui ty between the ground ci r-
cui t cavi ty of the power outl et wi re harness connector
power outl et wi re harness connector. I f OK, repl ace
the faul ty power outl et receptacl e. I f not OK, repai r
the open fused B(+) ci rcui t to the juncti on bl ock fuse
as requi red.
REMOVAL
cabl e.
Lower Bezel i n Body for the procedure.
(3) Pul l the ci gar l i ghter knob and el ement or the
protecti ve cap out of the ci gar l i ghter receptacl e base,
or open the power outl et door i n the i nstrument
panel center l ower bezel .
(4) Look i nsi de the ci gar l i ghter or power outl et
receptacl e base and note the posi ti on of the rectangu-
l ar retai ni ng bosses of the mount that secures the
receptacl e base to the i nstrument panel center l ower
bezel (Fi g. 15).
(5) I nsert a pai r of external snap ri ng pl i ers i nto
the ci gar l i ghter or power outl et receptacl e base and
engage the ti ps of the pl i ers wi th the retai ni ng
bosses of the mount.
(6) Squeeze the pl i ers to di sengage the mount
retai ni ng bosses from the receptacl e base and, usi ng
a gentl e rocki ng moti on, pul l the pl i ers and the
receptacl e base out of the mount.
(7) Remove the ci gar l i ghter or power outl et mount
from the i nstrument panel center l ower bezel .
INSTALLATION
(1) I nstal l the ci gar l i ghter or power outl et mount
i nto the i nstrument panel center l ower bezel .
(2) Al i gn the spl i nes on the outsi de of the ci gar
l i ghter or power outl et receptacl e base connector
receptacl e wi th the grooves on the i nsi de of the
mount.
(3) Press fi rml y on the ci gar l i ghter or power out-
l et receptacl e base unti l the retai ni ng bosses of the
mount are ful l y engaged i n thei r receptacl es.
(4) I nstal l the ci gar l i ghter knob and el ement or
the protecti ve cap i nto the ci gar l i ghter receptacl e
base, or cl ose the power outl et door i n the i nstrument
panel center l ower bezel .
Lower Bezel i n Body for the procedure.
POWER OUTLET RELAY
DESCRIPTION
The power outl et /ci gar l i ghter rel ay i s an el ectro-
mechani cal devi ce that swi tches fused battery cur-
rent to the ci gar l i ghter or power outl et when the
i gni ti on swi tch i s turned to the Accessory or On posi -
ti ons. The power outl et /ci gar l i ghter rel ay i s l ocated
i n the juncti on bl ock, bel ow the dri ver si de of the
i nstrument panel i n the passenger compartment.
The ci gar l i ghter rel ay i s a I nternati onal Standards
Organi zati on (I SO) rel ay. Rel ays conformi ng to the
functi ons.
Fig. 15 Cigar Lighter and Power Outlet Remove/
Install - Typical
1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
3 - BASE
4 - PARTIALLY REMOVED
5 - EXTERNAL SNAP-RING PLIERS
6 - MOUNT
7 - BASE
POWER OUTLET (Continued)
The ci gar l i ghter rel ay cannot be repai red or
adjusted and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
contact.
RELAY
The power outl et / ci gar l i ghter rel ay (Fi g. 16) i s
l ocated i n the juncti on bl ock, bel ow the dri ver si de
end of the i nstrument panel i n the passenger com-
partment. For compl ete ci rcui t di agrams, refer to
Horn/Cigar Lighter/Power Outlet i n Wi ri ng Di a-
grams.
WARNING: REFER TO RESTRAINTS BEFORE
PERSONAL INJURY.
(1) Remove the power outl et / ci gar l i ghter rel ay
from the juncti on bl ock. Refer to the procedure i n
thi s group.
DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) of
the juncti on bl ock i s connected to battery vol tage and
shoul d be hot at al l ti mes. Check for battery vol tage
at the fused B(+) ci rcui t cavi ty i n the juncti on bl ock
receptacl e for the ci gar l i ghter rel ay. I f OK, go to
Step 2. I f not OK, repai r the fused B(+) ci rcui t to the
Power Di stri buti on Center (PDC) fuse as requi red.
to the fused B(+) fuse i n the juncti on bl ock that feeds
the ci gar l i ghter when the rel ay i s energi zed by the
i gni ti on swi tch. There shoul d be conti nui ty between
the juncti on bl ock cavi ty for rel ay termi nal 87 and
the fused B(+) fuse i n the juncti on bl ock at al l ti mes.
I f OK, go to Step 4. I f not OK, repai r the open fused
B(+) ci rcui t to the juncti on bl ock fuse as requi red.
the el ectromagnet i n the rel ay. I t recei ves battery
feed to energi ze the ci gar l i ghter rel ay when the i gni -
ti on swi tch i s i n the Accessory or On posi ti ons. Turn
the i gni ti on swi tch to the On posi ti on. Check for bat-
tery vol tage at the fused i gni ti on swi tch output (acc/
run) ci rcui t cavi ty for rel ay termi nal 85 i n the
juncti on bl ock receptacl e for the ci gar l i ghter rel ay. I f
i gni ti on swi tch output (acc/run) ci rcui t to the i gni ti on
swi tch as requi red.
the el ectromagnet i n the rel ay. The juncti on bl ock
cavi ty for thi s termi nal shoul d have conti nui ty to
Fig. 16 Accessory Relay
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
POWER OUTLET RELAY (Continued)
ground at al l ti mes. I f not OK, repai r the open
REMOVAL
cabl e.
from the i nstrument panel . Refer to Steering Col-
umn Opening Cover i n Body for the procedure.
(3) The power outl et /ci gar l i ghter rel ay i s l ocated
on the l eft si de of the combi nati on fl asher i n the
juncti on bl ock.
(4) Remove the power outl et / ci gar l i ghter rel ay
from the juncti on bl ock.
INSTALLATION
(1) Posi ti on the power outl et /ci gar l i ghter rel ay i n
the proper receptacl e i n the juncti on bl ock.
(2) Al i gn the power outl et / ci gar l i ghter rel ay ter-
mi nal s wi th the termi nal cavi ti es i n the juncti on
bl ock receptacl e.
(3) Push i n fi rml y on the power outl et / ci gar
l i ghter rel ay unti l the termi nal s are ful l y seated i n
the termi nal cavi ti es i n the juncti on bl ock receptacl e.
the i nstrument panel . Refer to Steering Column
Opening Cover i n Body for the procedure.
IOD WIRE HARNESS
CONNECTOR
DESCRIPTION
Draw (I OD) connector that i s l ocated i n a mol ded
connector receptacl e on the l ower rear surface of the
Juncti on Bl ock (JB) housi ng (Fi g. 17). The JB i s con-
ceal ed above the mol ded pl asti c i nstrument panel
fuse cover. I ntegral l atches mol ded i nto the fuse
cover secure i t the JB, the Body Control Modul e
(BCM) and the 16-way data l i nk connector tab of the
The fuse cover can be pul l ed downward to di sengage
the l atches and provi de servi ce access to al l of the
fuses, rel ays and wi re harness connectors of the JB.
Refer to Instrument Panel Fuse Cover i n the
i ndex of thi s servi ce manual for the l ocati on of addi -
ti onal servi ce i nformati on coveri ng the fuse cover.
OPERATION
The term i gni ti on-off draw i denti fi es a normal con-
di ti on where power i s bei ng drai ned from the battery
wi th the i gni ti on swi tch i n the Off posi ti on. The I OD
connector feeds the memory and sl eep mode func-
ti ons for some of the el ectroni c modul es i n the vehi cl e
as wel l as vari ous other accessori es that requi re bat-
tery current when the i gni ti on swi tch i s i n the Off
posi ti on, i ncl udi ng the cl ock.
The I OD connector can be used by the vehi cl e
owner as a conveni ent means of reduci ng battery
depl eti on when a vehi cl e i s to be stored for peri ods
not to exceed about twenty days (short-term storage).
Si mpl y di sconnect the I OD connector from the JB
receptacl e. However, i t must be remembered that di s-
connecti ng the I OD connector wi l l not el i mi nate I OD,
but onl y reduce thi s normal condi ti on. When a vehi -
cl e wi l l not be used for more than twenty days, but
l ess than thi rty days, remove the I OD fuse from the
Power Di stri buti on Center (PDC). I f a vehi cl e wi l l be
stored for more than about thi rty days, the battery
negati ve cabl e shoul d be di sconnected to el i mi nate
normal I OD; and, the battery shoul d be tested and
recharged at regul ar i nterval s duri ng the vehi cl e
storage peri od to prevent the battery from becomi ng
di scharged or damaged. Refer to Ignition-Off Draw
Fig. 17 Ignition-Off Draw Connector
1 - SNAP CLIPS
2 - SCREW
3 - CONNECTOR
5 - IOD CONNECTOR
8 - SCREW
9 - CONNECTOR
10 - JUNCTION BLOCK
POWER OUTLET RELAY (Continued)
Fuse and Battery i n the i ndex i n thi s servi ce man-
ual for the l ocati on of addi ti onal servi ce i nformati on
coveri ng the i gni ti on-off draw fuse and the battery.
FUSE COVER
REMOVAL
cabl e.
(2) Pul l down on the rear edge (nearest the rear of
the vehi cl e) of the i nstrument panel fuse cover unti l
the rear l atches unsnap from the tabs on the l ower
juncti on bl ock housi ng and the si de l atch unsnaps
from the tab on the i nstrument panel steeri ng col -
umn support bracket outboard of the 16-way data
l i nk connector (Fi g. 18).
(3) Move the i nstrument panel fuse cover towards
the front of the vehi cl e to di sengage the front l atches
from the mounti ng sl ots i n the l ower housi ng of the
body control modul e.
(4) Remove the fuse cover from under the i nstru-
ment panel .
INSTALLATION
(1) Posi ti on the two front l atches of the i nstrument
panel fuse cover wi thi n the two l ocator channel for-
mati ons on the bottom of the body control modul e
(2) Whi l e appl yi ng a sl i ght upward pressure to the
i nstrument panel fuse cover over the front l atches,
sl owl y sl i de the front l atches through the l ocator
channel s toward the front of the vehi cl e unti l the
l atches exi t the front of the l ocator channel s. Thi s
wi l l l ocate the front l atches at the mounti ng sl ots i n
the l ower housi ng of the body control modul e.
(3) Appl y a sl i ght rearward pressure on the i nstru-
ment panel fuse cover to engage the front l atches i n
the mounti ng sl ots i n the l ower housi ng of the body
control modul e.
(4) Swi ng the rear edge (nearest the rear of the
vehi cl e) of the i nstrument panel fuse cover up toward
the juncti on bl ock.
(5) Press fi rml y upward on the i nstrument panel
fuse cover over the rear l atches unti l the l atches
snap i nto pl ace over the tabs on the l ower edge of the
juncti on bl ock housi ng.
(6) Press fi rml y upward on the 16-way data l i nk
connector cover formati on of the i nstrument panel
fuse cover unti l the si de l atch snaps i nto pl ace over
the tab on the outboard si de of the i nstrument panel
REAR POWER OUTLET
DESCRIPTION - REAR POWER OUTLET
A rear accessory power outl et i s opti onal equi p-
ment on thi s model . The rear power outl et i s
i nstal l ed i n the l ower ri ght quarter tri m panel near
the ri ght l i ftgate openi ng pi l l ar i n the cargo area of
Fig. 18 Instrument Panel Fuse Cover Remove/Install
1 - REAR LATCHES
2 - JUNCTION BLOCK AND BODY CONTROL MODULE UNIT
3 - INSTRUMENT PANEL FUSE COVER
4 - SIDE LATCH
5 - FRONT LATCHES
Fig. 19 Instrument Panel Fuse Cover Locator
Channels
1 - JUNCTION BLOCK
2 - SCREWS (4)
IOD WIRE HARNESS CONNECTOR (Continued)
the vehi cl e. The power outl et base and mount are
secured by a snap fi t wi thi n the quarter tri m panel .
A pl asti c protecti ve cap snaps i nto the power outl et
base when the power outl et i s not bei ng used, and
hangs from the power outl et base mount by an i nte-
gral bai l strap whi l e the power outl et i s i n use. Whi l e
the power outl et i s very si mi l ar to a ci gar l i ghter
base uni t, i t does not i ncl ude the two smal l spri ng-
cl i p retai ners i nsi de the bottom of the receptacl e
shel l that are used to secure the ci gar l i ghter heati ng
el ement to the i nsul ated contact.
The power outl et receptacl e uni t and the accessory
power outl et protecti ve cap are avai l abl e for servi ce.
The power outl et receptacl e cannot be repai red and,
OPERATION - REAR POWER OUTLET
The power outl et base or receptacl e shel l i s con-
nected to ground, and an i nsul ated contact i n the
The power outl et recei ves battery vol tage from a fuse
i n the Power Di stri buti on Center (PDC) through a
fuse i n the Juncti on Bl ock (JB) at al l ti mes. Refer to
Horn/Cigar Lighter/Power Outlet i n Wi ri ng Di a-
grams for the l ocati on of compl ete rear power outl et
ci rcui t di agrams.
DIAGNOSIS AND TESTING - REAR POWER
OUTLET
Refer to Horn/Cigar Lighter/Power Outlet i n
Wi ri ng Di agrams for the l ocati on of compl ete rear
power outl et ci rcui t di agrams.
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
Center (PDC) as requi red.
(3) Remove the pl asti c protecti ve cap from the rear
power outl et receptacl e. Check for conti nui ty between
the i nsi de ci rcumference of the rear power outl et
receptacl e and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 4. I f not OK, go to Step 5.
(4) Check for battery vol tage at the i nsul ated con-
tact l ocated at the back of the rear power outl et
receptacl e. I f not OK, go to Step 5.
cabl e. Remove the rear power outl et from the ri ght
quarter tri m panel . Check for conti nui ty between the
ground ci rcui t cavi ty of the rear power outl et wi re
harness connector and a good ground. There shoul d
the open ground ci rcui t to ground as requi red.
rear power outl et wi re harness connector. I f OK,
repl ace the faul ty rear power outl et receptacl e base.
I f not OK, repai r the open fused B(+) ci rcui t to the
JB fuse as requi red.
REMOVAL
cabl e.
(2) Pul l the protecti ve cap out of the rear power
outl et receptacl e base (Fi g. 20).
Fig. 20 Rear Power Outlet Remove/Install
1 - RIGHT QUARTER TRIM PANEL
2 - RIGHT BODY WIRE HARNESS CONNECTOR
3 - RECEPTACLE BASE
4 - PROTECTIVE CAP
5 - MOUNT
REAR POWER OUTLET (Continued)
(3) Look i nsi de the rear power outl et receptacl e
base and note the posi ti on of the rectangul ar retai n-
i ng bosses of the mount that secures the receptacl e
base to the ri ght quarter tri m panel (Fi g. 21).
(4) I nsert a pai r of external snap ri ng pl i ers i nto
the rear power outl et receptacl e base and engage the
ti ps of the pl i ers wi th the retai ni ng bosses of the
mount.
(5) Squeeze the pl i ers to di sengage the mount
retai ni ng bosses from the receptacl e base and, usi ng
a gentl e rocki ng moti on, pul l the pl i ers and the
receptacl e base out of the mount.
(6) Pul l the rear power outl et receptacl e base away
from the ri ght quarter tri m panel far enough to
access the wi re harness connector.
(7) Di sconnect the ri ght body wi re harness connec-
tor from the rear power outl et receptacl e base con-
nector receptacl e.
(8) Remove the rear power outl et mount from the
ri ght quarter tri m panel .
INSTALLATION
(1) Al i gn the spl i nes on the outsi de of the rear
power outl et receptacl e base connector receptacl e
wi th the grooves on the i nsi de of the mount.
(2) I nsert the rear power outl et receptacl e base
about hal f way through the mount.
(3) Reconnect the ri ght body wi re harness connec-
tor to the rear power outl et receptacl e base connector
receptacl e.
(4) I nsert the rear power outl et receptacl e base
and mount i nto the ri ght quarter tri m panel as a
uni t unti l the mount i s seated fl ush agai nst the tri m
panel .
(5) Press fi rml y on the rear power outl et receptacl e
base unti l the retai ni ng bosses of the mount are ful l y
engaged i n thei r receptacl es.
(6) I nstal l the protecti ve cap i nto the rear power
outl et receptacl e base.
Fig. 21 Power Outlet Remove/Install - Typical
1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
3 - BASE
4 - PARTIALLY REMOVED
5 - EXTERNAL SNAP-RING PLIERS
6 - MOUNT
7 - BASE
REAR POWER OUTLET (Continued)
ENGINE
TABLE OF CONTENTS
page page
ENGINE - 4. 0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE - 4. 7L . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ENGINE - 4.0L
TABLE OF CONTENTS
page page
ENGINE - 4.0L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 3
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTINGCYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE. . . . . . . 8
DIAGNOSIS AND TESTINGREAR SEAL
AREA LEAKS. . . . . . . . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . . . 9
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . . 10
STANDARD PROCEDUREHYDROSTATIC
LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - CYLINDER
BORE HONING . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
ENGINE - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 14
TORQUE - 4.0L ENGINE . . . . . . . . . . . . . . . . 17
AIR CLEANER ELEMENT
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . . 19
AIR CLEANER HOUSING
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . . 19
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
CYLINDER HEAD COVER(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
STANDARD PROCEDURE - VALVE SERVICE . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
STANDARD PROCEDURE - VALVE SPRING
TENSION TEST . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
ENGINE BLOCK
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CAMSHAFT & BEARINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
WJ ENGINE 9 - 1
REMOVAL
REMOVAL - CAMSHAFT BEARINGS . . . . . . . 31
REMOVAL - CAMSHAFT . . . . . . . . . . . . . . . . 31
INSPECTION
INSPECTION - CAMSHAFT BEARINGS . . . . . 31
INSPECTION - CAMSHAFT . . . . . . . . . . . . . . 31
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . . 32
INSTALLATION - CAMSHAFT . . . . . . . . . . . . 32
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - FITTING
CONNECTING ROD BEARINGS . . . . . . . . . . 33
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
CRANKSHAFT MAIN BEARINGS
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
HYDRAULIC LIFTERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
STANDARD PROCEDURE - PISTON FITTING . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
STRUCTURAL SUPPORT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 51
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OIL PAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
ENGINE OIL PRESSURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 57
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE . . . . . . . . . . . . . . . . . . 57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
ENGINE - 4.0L
DESCRIPTION
The 4.0 Li ter (242 CI D) si x-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne. Thi s
engi ne i s desi gned for unl eaded fuel .
The engi ne cyl i nder head has dual quench-type
combusti on chambers that create turbul ence and fast
burni ng of the ai r/fuel mi xture. Thi s resul ts i n better
fuel economy.
The cyl i nders are numbered 1 through 6 from front
to rear. The fi ri ng order i s 1-5-3-6-2-4 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n seven mai n beari ngs. The camshaft rotates
wi thi n four beari ngs.
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.2 and No.3 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
1st Di gi tThe year (8 = 1998).
2nd & 3rd Di gi tsThe month (01 - 12).
4th & 5th Di gi tsThe engi ne type/fuel system/
compressi on rati o (MX = A 4.0 Li ter (242 CI D) 8.7:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
9 - 2 ENGINE - 4. 0L WJ
6th & 7th Di gi tsThe day of engi ne bui l d (01 -
31).
(1) FOR EXAMPLE: Code * 801MX12 * i denti fi es
a 4.0 Li ter (242 CI D) engi ne wi th a mul ti -poi nt fuel
i njecti on system, 8.7:1 compressi on rati o and bui l t on
January 12, 1998.
DIAGNOSIS - INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther
mechani cal (e.g., a strange noi se), or performance
(e.g., engi ne i dl es rough and stal l s).
(Refer to 9 - ENGI NE - DI AGNOSI S AND TEST-
I NG - Preformance) or (Refer to 9 - ENGI NE - DI AG-
NOSI S AND TESTI NG - Mechani cal ). Refer to 14 -
FUEL SYSTEM for fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can-
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng:
Cyl i nder Compressi on Pressure Test (Refer to 9 -
ENGI NE - DI AGNOSI S AND TESTI NG)
Cyl i nder Combusti on Pressure Leakage Test
(Refer to 9 - ENGI NE - DI AGNOSI S AND TESTI NG)
Cyl i nder Head Gasket Fai l ure Di agnosi s (Refer
to 9 - ENGI NE/CYLI NDER HEAD - DI AGNOSI S
AND TESTI NG)
I ntake Mani fol d Leakage Di agnosi s (Refer to 9 -
ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -
DI AGNOSI S AND TESTI NG)
Lash Adjuster (Tappet) Noi se Di agnosi s (Refer to
9 - ENGI NE/ENGI NE BLOCK/HYDRAULI C LI FT-
ERS (CAM I N BLOCK) - DI AGNOSI S AND TEST-
I NG)
Engi ne Oi l Leak I nspecti on (Refer to 9 -
ENGI NE/LUBRI CATI ON - DI AGNOSI S AND TEST-
I NG)
Fig. 1 Engine Firing Order
Fig. 2 Build Date Code Location
1 - YEAR
2 - MONTH
3 - DAY
WJ ENGINE - 4. 0L 9 - 3
ENGINE - 4.0L (Continued)
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE), for correct
procedures. Check charging system.
(Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING), for correct procedures.
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to 8
- ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING), for
correct diagnostics/procedures
4. Siezed accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace siezed
component.
5. Engine internal mechanical failure
or hydro-static lock
5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING), for
correct diagnostics/procedures
ENGINE CRANKS BUT WILL
NOT START
1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL -
SPECIFICATIONS), for correct
procedures.
2. No fuel 2. Perform fuel pressure test (Refer
to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING), and if
necessary, inspect fuel injector(s) and
driver circuits. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL
INJECTOR - DIAGNOSIS AND
TESTING), for correct procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE -
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn camshaft position sensor
shaft
2. Remove and repair camshaft
position sensor.(Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
CAMSHAFT POSITION SENSOR -
REMOVAL).
9 - 4 ENGINE - 4. 0L WJ
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer to
8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression. (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition coil rail 11. Test and replace, as necessary.
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/COIL RAIL - REMOVAL).
ENGINE STALLS OR ROUGH
IDLE
1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL) for
correct procedure.
2. Engine idle speed too low 2. Check Idle Air Control circuit.
3. Worn or incorrectly gapped spark
plugs
3. Replace or clean and re-gap spark
plugs. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING)
4. Faulty coil rail 4. Test and replace, if necessary.
CONTROL/COIL RAIL - REMOVAL)
5. Intake manifold vacuum leak 5. Inspect intake manifold gasket and
vacuum hoses. Replace if necessary.
(Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - DIAGNOSIS
AND TESTING).
ENGINE MISSES ON
ACCELERATION
1. Worn or incorrectly gapped spark
plugs
1. Replace spark plugs or clean and
set gap.
2. Spark plug cables defective or
crossed
2. Replace spark plug cables.
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil rail 5. Test and replace as necessary.
CONTROL/COIL RAIL - REMOVAL)
WJ ENGINE - 4. 0L 9 - 5
DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to 9
- ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) for
engine oil pressure test/specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic tappets/
lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats or
valve faces
9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE) for
correct procedure/engine oil
specifications
4. Excessive connecting rod bearing
clearance
Measure bearings for correct
clearance with plasti-gage. Repair as
necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
DIAGNOSIS AND TESTING)
9 - 6 ENGINE - 4. 0L WJ
4. Excessive main bearing clearance 4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing for
excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
7. Loose flywheel or torque converter 7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged
8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or cracked 9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated gaskets 1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded plug.
Replace cup style plug
EXCESSIVE OIL
CONSUMPTION OR SPARK
PLUGS OIL FOULED
1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
WJ ENGINE - 4. 0L 9 - 7
DIAGNOSIS AND TESTING CYLINDER
COMPRESSION PRESSURE
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se, the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/SPARK PLUG -
REMOVAL).
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sconnect the i gni ti on coi l .
(5) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(6) Record the compressi on pressure on the thi rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
(Refer to 9 - ENGI NE - SPECI FI CATI ONS) for the
correct engi ne compressi on pressures.
COMBUSTION PRESSURE LEAKAGE
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng)
Leaks between adjacent cyl i nders or i nto water
jacket
Any causes for combusti on/compressi on pressure
l oss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
Start and operate the engi ne unti l i t attai ns nor-
mal operati ng temperature, then turn OFF the
engi ne.
Remove the spark pl ugs.
Remove the oi l fi l l er cap.
Remove the ai r cl eaner.
Cal i brate the tester accordi ng to the manufactur-
ers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
Perform the test procedure on each cyl i nder accord-
i ng to the tester manufacturers i nstructi ons. Whi l e
testi ng, l i sten for pressuri zed ai r escapi ng through
the throttl e body, tai l pi pe or oi l fi l l er cap openi ng.
Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder CYLI NDER COMBUSTI ON
PRESSURE LEAKAGE DI AGNOSI S CHART .
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
9 - 8 ENGINE - 4. 0L WJ
DIAGNOSIS AND TESTING REAR SEAL AREA
LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs, oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri zed the crank-
case as outl i ned i n (Refer to 9 - ENGI NE/LUBRI CA-
TI ON - DI AGNOSI S AND TESTI NG)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed. Refer to the servi ce Di agnosi sMechani -
cal , under the Oi l Leak row, for components
i nspecti ons on possi bl e causes and correcti ons.
(7) After the oi l l eak root cause and appropri ate
correcti ve acti on have been i denti fi ed, (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT OI L
SEAL - REAR - REMOVAL), for proper repl acement
procedures.
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous pl aces where form-i n-pl ace
gaskets are used on the engi ne. Care must be taken
when appl yi ng form-i n-pl ace gaskets to assure
obtai ni ng the desi red resul ts. Do not use form-in-
place gasket material unless specified. Bead si ze,
conti nui ty, and l ocati on are of great i mportance. Too
thi n a bead can resul t i n l eakage whi l e too much can
resul t i n spi l l -over whi ch can break off and obstruct
fl ui d feed l i nes. A conti nuous bead of the proper
wi dth i s essenti al to obtai n a l eak-free gasket.
There are numerous types of form-i n-pl ace gasket
materi al s that are used i n the engi ne area. Mopar
Engi ne RTV GEN I I , Mopar ATF-RTV, and Mopar
Gasket Maker gasket materi al s, each have di fferent
properti es and can not be used i n pl ace of the other.
MOPAR ENGINE RTV GEN II
Mopar Engi ne RTV GEN I I i s used to seal com-
ponents exposed to engi ne oi l . Thi s materi al i s a spe-
ci al l y desi gned bl ack si l i cone rubber RTV that
retai ns adhesi on and seal i ng properti es when
exposed to engi ne oi l . Moi sture i n the ai r causes the
materi al to cure. Thi s materi al i s avai l abl e i n three
ounce tubes and has a shel f l i fe of one year. After one
year thi s materi al wi l l not properl y cure. Al ways
i nspect the package for the expi rati on date before
use.
MOPAR ATF RTV
Mopar ATF RTV i s a speci fi cal l y desi gned bl ack
si l i cone rubber RTV that retai ns adhesi on and seal -
i ng properti es to seal components exposed to auto-
mati c transmi ssi on fl ui d, engi ne cool ants, and
moi sture. Thi s materi al i s avai l abl e i n three ounce
tubes and has a shel f l i fe of one year. After one year
thi s materi al wi l l not properl y cure. Al ways i nspect
the package for the expi rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker i s an anaerobi c type gasket
materi al . The materi al cures i n the absence of ai r
when squeezed between two metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. The anaerobi c
materi al i s for use between two machi ned surfaces.
Do not use on fl exi bl e metal fl anges.
MOPAR GASKET SEALANT
Mopar Gasket Seal ant i s a sl ow dryi ng, perma-
nentl y soft seal er. Thi s materi al i s recommended for
seal i ng threaded fi tti ngs and gaskets agai nst l eakage
of oi l and cool ant. Can be used on threaded and
machi ned parts under al l temperatures. Thi s mate-
ri al i s used on engi nes wi th mul ti -l ayer steel (MLS)
cyl i nder head gaskets. Thi s materi al al so wi l l pre-
vent corrosi on. Mopar Gasket Seal ant i s avai l abl e i n
a 13 oz. aerosol can or 4oz./16 oz. can w/appl i cator.
WJ ENGINE - 4. 0L 9 - 9
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care but i ts easi er then usi ng precut gaskets.
Mopar Gasket Maker materi al shoul d be appl i ed
spari ngl y 1 mm (0.040 i n.) di ameter or l ess of seal ant
to one gasket surface. Be certai n the materi al sur-
rounds each mounti ng hol e. Excess materi al can eas-
i l y be wi ped off. Components shoul d be torqued i n
pl ace wi thi n 15 mi nutes. The use of a l ocati ng dowel
i s recommended duri ng assembl y to prevent smear-
i ng materi al off the l ocati on.
Mopar Engi ne RTV GEN I I or ATF RTV gasket
materi al shoul d be appl i ed i n a conti nuous bead
approxi matel y 3 mm (0.120 i n.) i n di ameter. Al l
mounti ng hol es must be ci rcl ed. For corner seal i ng, a
3.17 or 6.35 mm (1/8 or 1/4 i n.) drop i s pl aced i n the
center of the gasket contact area. Uncured seal ant
may be removed wi th a shop towel . Components
shoul d be torqued i n pl ace whi l e the seal ant i s sti l l
wet to the touch (wi thi n 10 mi nutes). The usage of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng materi al off the l ocati on.
Mopar Gasket Seal ant i n an aerosol can shoul d be
appl i ed usi ng a thi n, even coat sprayed compl etel y
over both surfaces to be joi ned, and both si des of a
gasket. Then proceed wi th assembl y. Materi al i n a
can w/appl i cator can be brushed on evenl y over the
seal i ng surfaces. Materi al i n an aerosol can shoul d be
used on engi nes wi th mul ti -l ayer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
STANDARD PROCEDURE HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY -
(2) Di sconnect the negati ve cabl e(s) from the bat-
tery.
(3) I nspect ai r cl eaner, i nducti on system, and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the spark pl ugs.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (cool ant, fuel ,
oi l , etc.).
(7) Be sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt a smal l amount of engi ne oi l i nto the
cyl i nders to l ubri cate the wal l s. Thi s wi l l prevent
damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 41 Nm (30 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l . (Refer to LUBRI CATI ON &
MAI NTENANCE - SPECI FI CATI ONS).
(15) Connect the negati ve cabl e(s) to the battery.
(16) Start the engi ne and check for any l eaks.
STANDARD PROCEDURE - CYLINDER BORE
HONING
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823, equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round, as wel l as removi ng l i ght scuff-
i ng, scori ng and scratches. Usual l y, a few strokes wi l l
cl ean up a bore and mai ntai n the requi red l i mi ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). about 20-60
strokes, dependi ng on the bore condi ti on, wi l l be suf-
fi ci ent to provi de a sati sfactory surface. Usi ng honi ng
oi l C-3501-3880, or a l i ght honi ng oi l , avai l abl e from
major oi l di stri butors.
9 - 10 ENGINE - 4. 0L WJ
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 40 to 60
for proper seati ng of ri ngs (Fi g. 3).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 40 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Usi ng a bl unt tool such as a dri ft and a hammer,
stri ke the bottom edge of the cup pl ug. Wi th the cup
pl ug rotated, grasp fi rml y wi th pl i ers or other sui t-
abl e tool and remove pl ug (Fi g. 4).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Li ghtl y coat i nsi de of cup pl ug hol e wi th Mopar
Stud and Beari ng Mount. Make certai n the new pl ug
i s cl eaned of al l oi l or grease. Usi ng proper dri ve
pl ug, dri ve pl ug i nto hol e so that the sharp edge of
the pl ug i s at l east 0.5 mm (0.020 i n.) i nsi de the
l ead-i n chamfer.
I t i s not necessary to wai t for curi ng of the seal ant.
The cool i ng system can be refi l l ed and the vehi cl e
pl aced i n servi ce i mmedi atel y.
REMOVAL
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
(3) Remove the radi ator drai n cock and radi ator
cap to drai n the cool ant. DO NOT waste usabl e cool -
ant. I f the sol uti on i s cl ean, drai n the cool ant i nto a
(4) Remove the upper radi ator hose and cool ant
recovery hose.
(5) Remove the l ower radi ator hose.
(6) Remove upper radi ator support retai ni ng bol ts
and remove radi ator support.
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
Fig. 4 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
WJ ENGINE - 4. 0L 9 - 11
(7) Remove the fan assembl y from the water pump
(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
REMOVAL).
(8) Remove the fan shroud.
(9) Di sconnect the transmi ssi on fl ui d cool er l i nes
(automati c transmi ssi on).
(10) Di scharge the A/C system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
(11) Remove the servi ce val ves and cap the com-
pressor ports.
(12) Remove the radi ator or radi ator/condenser (i f
equi pped wi th A/C).
(13) Di sconnect the heater hoses at the engi ne
thermostat housi ng and water pump.
(14) Di sconnect the accel erator cabl e, transmi ssi on
l i ne pressure cabl e and speed control cabl e (i f
equi pped) from the throttl e body.
(15) Remove cabl es from the bracket and secure
out of the way.
(16) Di sconnect the body ground at the engi ne.
(17) Di sconnect the fol l owi ng connectors and
secure thei r harness out of the way.
Power steeri ng pressure swi tch
Cool ant temperature sensor
Si x (6) fuel i njector connectors
I ntake ai r temperature sensor
Map sensor
Oxygen sensor
Camshaft posi ti on sensor
Generator connector and B+ termi nal wi re
(18) Di sconnect the coi l rai l el ectri cal connecti ons
and the oi l pressure swi tch connector.
(19) Perform the fuel pressure rel ease procedure
(20) Di sconnect the fuel suppl y l i ne at the i njector
rai l (Refer to 14 - FUEL SYSTEM/FUEL DELI VERY/
QUI CK CONNECT FI TTI NG - STANDARD PROCE-
DURE).
(21) Remove the fuel l i ne bracket from the i ntake
mani fol d.
(22) Remove the ai r cl eaner assembl y (Fi g. 5).
(23) Di sconnect the hoses from the fi tti ngs at the
steeri ng gear.
(24) Drai n the pump reservoi r.
(25) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn objects from enteri ng the sys-
tem.
(27) Di sconnect the wi res from the engi ne starter
motor sol enoi d.
(28) Remove the engi ne starter motor (Refer to 8 -
ELECTRI CAL/STARTI NG/STARTER MOTOR -
REMOVAL).
(29) Di sconnect the oxygen sensor from the
exhaust pi pe.
(30) Di sconnect the exhaust pi pe from the mani -
fol d.
(31) Remove the exhaust pi pe support.
(32) Remove the bendi ng brace (Refer to 9 -
ENGI NE/ENGI NE BLOCK/STRUCT SUPPORT -
REMOVAL).
(33) Remove the engi ne fl ywheel /converter housi ng
access cover.
(34) Mark the converter and dri ve pl ate l ocati on.
(35) Remove the converter-to-dri ve pl ate bol ts.
(36) Remove the upper engi ne fl ywheel /converter
housi ng bol ts and l oosen the bottom bol ts.
(37) Remove the engi ne mount cushi on-to-engi ne
compartment bracket bol ts.
(39) Attach a l i fti ng devi ce to the engi ne.
(40) Rai se the engi ne off the front supports.
(41) Pl ace a support or fl oor jack under the con-
verter (or engi ne fl ywheel ) housi ng.
(42) Remove the remai ni ng converter (or engi ne
fl ywheel ) housi ng bol ts.
(43) Li ft the engi ne out of the engi ne compart-
ment.
Fig. 5 Air Cleaner Assembly
2 - AIR CLEANER ASSEMBLY
9 - 12 ENGINE - 4. 0L WJ
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the engine
flywheel.
(1) Attach a l i fti ng devi ce to the engi ne and l ower
the engi ne i nto the engi ne compartment. For easi er
i nstal l ati on, i t may be necessary to remove the
engi ne mount bracket as an ai d i n al i gnment of the
engi ne to the transmi ssi on.
(2) Al i gn the transmi ssi on torque converter hous-
i ng wi th the engi ne.
(3) Loosel y i nstal l the converter housi ng l ower
bol ts and i nstal l the next hi gher bol t and nut on each
si de.
(4) Ti ghten al l 4 bol ts fi nger ti ght.
(5) I nstal l the engi ne mount brackets (i f removed).
(6) Lower the engi ne and engi ne mount brackets
onto the engi ne compartment cushi ons. I nstal l the
bol ts and fi nger ti ghten the nuts.
(7) Remove the engi ne l i fti ng devi ce.
(9) I nstal l the remai ni ng engi ne fl ywheel /converter
housi ng bol ts. Ti ghten al l bol ts to 38 Nm (28 ft. l bs.)
torque.
(10) I nstal l the converter-to-dri ve pl ate bol ts.
(11) Ensure the i nstal l ati on reference marks are
al i gned.
(12) I nstal l the engi ne fl ywheel /converter housi ng
access cover.
(13) I nstal l the exhaust pi pe support and ti ghten
the screw.
(14) I nstal l the engi ne bendi ng brace (Refer to 9 -
ENGI NE/ENGI NE BLOCK/STRUCT SUPPORT -
I NSTALLATI ON).
(15) Ti ghten the engi ne mount-to-bracket bol ts.
(16) Connect the vehi cl e speed sensor wi re connec-
ti ons and ti ghten the screws.
(17) Connect the exhaust pi pe to the mani fol d.
(18) I nstal l the engi ne starter motor (Refer to 8 -
I NSTALLATI ON).
(19) Connect the wi res to the engi ne starter motor
sol enoi d.
(21) Connect al l the vacuum hoses and wi re con-
nectors i denti fi ed duri ng engi ne removal .
(22) Remove protecti ve caps from the power steer-
i ng hoses.
(23) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 Nm (38 ft. l bs.)
torque.
(24) Fi l l the pump reservoi r wi th fl ui d.
(25) I nspect the fuel suppl y l i ne o-ri ng(s) and
repl ace i f necessary. Connect fuel suppl y l i ne to i njec-
ti or rai l and veri fy connecti on by pul l i ng outward on
the l i ne.
(26) I nstal l the fuel l i ne bracket to the i ntake
mani fol d.
(27) Connect the coi l rai l el ectri cal connectors and
oi l pressure swi tch connector.
(28) Connect the fol l owi ng el ectri cal connectors:
Power steeri ng pressure swi tch
Cool ant temperature sensor
Si x (6) fuel i njector connectors
I ntake ai r temperature sensor
Map sensor
Oxygen sensor
Camshaft posi ti on sensor
Generator connector and B+ termi nal wi re
(29) Connect al l previ ousl y removed vacuum hoses.
(30) Connect the body ground strap.
(31) I nstal l the throttl e, transmi ssi on l i ne pres-
sure, and speed control cabl es to thei r mounti ng
bracket and connect them to the throttl e body.
(32) Connect the heater hoses at the engi ne ther-
mostat housi ng and water pump.
(33) I nstal l the fan assembl y (Refer to 7 - COOL-
I NG/ENGI NE/RADI ATOR FAN - I NSTALLATI ON).
(34) Pl ace the fan shroud i n posi ti on over the fan.
(35) I nstal l the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - I NSTALLATI ON).
(36) Connect the servi ce val ves to the A/C com-
pressor ports, i f equi pped wi th A/C.
(37) Charge the ai r condi ti oner system (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
(38) Connect the radi ator hoses and automati c
transmi ssi on fl ui d cool er pi pes, i f equi pped.
(39) I nstal l the fan shroud to the radi ator or radi -
ator/condenser (i f equi pped wi th A/C).
(40) I nstal l upper radi ator support.
(41) Connect the upper radi ator hose and ti ghten
the cl amp.
(42) Connect the l ower radi ator hose and ti ghten
the cl amp.
(43) Fi l l crankcase wi th engi ne oi l . (Refer to
LUBRI CATI ON & MAI NTENANCE/FLUI D CAPACI -
TI ES - SPECI FI CATI ONS) for correct capaci ti es.
(44) Fi l l the cool i ng system wi th reusabl e cool ant
or new cool ant (Refer to 7 - COOLI NG - STANDARD
PROCEDURE).
(45) Al i gn the hood to the scri be marks. I nstal l the
hood.
(46) I nstal l the ai r cl eaner assembl y.
(47) I nstal l the battery and connect the battery
cabl e.
WJ ENGINE - 4. 0L 9 - 13
(48) Start the engi ne, i nspect for l eaks and correct
the fl ui d l evel s, as necessary.
SPECIFICATIONS
ENGINE - 4. 0L
Engine Type In-line 6 Cylinder
Bore and Stroke 98.4 x 86.69 mm
(3.88 x 3.413 in.)
Displacement 4.0L (242 cu. in.)
Compression Ratio 8.8:1
Firing Order 153624
Lubrication Pressure FeedFull Flow
Filtration
Cooling System Liquid CooledForced
Circulation
Cylinder Block Cast Iron
Crankshaft Cast Nodular Iron
Cylinder Head Cast Iron
Camshaft Cast Iron
Pistons Aluminum Alloy
Combustion Chamber Dual-Quench
Connecting Rods Cast Malleable Iron
CAMSHAFT
Hydraulic Tappet
Clearance
Zero Lash
Bearing Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Bearing Journal Diameter
No. 1 51.54 to 51.56 mm
(2.029 to 2.030 in.)
No. 2 51.28 to 51.31 mm
(2.019 to 2.020 in.)
No. 3 51.03 to 51.05 mm
(2.009 to 2.010 in.)
No. 4 50.78 to 50.80 mm
(1.999 to 2.000 in.)
Base Circle Runout
(MAX)
0.03 mm
(0.001 in.)
Valve Lift
Intake 10.350 mm (0.4075 in.)
Exhaust 10.528 mm (0.4145 in.)
Valve Timing
Intake
Opens 12.4BTDC
Closes 60.9ABDC
Exhaust
Opens 49.8 BBDC
Closes 29.2ATDC
Valve Overlap 41.6
Intake Duration 253.3
Exhaust Duration 259.
CRANKSHAFT
End Play 0.038 to 0.165 mm
(0.0015 to 0.0065 in.)
Main Bearing Journal
Diameter
No. 1-6 63.489 to 63.502 mm
(2.4996 to 2.5001 in.)
No. 7 63.449 to 63.487 mm
(2.4980 to 2.4995 in.)
9 - 14 ENGINE - 4. 0L WJ
Main Bearing Journal
Width
No. 1 27.58 to 27.89 mm
(1.086 to 1.098 in.)
No. 3 32.28 to 32.33 mm
(1.271 to 1.273 in.)
No. 2-4-5-6-7 30.02 to 30.18 mm
(1.182 to 1.188 in.)
Main Bearing Clearance 0.03 to 0.06 mm
(0.001 to 0.0025 in.)
Preferred 0.051 mm (0.002 in.)
Connecting Rod Journal
Diameter 53.17 to 53.23 mm
(2.0934 to 2.0955 in.)
Connecting Rod Journal
Width
27.18 to 27.33 mm
(1.070 to 1.076 in.)
Out-of-Round (MAX) 0.013 mm (0.0005 in.)
Taper (MAX) 0.013 mm (0.0005 in.)
CYLINDER BLOCK
Deck Height 240.03 to 240.18 mm
(9.450 to 9.456 in.)
Deck Clearance (Below
Block)
0.546 mm (0.0215 in.)
Cylinder Bore Diameter
Standard 98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
Taper 0.025 mm (0.001 in.)
Out-ofRound 0.025 mm (0.001 in.)
Tappet Bore Diameter 23.000 to 23.025 mm
(0.9055 to 0.9065 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness Max. 0.20 mm max. for total
length
(0.008 in. max. for total
length)
Main Bearing Bore
Diameter
68.3514 to 68.3768 mm
(2.691 to 2.692 in.)
CONNECTING ROD
Total Weight (Less
Bearing)
663 to 671 grams
(23.39 to 23.67 oz.)
Length (Center-to-Center) 155.52 to 155.62 mm
(6.123 to 6.127 in.)
Piston Pin Bore Diameter 23.59 to 23.62 mm
(0.9288 to 0.9298 in.)
Bore (Less Bearings) 56.08 to 56.09 mm
(2.2080 to 2.2085 in.)
Bearing Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Preferred 0.044 to 0.050 mm
(0.0015 to 0.0020 in.)
Side Clearance 0.25 to 0.48 mm
(0.010 to 0.019 in.)
Twist (Max.) 0.002 mm per mm
(0.002 in. per inch)
Bend (Max.) 0.002 mm per mm
(0.002 in. per inch.)
CYLINDER COMPRESSION PRESSURE
Pressure Range 827 to 1,034 kPa
(120 to 150 psi)
Max. Variation Between
Cylinders 206 kPa (30 psi)
CYLINDER HEAD
Combustion Chamber 55.22 to 58.22 cc
(3.37 to 3.55 cu. in.)
Valve Guide I.D.
(Integral)
7.95 to 7.97 mm
(0.313 to 0.314 in.)
WJ ENGINE - 4. 0L 9 - 15
Valve Stem-to-Guide 0.025 to 0.076 mm
Clearance (0.001 to 0.003 in.)
Valve Seat Angle
Intake 44.5
Exhaust 44.5
Valve Seat Width 1.02 to 1.52 mm
(0.040 to 0.060 in.)
Valve Seat Runout 0.064 mm (0.0025 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness Max. 0.20 mm - max. for total
length
(0.008 in. max. for total
length)
ROCKER ARMS, PUSH RODS & TAPPETS
Rocker Arm Ratio 1.6:1
Push Rod Length 244.856 to 245.364 mm
(Pink) (9.640 to 9.660 in.)
Push Rod Diameter 7.92 to 8.00 mm
(0.312 to 0.315 in.)
Hydraulic Tappet
Diameter
22.962 to 22.974 mm
(0.904 to 0.9045 in.)
Tappet-to-Bore Clearance 0.025 to 0.063 mm
(0.001 to 0.0025 in.)
VALVES
Valve Length (Overall)
Intake 122.479 to 122.860 mm
(4.822 to 4.837 in.)
Exhaust 122.860 to 123.241 mm
(4.837 to 4.852 in.)
Valve Stem Diameter 7.899 to 7.925 mm
(0.311 to 0.312 in.)
Stem-to-Guide Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Valve Head Diameter
Intake 48.387 to 48.641 mm
(1.905 to 1.915 in.)
Exhaust 37.973 to 38.227 mm
(1.495 to 1.505 in.)
Valve Face Angle
Intake 46.5
Exhaust 46.5
Tip Refinishing (Max.
Allowable)
0.25 mm (0.010 in.)
VALVE SPRINGS
Free Length (Approx.) 47.65 mm (1.876 in.)
Spring Load
Valve Closed 316 to 351 N @ 41.656
mm
(71 to 79 lbf. @ 1.64 in.)
Valve Open 898.6 to 969.7 N @
30.89 mm
(202 to 218 lbf @ 1.216
in.)
Inside Diameter 21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height 41.656 mm (1.64 in.)
PISTONS
Weight (Less Pin) 417 to 429 grams
(14.7 to 15.1 oz.)
Piston Pin Bore
(Centerline
40.61 to 40.72 mm
to Piston Top) (1.599 to 1.603 in.)
Piston-to-Bore Clearance 0.018 to 0.038 mm
(0.0008 to 0.0015 in.)
Ring Gap Clearance
Top Compression Ring 0.229 to 0.610 mm
(0.0090 to 0.0240 in.)
2nd Compression Ring 0.483 to 0.965 mm
(0.0190 to 0.0380 in.)
Oil Control Steel Rails 0.254 to 1.500 mm
(0.010 to 0.060 in.)
9 - 16 ENGINE - 4. 0L WJ
Ring Side Clearance
Compression Rings 0.042 to 0.084 mm
(0.0017 to 0.0033 in.)
Oil Control Rings 0.06 to 0.21 mm
(0.0024 to 0.0083 in.)
Piston Ring Groove
Height
Compression Rings 1.530 to 1.555 mm
(0.0602 to 0.0612 in.)
Oil Control Ring 4.035 to 4.060 mm
(0.1589 to 0.1598 in.)
Piston Ring Groove
Diameter
No.1 Compression Ring 88.39 to 88.65 mm
(3.48 to 3.49 in.)
No.2 Compression Ring 87.63 to 87.88 mm
(3.45 to 3.46 in.)
Oil Control Ring 89.66 to 89.92 mm
(3.53 to 3.54 in.)
Piston Pin Bore Diameter 23.650 to 23.658 mm
(0.9312 to 0.9315 in.)
Piston Pin Diameter 23.637 to 23.640 mm
(0.9306 to 0.9307 in.)
Piston-to-Pin Clearance 0.0102 to 0.0208 mm
(0.0005 to 0.0009 in.)
Piston-to-Pin Connecting
Rod (Press Fit) 8.9 kN (2000 lbf.)
OIL PUMP
Gear-to-Body Clearance 0.051 to 0.102 mm
(Radial) (0.002 to 0.004 in.)
Gear-to-Body Clearance
(Radial) Preferred 0.051 mm (0.002 in.)
Gear End Clearance 0.051 to 0.152 mm
Plastigage (0.002 to 0.006 in.)
Gear End Clearance
Plastigage (Preferred) 0.051 mm (0.002 in.)
Gear End Clearance 0.1016 to 0.2032 mm
Feeler Gauge (0.004 to 0.008 in.)
Gear End Clearance
Feeler Gauge (Preferred) 0.1778 mm (0.007 in.)
Oil Pressure
At Idle Speed 89.6 kPa (13 psi)
At 1600 rpm & Higher 255 to 517 kPa
(37 to 75 psi)
Oil Pressure Relief 517 kPa (75 psi)
TORQUE - 4. 0L ENGINE
Lbs. Lbs.
A/C CompressorBolts 28 250
Block HeaterNut 2 16
Camshaft SprocketBolt 68 50
Camshaft Thrust Plate to
Cylinder BlockScrews 24 18
Clutch Cover to FlywheelBolts 54 40
Coil Bracket to BlockBolts 22 192
Connecting RodNuts 45 33
Cylinder BlockDrain Plugs 34 25
Cylinder HeadBolts 135 100
Cylinder Head CoverBolts 10 85
Distributor ClampBolts 23 204
Engine MountsFront
Support Bracket Bolts 61 45
Support Cushion Bolts/Nuts 41 30
Support Cushion Bracket Bolts 54 40
Support Cushion Bracket Stud
Nuts
41 30
Support Cushion Thru-Bolt 65 48
Engine MountsRear
Crossmember to Sill Bolts
(Automatic) 41 30
Insulator Stud AssemblyNut 41 30
Support Cushion/
Crossmember
Nuts 22 192
Support Cushion/BracketNuts
(Manual) 75 55
WJ ENGINE - 4. 0L 9 - 17
Lbs. Lbs.
Transmission Support Bracket
Bolt (Manual) 46 34
Transmission Support Bracket/
CushionBolt (4WD Auto) 75 55
Transmission Support Adaptor
BracketBolts (2WD Auto) 75 55
Exhaust Manifold/PipeNuts 27 20
Intake/Exhaust Manifold
Fasteners #1-5 33 24
Fasteners #6 and 7 14 126
Fasteners #8-11 33 24
Flywheel to Converter
HousingBolts
38 28
Flywheel to CrankshaftBolts 143 105
Front Cover to BlockBolts
1/4-20 7 60
5/16-18 22 192
Fuel RailBolts/Stud 12 108
GeneratorBolts 57 42
Generator Bracket to Engine
Bolts
47 35
Idler Pulley to Cylinder
HeadBolt
47 35
Main Bearing CapBolts 108 80
Oil Filter 18 156
Oil Filter Connector to
Adaptor 47 35
Block 68 50
Adaptor Bolts 102 50
Oil GalleyPlug 41 30
Oil PanBolts
1/4-20 9.5 84
5/16-18 15 132
Oil PanDrain Plug 34 25
Oil Pump
Mounting Bolts 23 204
Cover Bolts 8 70
Rocker Arm Assembly to
Cylinder
HeadCapscrews 30 21
Spark Plugs 37 27
Lbs. Lbs.
Starter MotorMounting Bolts 45 33
Thermostat HousingBolts 18 156
Throttle BodyBolts 10 90
Vibration DamperBolt 108 80
Water Pump to BlockBolts 23 17
AIR CLEANER ELEMENT
REMOVAL - 4. 0L
(1) Unl atch four cl i ps retai ni ng ai r cl eaner cover to
ai r cl eaner housi ng (Fi g. 6).
Fig. 6 Air Cleaner Assembly 4.0L Engine
1 - RESONATOR BOLTS
2 - CLAMPS
3 - AIR DUCT
4 - AIR CLEANER COVER
5 - CLIPS
6 - HOUSING
7 - HOUSING BOLTS (3)
8 - LOWER HOUSING NUTS (3)
9 - RESONATOR
9 - 18 ENGINE - 4. 0L WJ
(2) Li ft cover up and posi ti on to the si de.
(3) Remove ai r cl eaner el ement.
(1) Cl ean i nsi de of ai r cl eaner housi ng before
i nstal l i ng new el ement.
(2) I nstal l ai r cl eaner el ement i nto housi ng.
(3) Latch cl i ps and cl amp cover down to secure. Be
sure ai r cl eaner cover i s properl y seated to ai r
cl eaner housi ng.
AIR CLEANER HOUSING
REMOVAL - 4. 0L
(1) Di sconnect ai r cl eaner cover-to-ai r duct cl amp
(Fi g. 6).
(2) Di sconnect ai r duct at housi ng.
(3) Each of the 3 air cleaner housing mount-
ing bolts is attached with 2 nuts (an upper nut
and lower nut). DO NOT REMOVE BOLTS. To
prevent stripping bolts, only remove lower
nuts. The lower housing nuts are located under
left front inner fender (Fig. 6).
(a) To gai n access to l ower nuts, rai se vehi cl e.
(b) Remove cl i ps retai ni ng rubber i nner fender
shi el d.
(c) Pry back shi el d enough to gai n access to
l ower nuts.
(d) Remove 3 nuts.
(e) Remove ai r cl eaner assembl y from vehi cl e.
(4) I f resonator i s to be removed, di sconnect
breather tube at resonator, di sconnect ai r duct cl amp
at resonator (Fi g. 6)and remove 1 resonator mount-
i ng bol t. Remove resonator from throttl e body by
l ooseni ng cl amp (Fi g. 7).
(1) Posi ti on ai r cl eaner assembl y to body and
i nstal l 3 nuts. Ti ghten nuts to 10 Nm (93 i n. l bs.)
torque. To prevent excessive vibration transmit-
ted through housing, the nuts must be properly
torqued. Do not overtighten nuts.
(2) I f resonator was removed: I nstal l resonator and
bol ts. Ti ghten bol ts to 4 Nm (35 i n. l bs.) torque.
Ti ghten cl amp at throttl e body to 4 Nm (35 i n. l bs.)
torque.
(3) Posi ti on fender l i ner and i nstal l cl i ps.
(4) Connect ai r duct at housi ng (Fi g. 6).
(5) Ti ghten ai r duct cl amp.
CYLINDER HEAD
DESCRIPTION
The cyl i nder head i s made of cast i ron contai ni ng
twel ve val ves made of chrome pl ated heat resi stant
steel , val ve stem seal s, spri ngs, retai ners and keep-
ers. The cyl i nder head and val ve seats can be resur-
faced for servi ce purposes.
The val ve gui des are i ntegral to the cyl i nder head,
They are not repl aceabl e. However, they are servi ce-
abl e.
The cyl i nder head uses dual quench-type desi gn
combusti on chambers whi ch cause turbul ence i n the
cyl i nders al l owi ng faster burni ng of the ai r/fuel mi x-
ture, resul ti ng i n better fuel economy (Fi g. 8).
REMOVAL
NOTE: This procedure can be done with the engine
in or out of the vehicle.
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
Fig. 7 RESONATOR CLAMP - 4.0L
1 - RESONATOR
2 - AIR DUCT
3 - CLAMP
WJ ENGINE - 4. 0L 9 - 19
AIR CLEANER ELEMENT (Continued)
(2) Drai n the cool ant (Refer to 7 - COOLI NG -
STANDARD PROCEDURE) and di sconnect the hoses
at the engi ne thermostat housi ng and the water
pump i nl et. DO NOT waste reusabl e cool ant. I f the
sol uti on i s cl ean and i s bei ng drai ned onl y to servi ce
the engi ne or cool i ng system, drai n the cool ant i nto a
(3) Remove the ai r cl eaner assembl y (Refer to 9 -
(4) Remove the cyl i nder head cover (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL).
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms (Refer to 9 - ENGI NE/CYLI N-
DER HEAD/ROCKER ARM / ADJUSTER ASSY -
REMOVAL).
(6) Remove the push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order as removed.
(7) Remove the accessory dri ve bel t (Refer to 7 -
REMOVAL).
(8) Remove the A/C compressor mounti ng bol ts
and secure the compressor to the si de.
(9) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and water pump. Set the
pump and bracket asi de. DO NOT di sconnect the
hoses.
(10) Perform the Fuel System Pressure Rel ease
procedure. (Refer to 14 - FUEL SYSTEM/FUEL
DELI VERY - STANDARD PROCEDURE).
(11) Di sconnect the fuel suppl y l i ne at the fuel rai l .
(12) Remove the i ntake and exhaust mani fol ds
from the engi ne cyl i nder head (Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - REMOVAL).
(13) Remove the coi l rai l (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/COI L RAI L - REMOV-
AL).
(14) Remove spark pl ugs (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/SPARK PLUG - REMOV-
AL).
(15) Di sconnect the temperature sendi ng uni t wi re
connector.
(16) Remove the engi ne cyl i nder head bol ts. Bol t
No.14 cannot be removed unti l the head i s moved for-
ward (Fi g. 9). Pul l bol t No.14 out as far as i t wi l l go
and then suspend the bol t i n thi s posi ti on (tape
around the bol t).
(17) Remove the engi ne cyl i nder head and gasket
(Fi g. 9).
(18) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i snt known i f they were used before, di scard the
bol ts.
(19) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
NOTE: If the valves, springs, or seals are to be
inspected/replaced at this time, (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE) for
proper inspection procedures.
Fig. 8 Cylinder Head 4.0L Engine
1 - CYLINDER HEAD BOLTS
2 - CYLINDER HEAD GASKET
3 - CYLINDER HEAD
Fig. 9 Engine Cylinder
1 - CYLINDER HEAD BOLTS
2 - CYLINDER HEAD GASKET
3 - CYLINDER HEAD
9 - 20 ENGINE - 4. 0L WJ
CYLINDER HEAD (Continued)
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
engi ne exhaust mani fol d and engi ne cyl i nder head
mati ng surfaces. Remove al l gasket materi al and car-
bon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) Posi ti on the engi ne cyl i nder head gasket (wi th
the numbers faci ng up) usi ng the al i gnment dowel s
i n the cyl i nder bl ock, to posi ti on the gasket.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(3) Wi th bol t No.14 hel d i n pl ace (tape around
bol t), i nstal l the engi ne cyl i nder head over the same
dowel s used to l ocate the gasket. Remove the tape
from bol t No.14.
(4) Coat the threads of stud bol t No.11 wi th Loc-
ti te 592 seal ant, or equi val ent.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
10).
CAUTION: During the final tightening sequence,
bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.
(a) Ti ghten al l bol ts i n sequence (1 through 14)
to 30 Nm (22 ft. l bs.) torque.
(b) Ti ghten al l bol ts i n sequence (1 through 14)
(c) Check al l bol ts to veri fy they are set to 61
(d) Ti ghten bol ts i n sequence:
Bol ts 1 through 10 to 149 Nm (110 ft. l bs.)
torque.
Bol t 11 to 135 Nm (100 ft. l bs.) torque.
Bol ts 12 through 14 to 149 Nm (110 ft. l bs.)
torque.
CYLINDER HEAD BOLTS
POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
8,9 1/2 in.-13 BOLT WITH DOWEL
POINT
2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16 in.-14 STUD
END
All bolts are 12 point drives for rocker cover clearance
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(6) I nstal l the spark pl ugs (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/SPARK PLUG - I NSTAL-
LATI ON).
(7) Connect the temperature sendi ng uni t wi re
connector.
(8) I nstal l the i gni ti on coi l rai l (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/COI L RAI L -
I NSTALLATI ON).
(9) I nstal l the i ntake and exhaust mani fol ds (Refer
to 9 - ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -
I NSTALLATI ON).
(10) I nstal l the fuel l i ne.
(11) Attach the power steeri ng pump and bracket.
Fig. 10 Engine Cylinder Head Bolt Tightening
Sequence
WJ ENGINE - 4. 0L 9 - 21
(12) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed (Refer to 9 -
ENGI NE/CYLI NDER HEAD/ROCKER ARM /
ADJUSTER ASSY - I NSTALLATI ON).
(13) I nstal l the engi ne cyl i nder head cover (Refer
to 9 - ENGI NE/CYLI NDER HEAD/CYLI NDER
HEAD COVER(S) - I NSTALLATI ON).
(14) Attach the ai r condi ti oner compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
Ti ghten the bol ts to 40 Nm (30 ft. l bs.) torque.
(15) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.)
torque.
CAUTION: The serpentine drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(16) I nstal l the serpenti ne dri ve bel t. (Refer to 7 -
I NSTALLATI ON).
(17) I nstal l the ai r cl eaner and ducti ng.
(18) Connect the hoses to the engi ne thermostat
housi ng and fi l l the cool i ng system to the speci fi ed
l evel (Refer to 7 - COOLI NG - STANDARD PROCE-
DURE).
(19) The automati c transmi ssi on throttl e l i nkage
and cabl e must be adjusted after compl eti ng the
engi ne cyl i nder head i nstal l ati on (Refer to 21 -
TRANSMI SSI ON/TRANSAXLE/AUTOMATI C - AW4/
THROTTLE VALVE CABLE - ADJUSTMENTS).
(20) I nstal l the temperature sendi ng uni t and con-
nect the wi re connector.
(21) I f equi pped wi th ai r condi ti oni ng, i nstal l A/C
compressor (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/A/C COMPRESSOR -
I NSTALLATI ON) and charge A/C system (Refer to 24
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(23) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the engi ne thermostat opens. Add cool ant, i f
requi red.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cyl i nder head cover (Fi g. 11) i s made of
stamped steel and i ncorporates the Crankcase Venti -
l ati on (CCV) Hoses and the oi l fi l l openi ng.
REMOVAL
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
(1) Di sconnect negati ve cabl e from battery.
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover.
(3) Di sconnect the fresh ai r i nl et hose from the
engi ne cyl i nder head cover.
(4) Di sconnect the accel erator, transmi ssi on, and
speed (i f equi pped) control cabl es from the throttl e
body (Fi g. 12).
(5) Remove the three bol ts that fasten the control
cabl e bracket to the i ntake mani fol d.
(6) Remove control cabl es from cyl i nder head cover
cl i p.
(7) Posi ti on control cabl es and bracket away from
cyl i nder head cover secure wi th ti e straps.
(8) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(9) Remove the engi ne cyl i nder head cover and
gasket.
Fig. 11 Cylinder Head Cover
9 - 22 ENGINE - 4. 0L WJ
CLEANING
Remove any ori gi nal seal er from the cover seal i ng
surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
Remove al l resi due from the seal i ng surface usi ng
a cl ean, dry cl oth.
INSPECTION
I nspect the engi ne cyl i nder head cover for cracks.
Repl ace the cover, i f cracked.
The ori gi nal dark grey gasket materi al shoul d
NOT be removed. I f secti ons of the gasket materi al
are mi ssi ng or are compressed, repl ace the engi ne
cyl i nder head cover. However, secti ons wi th mi nor
damage such as smal l cracks, cuts or chi ps may be
repai red wi th a hand hel d appl i cator. The new mate-
ri al must be smoothed over to mai ntai n gasket
hei ght. Al l ow the gasket materi al to cure pri or to
engi ne cyl i nder head cover i nstal l ati on.
INSTALLATION
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
(1) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet and oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(2) I nstal l cyl i nder head cover and gasket (Fi g. 13).
Ti ghten the mounti ng bol ts to 10 Nm (85 i n. l bs.)
torque.
(3) Connect the CCV hoses.
(4) I nstal l control cabl es and bracket on i ntake
mani fol d and ti ghten bol ts to 8.7 Nm (77 i n. l bs.)
torque.
(5) Connect control cabl es to throttl e body l i nkage.
(6) Snap control cabl es i nto cyl i nder head cover
cl i p.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Al l
val ves use three bead l ocks to promote val ve rotati on
(Fi g. 14).
STANDARD PROCEDURE - VALVE SERVICE
VALVE REFACING
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 15). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
gui des and head.
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
Fig. 12 Engine Cylinder Head Cover
1 - TRANS CONTROL CABLE
3 - CONTROL CABLE BRACKET
4 - CYLINDER HEAD COVER
Fig. 13 Cylinder Head Cover Gasket Locator Pins at
#8 & #9
WJ ENGINE - 4. 0L 9 - 23
CYLINDER HEAD COVER(S) (Continued)
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 16).
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
PREFERRED METHOD
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 17).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
ALTERNATIVE METHOD
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 18).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
Fig. 14 VALVE AND KEEPER CONFIGURATION 4.0L
1 - VALVE LOCKS (3BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 15 Valve Facing
1 - VALVE MARGIN
2 - NO MARGIN
Fig. 16 Measurement of Valve Seat Runout
1 - DIAL INDICATOR
9 - 24 ENGINE - 4. 0L WJ
INTAKE/EXHAUST VALVES & SEATS (Continued)
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
REMOVAL
NOTE: This procedure is done with the engine cyl-
inder head removed from the block.
(1) Remove the engi ne cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - REMOVAL) from the
cyl i nder bl ock.
(2) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s (Fi g. 19).
(4) Use a smooth stone or a jewel ers fi l e to remove
any burrs on the top of the val ve stem, especi al l y
around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
the same order as removed.
INSTALLATION
NOTE: This procedure is done with the engine cyl-
inder head removed from the block.
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems (Fi g. 20). I f the 0.381 mm (0.015
i nch) oversi ze val ve stems are used, oversi ze oi l seal s
are requi red.
Fig. 17 Measurement of Valve Guide Bore Diameter
1 - GAUGE
2 - 9.525 MM (3/8 INCH)
3 - VALVE STEM GUIDE
4 - CYLINDER HEAD
Fig. 18 Measurement of Lateral Movement Of Valve
Stem
1 - DIAL INDICATOR
Fig. 19 Valve and Valve Components
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
WJ ENGINE - 4. 0L 9 - 25
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
(8) I nstal l the engi ne cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON).
ROCKER ARM / ADJ USTER
ASSEMBLY
DESCRIPTION
The rocker arms are made of stamped steel and
have a operati onal rati o of 1.6:1 (Fi g. 21).
OPERATION
When the push rods are forced upward by the cam-
shaft l obes the push rod presses upward on the
rocker arms, the rocker arms pi vot, forci ng down-
ward pressure on the val ves forci ng the val ves to
move downward and off from thei r seats.
REMOVAL
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 22). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 22). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 21 Rocker ArmsTypical
1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
9 - 26 ENGINE - 4. 0L WJ
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or
equi val ent, l ubri cate the area of the rocker arm that
the pi vot contacts. I nstal l rocker arms, pi vots and
bri dge above each cyl i nder i n thei r ori gi nal l y posi ti on
(Fi g. 23).
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 Nm (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover (Refer to
9 - ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON).
VALVE STEM SEALS
DESCRIPTION
The val ve stem seal s (Fi g. 24) are made of rubber
and i ncorporate a garter spri ng to mai ntai n consi s-
tent l ubri cati on control .
Fig. 22 Rocker Arm
1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
Fig. 23 Rocker Arm
1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
WJ ENGINE - 4. 0L 9 - 27
ROCKER ARM / ADJ USTER ASSEMBLY (Continued)
VALVE SPRINGS
DESCRIPTION
The val ve spri ngs (Fi g. 25) are made of hi gh
strength si l i con chrome spri ng steel . The spri ngs are
common for both i ntake and exhaust val ves.
STANDARD PROCEDURE - VALVE SPRING
TENSION TEST
gui des and head.
Use a uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 26).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
REMOVAL
cylinder head installed on the block.
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(1) Remove the engi ne cyl i nder head cover (Refer
HEAD COVER(S) - REMOVAL).
Fig. 24 Valve
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 25 VALVE AND KEEPER CONFIGURATION 4.0L
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 26 Valve Spring Tester
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
9 - 28 ENGINE - 4. 0L WJ
VALVE STEM SEALS (Continued)
(2) Remove cap screws, bri dge and pi vot assem-
bl i es and rocker arms (Refer to 9 - ENGI NE/CYLI N-
DER HEAD/ROCKER ARM / ADJUSTER ASSY -
REMOVAL) for access to each val ve spri ng to be
removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 27).
(8) Remove val ve spri ng and retai ner (Fi g. 27).
(9) Remove val ve stem oi l seal s (Fi g. 27). Note the
val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(i ntake/bl ack i n col or) or EXH (exhaust/brown i n
col or). DO NOT mi x the seal s.
INSTALLATION
cylinder head installed on the block.
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner (Fi g. 28).
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge
(Refer to 9 - ENGI NE/CYLI NDER HEAD/ROCKER
ARM /ADJUSTER ASSY - I NSTALLATI ON) at thei r
ori gi nal l ocati on.
(8) I nstal l the engi ne cyl i nder head cover (Refer to
9 - ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
WJ ENGINE - 4. 0L 9 - 29
VALVE SPRINGS (Continued)
ENGINE BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 Nm (25 ft. l bs.) torque.
INSPECTION
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter (Fi g. 29). To
correctl y sel ect the proper si ze pi ston, a cyl i nder bore
gauge, capabl e of readi ng i n 0.003 mm (.0001 i n.)
I NCREMENTS i s requi red. I f a bore gauge i s not
avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
must be bored and then honed to accept an oversi ze
pi ston. A sl i ght amount of taper al ways exi sts i n the
cyl i nder bore after the engi ne has been i n use for a
peri od of ti me.
CAMSHAFT & BEARINGS
DESCRIPTION
The camshaft i s made of gray cast i ron wi th twel ve
machi ned l obes and four beari ng journal s (Fi g. 30).
When the camshaft rotates the l obes actuate the tap-
pets and push rods, forci ng upward on the rocker
arms whi ch appl i es downward force on the val ves.
Fig. 28 Valve and Valve
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 29 Cylinder Bore Measurement
9 - 30 ENGINE - 4. 0L WJ
VALVE SPRINGS (Continued)
REMOVAL
REMOVAL - CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated. Camshaft
end pl ay i s mai ntai ned by the thrust pl ate.
(1) Remove the camshaft (Refer to 9 - ENGI NE/
ENGI NE BLOCK/CAMSHAFT & BEARI NGS (I N
BLOCK) - REMOVAL).
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Usi ng Speci al tool 8544 Camshaft Bushi ng
Remover I nstal l er, remove the camshaft beari ngs.
REMOVAL - CAMSHAFT
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(2) Drai n the cool i ng system (Refer to 7 - COOL-
(3) Remove the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - REMOVAL) and condenser
PLUMBI NG/A/C CONDENSER - REMOVAL), i f
equi pped wi th A/C.
(4) Remove the engi ne cyl i nder head cover (Refer
(5) Remove the rocker arms, bri dges and pi vots
(Refer to 9 - ENGI NE/CYLI NDER HEAD/ROCKER
ARM /ADJUSTER ASSY - REMOVAL).
(6) Remove the push rods.
(7) Remove the engi ne cyl i nder head and gasket
(Refer to 9 - ENGI NE/CYLI NDER HEAD - REMOV-
AL).
(8) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder bl ock (Refer to 9 - ENGI NE/ENGI NE
BLOCK/HYDRAULI C LI FTERS (CAM I N BLOCK) -
REMOVAL).
(9) Remove the vi brati on damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
REMOVAL).
(10) Remove the ti mi ng case cover (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
(11) Rotate the crankshaft unti l the crankshaft
sprocket ti mi ng mark i s al i gned on centerl i ne wi th
the camshaft sprocket ti mi ng mark (Fi g. 32).
(12) Remove the ti mi ng chai n and sprockets (Refer
to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT/
CHAI N AND SPROCKETS - REMOVAL).
(13) Remove the front bumper and/or gri l l e, as
requi red.
(14) Remove the two thrust pl ate retai ni ng screws,
thrust pl ate and camshaft (Fi g. 31).
INSPECTION
INSPECTION - CAMSHAFT BEARINGS
(1) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(2) I nspect the beari ngs for wear.
INSPECTION - CAMSHAFT
(1) I nspect the cam l obes for wear.
(2) I nspect the camshaft posi ti on sensor dri ve gear
for wear.
(3) I f the camshaft appears to have been rubbi ng
agai nst the thrust washer, exami ne the oi l pressure
Fig. 30 CamshaftTypical
1 - CAMSHAFT
2 - LOBES
3 - BEARING JOURNAL
WJ ENGINE - 4. 0L 9 - 31
CAMSHAFT & BEARINGS (Continued)
rel i ef hol es i n the rear cam journal . The oi l pressure
rel i ef hol es must be free of debri s.
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS
CAUTION: Make sure outside diameter of number 1
bearing is clean. Make sure that the bearing is
properly installed in the engine block, align the oil
hole in the bearing with the oil gallery in the bear-
ing bore. Failure to do so will cause inadequate oil
supply for the sprockets and timing chain.
(1) Usi ng recommended speci al tool 8544 Cam-
shaft Beari ng Remover/I nstal l er, i nstal l new cam-
shaft beari ngs.
INSTALLATION - CAMSHAFT
(1) Lubri cate the camshaft wi th Mopar Engi ne
Oi l Suppl ement, or equi val ent.
(2) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs.
(3) Posi ti on thrust pl ate and i nstal l retai ni ng
screws. Ti ghten screws to 24 Nm (18 ft. l bs.).
(4) Lubri cate the camshaft wi th Mopar engi ne oi l
suppl ement, or equi val ent.
(5) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON).
(6) Ti ghten the camshaft sprocket bol t and washer
to 68 Nm (50 ft. l bs.).
(7) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft two ful l revol uti ons then
posi ti on the camshaft sprocket ti mi ng mark as shown
i n (Fi g. 33).
(8) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 34). (Refer to 9 - ENGI NE/VALVE
TI MI NG/TI MI NG BELT / CHAI N COVER(S) -
I NSTALLATI ON).
(9) I nstal l the vi brati on damper (Fi g. 34) (Refer to
9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - I NSTALLATI ON).
(10) I nstal l the hydraul i c val ve tappets (Refer to 9
- ENGI NE/ENGI NE BLOCK/HYDRAULI C LI FTERS
(CAM I N BLOCK) - I NSTALLATI ON).
(11) I nstal l the cyl i nder head gasket wi th the
numbers faci ng up.
(12) I nstal l the cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON).
(13) I nstal l the push rods.
(14) I nstal l the rocker arms and pi vot and bri dge
assembl i es (Refer to 9 - ENGI NE/CYLI NDER HEAD/
ROCKER ARM / ADJUSTER ASSY - I NSTALLA-
TI ON).
(15) I nstal l the engi ne cyl i nder head cover (Refer
HEAD COVER(S) - I NSTALLATI ON).
Fig. 31 Camshaft Removal
1 - CAMSHAFT
2 - CRANKSHAFT
Fig. 32 Crankshaft / Camshaft Sprocket Timing Mark
Alignment
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
9 - 32 ENGINE - 4. 0L WJ
(16) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
I NSTALLATI ON).
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with
Mopar Engine Oil Supplement, or equivalent. The
Mopar Engine Oil Supplement, or equivalent must
remain with the engine oil for at least 1609 km
(1,000 miles). The oil supplement need not be
drained until the next scheduled oil change.
(17) I nstal l the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - I NSTALLATI ON).
(18) Check the i gni ti on ti mi ng and adjust as nec-
essary.
(19) I nstal l the gri l l e and bumper, i f removed.
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 35) (Fi g. 36). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 37). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
Fig. 33 Crankshaft / Camshaft Chain Drive
InstallationTypical
2 - TIMING MARKS
Fig. 34 Timing Case Cover Components
1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
Fig. 35 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 - WEAR PATTERN - ALWAYS GREATER ON UPPER BEARING
5 - LOWER BEARING HALF
WJ ENGINE - 4. 0L 9 - 33
BEARING-TO-JOURNAL CLEARANCE
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
duri ng i nstal l ati on.
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
38). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 Nm (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to- journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 39). Plastigage
should indicate the same clearance across the
entire width of the insert. If the clearance var-
ies, it may be caused by either a tapered jour-
nal, bent connecting rod or foreign material
trapped between the insert and cap or rod.
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
Fig. 36 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 37 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
Fig. 38 Rod and Piston Assembly Installation
Fig. 39 Measuring Bearing Clearance with
Plastigage
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
9 - 34 ENGINE - 4. 0L WJ
CONNECTING ROD BEARINGS (Continued)
i s needed to provi de the correct cl earance. Refer to
CONNECTI NG ROD BEARI NG FI TTI NG CHART .
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow
53.2257 - 53.2079 mm
Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
Orange
53.2079 - 53.1901 mm
Yellow - Standard
Blue - Undersize (2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
Blue
53.1901 - 53.1724 mm
Blue - Undersize Blue - Undersize (2.0941 - 2.0934 in.)
0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
Red
52.9717 - 52.9539 mm
Red - Undersize Red - Undersize (2.0855 - 2.0848 in.)
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 45 Nm (33 ft. l bs.) torque.
SIDE CLEARANCE MEASUREMENT
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 40).
(Refer to 9 - ENGI NE - SPECI FI CATI ONS). Repl ace
the connecti ng rod i f the si de cl earance i s not wi thi n
speci fi cati on.
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
The crankshaft i s a crosshaped four throw desi gn
wi th ei ght counterwei ghts for bal anci ng purposes.
The crankshaft i s supported by seven sel ect mai n
beari ngs wi th the number three servi ng as the thrust
washer l ocati on. The mai n journal s of the crankshaft
are cross dri l l ed to i mprove rod beari ng l ubri cati on.
The sel ect fi t mai n beari ng marki ngs are l ocated on
the crankshaft counter wei ghts. The crankshaft rear
oi l seal i s a two pi ece desi gn. The front oi l seal i s a
one pi ece desi gn retai ned i n the ti mi ng chai n cover
(Fi g. 41).
Fig. 40 Checking Connecting Rod Side Clearance -
Typical
WJ ENGINE - 4. 0L 9 - 35
CRANKSHAFT MAIN
BEARINGS
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 7 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark (Fi g. 42)on the adja-
cent cheek or counterwei ght towards the rear of the
crankshaft (fl ange end). The rear mai n journal , i s
i denti fi ed by a col or-coded pai nt mark on the crank-
shaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, (Refer
to 9 - ENGI NE/ENGI NE BLOCK/CRANKSHAFT
MAI N BEARI NGS - I NSTALLATI ON).
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 43). (Refer to 9 - ENGI NE - SPECI FI CATI ONS)
for the proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
ceed to (Refer to 9 - ENGI NE/ENGI NE BLOCK/
CRANKSHAFT MAI N BEARI NGS -
I NSTALLATI ON).
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cate wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
Fig. 41 Crankshaft with Select Fit Marking Location
1 - 1/4 LETTERS
2 - (ROD)
3 - (MAIN)
9 - 36 ENGINE - 4. 0L WJ
CRANKSHAFT (Continued)
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
Repl ace the crankshaft or gri nd to accept the
appropri ate undersi ze beari ng i nserts i f:
Journal di ameters 1 through 6 are l ess than
63.4517 mm (2.4981 i nches)
Journal 7 di ameter i s l ess than 63.4365 mm
(2.4975 i nches).
Once the proper cl earances have been obtai ned,
proceed to (Refer to 9 - ENGI NE/ENGI NE BLOCK/
CRANKSHAFT MAI N BEARI NGS - I NSTALLA-
TI ON).
JOURNAL DIAMETER (CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock.
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
MAI N BEARI NG FI TTI NG CHART . Sel ect i nserts
requi red to obtai n the speci fi ed beari ng-to-journal
cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock.
Fig. 42 Crankshaft Journal Size Paint I.D. Location
1 - NO. 7 MAIN JOURNAL SIZE PAINT MARK
2 - NO. 6 CONNECTING ROD JOURNAL SIZE PAINT MARK
3 - NO. 1 CONNECTING ROD JOURNAL SIZE PAINT MARK
4 - NO. 1 MAIN JOURNAL SIZE PAINT MARK
Plastigage
WJ ENGINE - 4. 0L 9 - 37
CRANKSHAFT MAIN BEARINGS (Continued)
MAIN BEARING FITTING CHART
Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert
Yellow
63.5025 -63.4898 mm
(2.5001 - 2.4996 in.)
Orange
63.4898 - 63.4771 mm
Yellow - Standard
Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue
63.4771 - 63.4644 mm
Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
Green
63.4644 - 63.4517 mm
Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
Red
63.2485 - 63.2358 mm
Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
Crankshaft Journal #7 Only Corresponding Bearing Insert
Yellow
63.4873 - 63.4746 mm
(2.4995 - 2.4990 in.)
Orange
63.4746 - 63.4619 mm
Yellow - Standard
Blue - Undersize
0.025 mm (0.001 in.)
(2.4990 - 2.4985 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue
63.4619 - 63.4492 mm
Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4985 - 2.4980 in.)
0.0254 mm (0.001 in.)
Undersize
Green
63.4492 - 63.4365 mm
Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4980 - 2.4975 in.)
0.0381 mm (0.0015 in.)
Undersize
Red
63.2333 - 63.2206 mm
Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4895 - 2.4890 in.)
0.254 mm (0.010 in.)
Undersize
9 - 38 ENGINE - 4. 0L WJ
REMOVAL
(2) Remove the spark pl ugs (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/SPARK PLUG -
REMOVAL).
(4) Remove the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - REMOVAL) and oi l pump
(Refer to 9 - ENGI NE/LUBRI CATI ON/OI L PUMP -
REMOVAL).
(5) Remove mai n beari ng cap brace (Fi g. 44).
(6) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 45).
(7) Remove the l ower i nsert from the beari ng cap.
(8) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 46). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 46). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(9) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
Fig. 44 Main Bearing Caps and Brace.
1 - BLOCK
2 - MAIN BEARING CAP BRACE
Fig. 45 Removing Main Bearing Caps and Lower
Inserts
1 - CONNECTING ROD JOURNAL
2 - MAIN BEARING CAPS
Fig. 46 Removing Upper Inserts
1 - COTTER PIN
2 - BEARING INSERT
3 - TONGUE DEPRESSOR
WJ ENGINE - 4. 0L 9 - 39
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 47). I n general the
l ower beari ng hal f wi l l have a heaver wear pattern.
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) On the rear mai n cap, appl y Mopar Gasket
Maker seal er on both si des of cyl i nder bl ock as
shown i n (Fi g. 48). The dab of seal er shoul d be 3 mm
(0.125 i n.) i n di ameter.
(5) Appl y Mopar Gasket Maker on the rear bear-
i ng cap. The bead shoul d be 2.3 mm (0.09 i n.) i n
di ameter. DO NOT appl y seal er to the l i p of the seal .
(6) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(7) Ti ghten the bol ts of caps 1, 2, 4, 5, 6, and 7 to
54 Nm (40 ft. l bs.) torque. Now ti ghten these bol ts to
95 Nm (70 ft. l bs.) torque. Fi nal l y, ti ghten these
(8) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.3 to 54 Nm (40 ft. l bs.) torque. Then ti ghten
to 95 Nm (70 ft. l bs.) torque and fi nal l y ti ghten to
108 Nm (80 ft. l bs.) torque.
(9) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(10) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 49). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
Fig. 47 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
Fig. 48 Location of Sealer
1 - DOWEL
2 - SEALER LOCATIONS
3 - CYLINDER BLOCK
4 - HALFWAY BETWEEN
5 - REAR FACE OF CYLINDER BLOCK
6 - 3mm (0.125 in.)
9 - 40 ENGINE - 4. 0L WJ
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(11) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock.
(12) I nstal l mai n beari ng cap brace ti ghten nuts to
(13) I nstal l oi l pump assy. and ti ghten attachi ng
bol ts to 23 Nm (17 ft. l bs.)
(14) I nstal l the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - I NSTALLATI ON).
(15) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
(17) I nstal l the spark pl ugs. Ti ghten the pl ugs to
(18) Fi l l the oi l pan wi th engi ne oi l to the ful l
mark on the di psti ck l evel .
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
(2) Remove the serpenti ne dri ve bel t (Refer to 7 -
REMOVAL).
REMOVAL).
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 50). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
(4) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper (Refer to 9 -
I NSTALLATI ON).
(5) I nstal l the serpenti ne bel t (Refer to 7 - COOL-
LATI ON).
(6) I nstal l the radi ator shroud.
Fig. 49 Crankshaft End Play Measurement
1 - DIAL INDICATOR
2 - CRANKSHAFT
Fig. 50 Timing Case Cover Oil Seal Installation
1 - SEAL INSTALLATION TOOL
2 - DRAW SCREW TOOL
WJ ENGINE - 4. 0L 9 - 41
REAR
REMOVAL
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
(1) Remove transmi ssi on i nspecti on cover.
(2) Remove oi l pan. (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PAN - REMOVAL)
(3) Remove mai n beari ng cap brace.
(4) Remove rear mai n beari ng cap (No.7).
(5) Push upper seal out of the groove. Ensure that
the crankshaft and seal groove are not damaged.
(6) Remove l ower hal f of the seal from the beari ng
cap.
INSTALLATION
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Appl y a thi n coat of engi ne oi l .
(3) Coat l i p of the seal wi th engi ne oi l .
(4) Careful l y posi ti on the upper seal i nto the
groove i n the cyl i nder bl ock. The l i p of the seal faces
toward the front of the engi ne.
(5) Appl y Mopar Gasket Maker seal er on both
si des of cyl i nder bl ock as shown i n (Fi g. 51). The dab
of seal er shoul d be 3 mm (0.125 i n.) i n di ameter.
(6) Appl y Mopar Gasket Maker on the rear bear-
i ng cap (Fi g. 51). The bead shoul d be 2.3 mm (0.09
i n.) i n di ameter. DO NOT appl y seal er to the l i p of
the seal .
(7) Posi ti on the l ower seal i nto the beari ng cap
recess and seat i t fi rml y. Be sure the seal i s fl ush
wi th the cyl i nder bl ock pan rai l .
(8) Coat the outer curved surface of the l ower seal
wi th soap and the l i p of the seal wi th engi ne oi l .
(9) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(10) Ti ghten al l mai n beari ng bol ts to 108 Nm (80
ft. l bs.) torque.
(11) I nstal l the mai n beari ng cap brace. Ti ghten
nuts to 47 Nm (35 ft. l bs.).
(12) I nstal l the oi l pan gasket and oi l pan (Refer to
9 - ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces) (Fi g. 52)
(14) I nstal l transmi ssi on i nspecti on cover.
Fig. 51 Location of Sealer
1 - DOWEL
3 - CYLINDER BLOCK
4 - HALFWAY BETWEEN
5 - REAR FACE OF CYLINDER BLOCK
6 - 3mm (0.125 in.)
Fig. 52 Oil Pan
9 - 42 ENGINE - 4. 0L WJ
HYDRAULIC LIFTERS
DESCRIPTION
Val ve l ash i s control l ed by hydraul i c tappets
l ocated i nsi de the cyl i nder bl ock, i n tappet bores
above the camshaft.
REMOVAL
NOTE: Retain all the components in the same order
as removed.
(1) Remove the engi ne cyl i nder head(Refer to 9 -
ENGI NE/CYLI NDER HEAD - REMOVAL).
(3) Remove the tappets through the push rod open-
i ngs i n the cyl i nder bl ock wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 53).
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and tappets.
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 54).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
INSTALLATION
Retai n al l the components i n the same order as
removed.
Fig. 53 HYDRAULIC VALVE TAPPET REMOVAL -
4.0L
1 - HYDRAULIC TAPPET REMOVAL TOOL
2 - CYLINDER BLOCK
Fig. 54 Leak-Down Tester
1 - POINTER
2 - WEIGHTED ARM
3 - RAM
4 - CUP
5 - HANDLE
6 - PUSH ROD
WJ ENGINE - 4. 0L 9 - 43
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the cyl i nder head (Refer to 9 - ENGI NE/
CYLI NDER HEAD - I NSTALLATI ON).
(4) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(5) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(6) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
(7) Pour the remai ni ng Mopar Engi ne Oi l Suppl e-
ment, or equi val ent over the enti re val ve actuati ng
assembl y. The Mopar Engi ne Oi l Suppl ement, or equi v-
al ent must remai n wi th the engi ne oi l for at l east 1 609
km (1,000 mi l es). The oi l suppl ement need not be
drai ned unti l the next schedul ed oi l change.
(8) I nstal l the cyl i nder head cover (Refer to 9 -
DESCRIPTION
The pi stons (Fi g. 55) are made of a hi gh strength
al umi num al l oy, the pi ston ski rts are coated wi th a
sol i d l ubri cant (Mol ykote) to reduce fri cti on and pro-
vi de scuff resi stance. The connecti ng rods are made
of cast i ron.
STANDARD PROCEDURE - PISTON FITTING
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm
(.0001 i n.) I NCREMENTS i s requi red. I f a bore
gauge i s not avai l abl e, do not use an i nsi de mi crome-
ter.
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 57).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 56). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
Fig. 55 Piston and Connecting Rod Assembly
Fig. 56 Moly Coated Piston
1 - MOLY COATED
2 - MOLY COATED
9 - 44 ENGINE - 4. 0L WJ
HYDRAULIC LIFTERS (Continued)
PISTON SIZE CHART
CYLINDER BORE SIZE PISTON LETTER SIZE
98.438 - 98.448 mm
(3.8755 - 3.8759 in.)
A
98.448 - 98.458 mm
(3.8759 - 3.8763 in.)
B
98.458 - 98.468 mm
(3.8763 - 3.8767 in.)
C
98.468 - 98.478 mm
(3.8767 - 3.8771 in.)
D
98.478 - 98.488 mm
(3.8771 - 3.8775 in.)
E
98.488 - 98.498 mm
(3.8775 - 3.8779 in.)
F
REMOVAL
(1) Remove the engi ne cyl i nder head cover. (Refer
(2) Remove the rocker arms, bri dges and pi vots.
(4) Remove the engi ne cyl i nder head. (Refer to 9 -
ENGI NE/CYLI NDER HEAD - REMOVAL).
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(7) Drai n the engi ne oi l .
(8) Remove the oi l pan and gasket. (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(9) Remove mai n beari ng cap brace (Fi g. 58).
(10) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 59).
Fig. 57 Bore Gauge
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 49.5 MM (1-15/16 in.)
Fig. 58 Main Bearings Caps and Brace
1 - BLOCK
2 - MAIN BEARING CAP BRACE
Fig. 59 Stamped Connecting Rods and Caps
1 - CONNECTING ROD CAP
2 - CONNECTING ROD
WJ ENGINE - 4. 0L 9 - 45
PISTON & CONNECTING ROD (Continued)
(11) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(12) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 60).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed (Refer to 9 - ENGI NE/ENGI NE BLOCK/
PI STON RI NGS - STANDARD PROCEDURE).
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 61).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 61).
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the rods
face the camshaft and that the arrows on the pis-
tons face the front of the engine.
(11) I nstal l mai n beari ng cap brace (Fi g. 58).
Ti ghten nuts to 47 Nm (35 ft. l bs.).
Fig. 60 Removal of Connecting Rod and Piston
Assembly
1 - PISTON
2 - CONNECTING ROD
3 - BLOCK
Fig. 61 Rod and Piston Assembly Installation
9 - 46 ENGINE - 4. 0L WJ
(12) I nstal l the oi l pan and gasket (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
(14) I nstal l the engi ne cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON),
push rods, rocker arms, bri dges, pi vots and engi ne
cyl i nder head cover(Refer to 9 - ENGI NE/CYLI NDER
HEAD/CYLI NDER HEAD COVER(S) - I NSTALLA-
TI ON).
(15) Fi l l the crankcase wi th engi ne oi l .
PISTON RINGS
FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 62) (Fi g. 63). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
RING SIDE CLEARANCE CHART
ITEM SPECIFICATION
Top Compression Ring 0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Second Compression
Ring
0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Oil Control Ring 0.06 - 0.21 mm
(0.0024 - 0.0083 in.)
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 64).
RING GAP MEASUREMENT CHART
ITEM SPECIFICATION
(0.0090 - 0.0240 in.)
Second Compression
Ring
0.483 - 0.965 mm
(0.0190 - 0.080 in.)
Oil Control Ring 0.254 - 1.500 mm
(0.010 - 0.060 in.)
Fig. 62 Piston Dimensions
Fig. 63 Ring Side Clearance Measurement
1 - FEELER GAUGE
WJ ENGINE - 4. 0L 9 - 47
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 65).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 66) and (Fi g.
67).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 66) (Fi g.
68).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Ring Gap Orientation
Posi ti on the gaps on the pi ston as shown (Fi g.
69).
Oi l spacer - Gap on center l i ne of pi ston ski rt.
Oi l rai l s - gap 180 apart on centerl i ne of pi ston
pi n bore.
No. 2 Compressi on ri ng - Gap 180 from top oi l
rai l gap.
No. 1 Compressi on ri ng - Gap 180 from No. 2
compressi on ri ng gap.
Fig. 64 Gap Measurement
1 - FEELER GAUGE
Fig. 65 Top Compression ring identification
1 - TOP COMPRESSION RING
Fig. 66 Second Compression Ring Identification
1 - SECOND COMPRESSION RING
2 - CHAMFER
3 - ONE DOT
Fig. 67 Compression Ring Chamfer Location
2 - SECOND COMPRESSION RING
3 - PISTON
4 - CHAMFER
9 - 48 ENGINE - 4. 0L WJ
PISTON RINGS (Continued)
VIBRATION DAMPER
REMOVAL
REMOVAL) and fan shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 70).
INSTALLATION
key. Wi th the key i n posi ti on, al i gn the keyway on
the vi brati on damper hub wi th the crankshaft key
and tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 Nm
(80 ft. l bs.) torque.
I NSTALLATI ON) and fan shroud.
STRUCTURAL SUPPORT
REMOVAL
The engi ne bendi ng braces are used to add
strength to the powertrai n and to address some
mi nor NVH concerns.
Fig. 68 Compression Ring Installation
1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED
Fig. 69 Ring Gap Orientation
2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL
4 - OIL RAIL SPACER
5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
Fig. 70 Vibration Damper Removal Tool 7697
1 - VIBRATION DAMPER REMOVAL TOOL
2 - WRENCH
WJ ENGINE - 4. 0L 9 - 49
NOTE: Before the engine or the transmission can
be removed the engine bending braces must be
removed.
NOTE: Both left and right side bending braces are
removed the sameway. Only the right side is
shown.
NOTE: The exhaust does not require removal to
preform this procedure.
(2) Remove the exhaust hanger bracket retai ni ng
bol t.
(3) Remove l ocknut and transmi ssi on bendi ng
brace bar.
(4) Remove engi ne-to-bendi ng brace retai ni ng bol t,
bendi ng brace bar and cross bar.
INSTALLATION
NOTE: DO NOT tighten the retaining hardware until
all bending braces are in place.
(1) Posi ti on the cross brace i nto the engi ne-to-
transmi ssi on brace, then posi ti on the engi ne-to-trans-
mi ssi on brace and i nstal l retai ni ng bol t.
(2) Posi ti on the transmi ssi on bendi ng brace onto
through brace and i nstal l new l ocknut.
(3) Posi ti on exhaust hanger and transmi ssi on
brace, i nstal l retai ni ng bol t (Fi g. 72).
(4) Ti ghten engi ne-to-transmi ssi on brace retai ni ng
bol t (Fi g. 71)to 40 Nm (30 ft. l bs.).
(5) Ti ghten transmi ssi on brace retai ni ng bol ts (Fi g.
72)to 40 Nm (30 ft. l bs.), then ti ghten transmi ssi on
brace retai ni ng l ock nuts (Fi g. 72) to 108 Nm (80 ft.
l bs.).
LUBRICATION
DESCRIPTION
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng.
OPERATION
The pump draws oi l through the screen and i nl et
tube from the sump at the rear of the oi l pan. The oi l
i s dri ven between the dri ve and i dl er gears and
pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
Fig. 71 Engine-to-Transmission Bending Braces
1 - ENGINE-TO-TRANSMISSION BENDING BRACE
2 - CROSS BRACE
3 - ENGINE-TO-TRANSMISSION BENDING BRACE RETAINING
BOLT
Fig. 72 Transmission Bending Braces and Exhaust
Hanger
1 - TRANSMISSION BENDING BRACE RETAINING BOLT
2 - ENGINE-TO-TRANSMISSION BENDING BRACE
3 - LOCKNUT
4 - TRANSMISSION BRACE
5 - EXHAUST HANGER
9 - 50 ENGINE - 4. 0L WJ
STRUCTURAL SUPPORT (Continued)
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan (Fi g. 73).
PRESSURE
(1) Di sconnect connector and remove oi l pressure
sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292 or equi val ent. Start engi ne and record pres-
sure. (Refer to 9 - ENGI NE - SPECI FI CATI ONS) for
the correct pressures.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.If the oil leak source is not pos-
itively identified at this time, proceed wi th the ai r
l eak detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the CCV val ve from the cyl i nder head
cover. Cap or pl ug the CCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce i nforma-
ti on procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
I NSPECTI ON FOR REAR SEAL AREA LEAKS .
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the CCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
area:
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
WJ ENGINE - 4. 0L 9 - 51
LUBRICATION (Continued)
Fig. 73 Oil Lubrication System4.0L Engine
1 - CAM/CRANK MAIN GALLERY (7)
2 - TAPPET GALLERY
3 - TAPPET GALLERY
4 - CAMSHAFT BEARING
5 - NUMBER 1 CAMSHFT BEARING JOURNAL
7 - TAPPET GALLERY
9 - 52 ENGINE - 4. 0L WJ
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
seal.
assembl ed.
OIL
SERVICE
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Repl ace engi ne oi l fi l ter. (Refer to 9 - ENGI NE/
LUBRI CATI ON/OI L FI LTER - REMOVAL).
(8) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type of engi ne oi l (Refer to LUBRI CATI ON & MAI N-
TENANCE/FLUI D TYPES - DESCRI PTI ON) and
amount of engi ne oi l (Refer to LUBRI CATI ON &
MAI NTENANCE - SPECI FI CATI ONS).
(9) I nstal l oi l fi l l cap.
(10) Start engi ne and i nspect for l eaks.
(11) Stop engi ne and i nspect oi l l evel . Refer to
CRANKCASE OI L LEVEL I NSPECTI ON .
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
The engi ne oi l l evel i ndi cator (Di psti ck) i s l ocated
at the ri ght rear of the 4.0L engi ne. I nspect engi ne
oi l l evel approxi matel y every 800 ki l ometers (500
mi l es). Unl ess the engi ne has exhi bi ted l oss of oi l
pressure, run the engi ne for about fi ve mi nutes
before checki ng oi l l evel . Checki ng engi ne oi l l evel on
a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck (Fi g. 74).
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng (Fi g. 74).
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
OIL FILTER
REMOVAL
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Fig. 74 Engine Oil Dipstick4.0L Engine
1 - DIPSTICK
2 - ADD
3 - SAFE
WJ ENGINE - 4. 0L 9 - 53
Al l Jeep engi nes are equi pped wi th a hi gh qual i ty
ful l -fl ow, throw-away type oi l fi l ter. Dai ml erChrysl er
Corporati on recommends a Mopar or equi val ent oi l
fi l ter be used.
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss or fi l ter
adapter housi ng (Fi g. 75).
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(5) Make sure ol d gasket comes off wi th oi l fi l ter.
Wi th a wi pi ng cl oth, cl ean the gasket seal i ng surface
(Fi g. 76) of oi l and gri me.
INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 76) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
OIL PAN
DESCRIPTION
The oi l pan i s made of stamped steel . The oi l pan
gasket i s a one pi ece steel backbone si l i cone coated
gasket (Fi g. 77).
REMOVAL
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the exhaust
mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(6) Remove the starter motor. (Refer to 8 - ELEC-
TRI CAL/STARTI NG/STARTER MOTOR - REMOV-
AL).
(7) Remove the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(8) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(9) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
Fig. 75 Oil Filter4.0L Engine
1 - CYLINDER BLOCK
2 - ADAPTER
3 - OIL FILTER
Fig. 76 Oil Filter Sealing SurfaceTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
Fig. 77 Oil Pan
1 - OIL PAN
2 - OIL PAN DRAIN PLUG
9 - 54 ENGINE - 4. 0L WJ
OIL FILTER (Continued)
(10) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(11) Remove the engi ne mount through bol ts.
(12) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(13) Remove transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
are attached to the oi l pan studs.
(14) Remove the oi l pan bol ts and studs. Careful l y
sl i de the oi l pan and gasket to the rear. I f equi pped
wi th an oi l l evel sensor, take care not to damage the
sensor.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1 1/2 x 1/4
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 78).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 79).
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces) (Fi g. 80).
(5) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(6) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(7) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 Nm (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 81). Ti ghten these bol ts to 15
Nm (132 i n. l bs.) torque.
(8) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 Nm (84
i n. l bs.) torque.
Fig. 78 Fabrication of Alignment Dowels
1 - 1/4 1 1/2 BOLT
2 - DOWEL
3 - SLOT
Fig. 79 Position of Dowels in Cylinder Block
1 - DOWEL HOLES
2 - CYLINDER BLOCK
3 - 5/16 HOLES
4 - 5/16 HOLES
Fig. 80 Oil Pan Sealer Location
Fig. 81 Position of 5/16 inch Oil Pan Bolts
1 - OIL PAN
2 - OIL PAN DRAIN PLUG
WJ ENGINE - 4. 0L 9 - 55
OIL PAN (Continued)
(9) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(10) I nstal l the through bol ts and ti ghten the nuts.
(11) Lower the jack stand and remove the pi ece of
wood.
(12) I nstal l the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(13) I nstal l the engi ne starter motor. (Refer to 8 -
I NSTALLATI ON).
(14) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(15) I nstal l transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
attach to the oi l pan studs.
(16) I nstal l the oi l pan drai n pl ug (Fi g. 81).
Ti ghten the pl ug to 34 Nm (25 ft. l bs.) torque.
(19) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
(20) Start the engi ne and i nspect for l eaks.
ENGINE OIL PRESSURE
SENSOR
DESCRIPTION
The 3wi re, sol i d-state engi ne oi l pressure sensor
(sendi ng uni t) i s l ocated i n an engi ne oi l pressure
gal l ery.
OPERATION
The oi l pressure sensor uses three ci rcui ts. They
are:
A 5vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
A sensor ground through the PCMs sensor
return
A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
The oi l pressure sensor has a 3wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
OIL PUMP
REMOVAL
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
(1) Drai n the engi ne oi l .
(2) Remove the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - REMOVAL).
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
82).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
Fig. 82 Oil Pump Assembly
1 - OIL FILTER ADAPTOR
2 - BLOCK
3 - GASKET
4 - OIL INLET TUBE
5 - OIL PUMP
6 - STRAINER ASSEMBLY
7 - ATTACHING BOLTS
9 - 56 ENGINE - 4. 0L WJ
OIL PAN (Continued)
INSTALLATION
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 Nm
(2) I nstal l the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - I NSTALLATI ON).
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d (Fi g. 83) i s made of cast al u-
mi num and uses el even bol ts to mount to the cyl i n-
der head. Thi s mounti ng styl e i mproves seal i ng and
reduces the chance of l eaks.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(2) Remove ai r cl eaner i nl et hose from the resona-
tor assembl y.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped) and the transmi ssi on l i ne pres-
sure cabl e (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C - AW4/THROTTLE VALVE
CABLE - REMOVAL).
(5) Di sconnect the fol l owi ng el ectri cal connecti ons
and secure thei r harness out of the way:
Throttl e Posi ti on Sensor
I dl e Ai r Control Motor
Cool ant Temperature Sensor (at thermostat
housi ng)
I ntake Ai r Temperature Sensor
Oxygen Sensor
Crank Posi ti on Sensor
Si x (6) Fuel I njector Connectors
Mani fol d Absol ute Pressure (MAP) Sensor.
(6) Di sconnect HVAC, and Brake Booster vacuum
suppl y hoses at the i ntake mani fol d.
(7) Perform the fuel pressure rel ease procedure.
(8) Di sconnect and remove the fuel system suppl y
l i ne from the fuel rai l assembl y.
(9) Remove the accessory dri ve bel t (Refer to 7 -
REMOVAL).
(10) Remove the power steeri ng pump from the
i ntake mani fol d and set asi de.
(12) Di sconnect the exhaust pi pes from the engi ne
exhaust mani fol ds.
(14) Remove the i ntake mani fol d and exhaust
mani fol d bol ts and mani fol ds (Fi g. 84).
INSTALLATION
I f the mani fol d i s bei ng repl aced, ensure al l the fi t-
ti ng, etc. are transferred to the repl acement mani -
fol d.
(1) I nstal l a new engi ne exhaust/i ntake mani fol d
gasket over the al i gnment dowel s on the cyl i nder
head.
(2) Posi ti on the engi ne exhaust mani fol ds to the
cyl i nder head. I nstal l fastener Number 3 and fi nger
ti ghten at thi s ti me (Fi g. 84).
Fig. 83 Intake Manifold 4.0L Engine
WJ ENGINE - 4. 0L 9 - 57
OIL PUMP (Continued)
(3) I nstal l i ntake mani fol d on the cyl i nder head
dowel s.
(4) I nstal l washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fi g. 84).
(5) I nstal l washer and fastener Numbers 6 and 7
(Fi g. 84).
(6) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 84).
Fastener Numbers 1 through 5Ti ghten to 33
Fastener Numbers 6 and 7Ti ghten to 31 Nm
Fastener Numbers 8 through 11Ti ghten to 33
(7) I nstal l the power steeri ng pump to the i ntake
mani fol d.
(8) I nstal l the accessory dri ve bel t (Refer to 7 -
I NSTALLATI ON).
(9) I nstal l the fuel system suppl y l i ne to the fuel
rai l assembl y.
(10) Connect al l el ectri cal connecti ons on the
i ntake mani fol d.
(11) Connect the vacuum hoses previ ousl y
removed.
(12) I nstal l throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped).
(13) I nstal l the transmi ssi on l i ne pressure cabl e (i f
equi pped) (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C - AW4/THROTTLE VALVE
CABLE - I NSTALLATI ON).
(14) I nstal l ai r cl eaner assembl y.
(15) Connect ai r i nl et hose to the resonator assem-
bl y.
(17) Connect the exhaust pi pes to the engi ne
exhaust mani fol ds. Ti ghten the bol ts to 31 Nm (23
ft. l bs.)
(20) Start the engi ne and check for l eaks.
EXHAUST MANIFOLD
DESCRIPTION
The two exhaust mani fol ds (Fi g. 85) are l og styl e
and are made of hi gh si l i con mol ybdenum cast i ron.
The exhaust mani fol ds share a common gasket wi th
the i ntake mani fol d. The exhaust mani fol ds al so
i ncorporate bal l fl ange outl ets for i mproved seal i ng
and strai n free connecti ons.
REMOVAL
The i ntake and engi ne exhaust mani fol ds on the
4.0L engi ne must be removed together. The mani fol ds
use a common gasket at the cyl i nder head.
(Refer to 9 - ENGI NE/MANI FOLDS/I NTAKE
MANI FOLD - REMOVAL).
INSTALLATION
(1) The exhaust mani fol d and the i ntake mani fol d
must be i nstal l ed together usi ng a common gasket.
(2) (Refer to 9 - ENGI NE/MANI FOLDS/I NTAKE
MANI FOLD - I NSTALLATI ON).
TIMING BELT / CHAIN
COVER(S)
REMOVAL
REMOVAL).
(3) Remove the fan, hub assembl y and fan shroud
REMOVAL).
(4) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(5) Remove the A/C compressor (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
COMPRESSOR - REMOVAL) (i f equi pped) and gen-
erator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(7) Remove the ti mi ng case cover and gasket from
the engi ne.
(8) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 86).
INSTALLATION
Cl ean the ti mi ng case cover, oi l pan and cyl i nder
bl ock gasket surfaces.
Fig. 84 Intake and Exhaust Manifolds Installation
9 - 58 ENGINE - 4. 0L WJ
INTAKE MANIFOLD (Continued)
(1) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(2) Posi ti on the gasket on the cyl i nder bl ock.
(3) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(4) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 87).
(5) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
(6) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
Nm (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 Nm (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 9.5 Nm
(7) Remove the cover al i gnment tool .
(8) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
key. Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper (Refer to 9 -
I NSTALLATI ON).
(10) I nstal l the A/C compressor (Refer to 24 -
COMPRESSOR - I NSTALLATI ON) (i f equi pped) and
generator bracket assembl y.
(11) I nstal l the engi ne fan, hub assembl y and
shroud (Refer to 7 - COOLI NG/ENGI NE/RADI ATOR
FAN - I NSTALLATI ON).
I NSTALLATI ON).
Fig. 85 EXHAUST MANIFOLDS 4.0L ENGINE
Fig. 86 Timing Case Cover Components
1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
Fig. 87 Timing Case Cover Alignment
1 - TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
WJ ENGINE - 4. 0L 9 - 59
TIMING BELT / CHAIN COVER(S) (Continued)
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(2) Remove the fan and shroud (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR FAN - REMOVAL).
REMOVAL).
(4) Remove the crankshaft vi brati on damper (Refer
to 9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - REMOVAL).
(5) Remove the ti mi ng case cover (Refer to 9 -
(6) Rotate crankshaft unti l the 0 ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 88).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the camshaft sprocket bol t and washer
(Fi g. 89).
(9) Remove the crankshaft sprocket, camshaft
sprocket and ti mi ng chai n as an assembl y.
(10) I nstal l ati on of the ti mi ng chai n wi th the ti m-
i ng marks on the crankshaft and camshaft sprockets
properl y al i gned ensures correct val ve ti mi ng. A worn
or stretched ti mi ng chai n wi l l adversel y affect val ve
ti mi ng. I f the ti mi ng chai n defl ects more than 12.7
mm (1/2 i nch) repl ace i t.
INSTALLATION
Assembl e the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned (Fi g. 88).
key. Wi th the key i n the keyway on the crankshaft,
i nstal l the assembl y on the crankshaft and camshaft.
(2) I nstal l the camshaft sprocket bol t and washer
(Fi g. 89). Ti ghten the bol t to 68 Nm (50 ft. l bs.) torque.
(3) To veri fy correct i nstal l ati on of the ti mi ng
chai n, rotate the crankshaft 2 revol uti ons. The cam-
shaft and crankshaft sprocket ti mi ng mark shoul d
al i gn (Fi g. 88).
(4) I nstal l the crankshaft oi l sl i nger.
(5) Repl ace the oi l seal i n the ti mi ng case cover
(Refer to 9 - ENGI NE/ENGI NE BLOCK/CRANK-
SHAFT OI L SEAL - FRONT - REMOVAL).
(6) I nstal l the ti mi ng case cover and gasket (Refer
to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT /
CHAI N COVER(S) - I NSTALLATI ON).
(7) Wi th the key i nstal l ed i n the crankshaft key-
way, i nstal l the vi brati on damper (Refer to 9 -
I NSTALLATI ON).
I NSTALLATI ON).
(9) I nstal l the fan, hub assembl y and shroud
I NSTALLATI ON).
Fig. 88 CrankshaftCamshaft Alignment
2 - TIMING MARKS
Fig. 89 Camshaft Sprocket and Thrust Plate
1 - CAMSHAFT
2 - CAMSHAFT SPROCKET W/INTEGRAL KEY
3 - BOLT AND WASHER
4 - THRUST PLATE
9 - 60 ENGINE - 4. 0L WJ
ENGINE - 4.7L
TABLE OF CONTENTS
page page
ENGINE - 4.7L
DESCRIPTION4.7L ENGINE . . . . . . . . . . . . . 63
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 64
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 65
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 66
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . . 67
COMPRESSION PRESSURE . . . . . . . . . . . . . 68
COMBUSTION PRESSURE LEAKAGE . . . . . . 69
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . . 70
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . . 70
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION. . . . . . . . 70
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
SPECIFICATIONS
4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 74
SPECIFICATIONS - 4.7L H.O. ENGINE . . . . . 77
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SPECIAL TOOLS
4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 80
AIR CLEANER ELEMENT
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . . . 83
AIR CLEANER HOUSING
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . . . 84
CYLINDER HEAD - LEFT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD . . . . . . . . 84
DESCRIPTION - VALVE GUIDES . . . . . . . . . . 84
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 84
HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . 85
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87
CAMSHAFT(S) - LEFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 88
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 90
CYLINDER HEAD COVER(S) - LEFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 93
REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . . . 93
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATIONLEFT SIDE . . . . . . . . . . . . . . . 93
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 94
STANDARD PROCEDUREREFACING . . . . . . 94
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 96
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 97
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 97
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD . . . . . . . . 97
DESCRIPTION - VALVE GUIDES . . . . . . . . . . 97
HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . 97
LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 98
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 99
CAMSHAFT(S) - RIGHT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
CYLINDER HEAD COVER(S) - RIGHT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 104
REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . . 104
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION - RIGHT SIDE . . . . . . . . . . . . . 104
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 104
STANDARD PROCEDUREREFACING . . . . . 105
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
WJ ENGINE - 4. 7L 9 - 61
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 107
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 108
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 108
ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 108
STANDARD PROCEDURECYLINDER BORE
HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 109
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING . . . . . . . . . . . . . . . 109
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 111
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY . . . . . . . . . . . . . . 111
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112
STANDARD PROCEDURECRANKSHAFT
MAIN BEARING - FITTING . . . . . . . . . . . . . . 114
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 116
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117
FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 118
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 118
STANDARD PROCEDUREPISTON FITTING . 118
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
PISTON RINGS
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123
STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 124
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 124
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 125
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 126
DIAGNOSIS AND TESTINGENGINE OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 128
DIAGNOSIS AND TESTINGREAR SEAL
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 128
DIAGNOSIS AND TESTINGENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
OIL
STANDARD PROCEDURE - ENGINE OIL . . . . 130
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132
OIL PAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 132
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 133
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 133
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 133
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 134
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 134
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 135
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 136
DIAGNOSIS AND TESTINGINTAKE
MANIFOLD LEAKAGE . . . . . . . . . . . . . . . . . 136
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
EXHAUST MANIFOLD - LEFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 138
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
EXHAUST MANIFOLD - RIGHT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 139
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141
9 - 62 ENGINE - 4. 7L WJ
VALVE TIMING
DESCRIPTION - TIMING DRIVE SYSTEM . . . . 141
OPERATION - TIMING DRIVE SYSTEM . . . . . 141
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE TIMING
- VERIFICATION . . . . . . . . . . . . . . . . . . . . . 141
STANDARD PROCEDUREMEASURING
TIMING CHAIN WEAR . . . . . . . . . . . . . . . . . 145
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 146
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 149
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 149
ENGINE - 4.7L
The 4.7 l i ter (287 CI D) ei ght-cyl i nder engi ne i s an
90 si ngl e overhead camshaft engi ne. The cast i ron
cyl i nder bl ock i s made up of two di fferent compo-
nents; the fi rst component i s the cyl i nder bore and
upper bl ock, the second component i s the bedpl ate
that compri ses the l ower porti on of the cyl i nder bl ock
and houses the l ower hal f of the crankshaft mai n
beari ngs. The cyl i nders are numbered from front to
rear wi th the l eft bank bei ng numbered 1,3,5 and 7,
and the ri ght bank bei ng numbered 2,4,6 and 8. The
fi ri ng order i s 18436572. The engi ne seri al
number i s l ocated at the ri ght front si de of the
engi ne bl ock (Fi g. 1)
WJ ENGINE - 4. 7L 9 - 63
DIAGNOSIS - INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
I NG)PERFORMANCE and (Refer to 9 - ENGI NE -
DI AGNOSI S AND TESTI NG)MECHANI CAL for
possi bl e causes and correcti ons of mal functi ons.
DI AGNOSI S AND TESTI NG) and (Refer to 14 -
FUEL SYSTEM/FUEL I NJECTI ON - DI AGNOSI S
AND TESTI NG) for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
Cyl i nder Compressi on Pressure Test (Refer to 9 -
ENGI NE - DI AGNOSI S AND TESTI NG).
Cyl i nder Combusti on Pressure Leakage Test
I NG).
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s
(Refer to 9 - ENGI NE/CYLI NDER HEAD - DI AGNO-
SI S AND TESTI NG).
I ntake Mani fol d Leakage Di agnosi s (Refer to 9 -
DI AGNOSI S AND TESTI NG).
Fig. 1 Engine Identification Location
1 - VEHICLE VIN NUMBER LOCATION
2 - CYLINDER BLOCK RIGHT HAND SIDE
3 - CYLINDER BORE #2
9 - 64 ENGINE - 4. 7L WJ
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL -
REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
6. Dirt or water in fuel system. 6. Clean system and replace fuel filter.
7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary.
ENGINE STALLS OR ROUGH
IDLE
1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - REMOVAL).
2. Idle mixture to lean or to rich. 2. Refer to Powertrain Diagnosis
Information.
3. Vacuum leak. 3. Inspect intake manifold and vacuum
hoses, repair or replace as necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark
plugs.
1. (Refer to 8 - ELECTRICAL/
CLEANING).
3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL PUMP - DIAGNOSIS
AND TESTING).
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING), repair as necessary.
6. Burned, warped or pitted valves. 6. Replace as necessary.
7. Plugged or restricted exhaust
system.
7. Inspect and replace as necessary.
REMOVAL).
WJ ENGINE - 4. 7L 9 - 65
1. ENGINE MISSES ON
ACCELERATION
1. Spark plugs dirty or incorrectly
gapped.
CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
REMOVAL).
1. ENGINE MISSES AT HIGH
SPEED
1. Spark plugs dirty or incorrectly
gapped.
CLEANING).
REMOVAL).
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in crankcase. 1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Thin or diluted oil. 2. Change oil and filter.
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive wear.
4. Dirt in lash adjusters. 4. Replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
6. Worn lash adjusters 6. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES &
SEATS - STANDARD PROCEDURE).
8. Excessive runout of valve seats
on valve faces.
8. Service valves and valve seats.
(Refer to 9 - ENGINE/CYLINDER
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
SPECIFICATIONS).
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal out-of-
round.
5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
9 - 66 ENGINE - 4. 7L WJ
CONDITION POSSIBLE CAUSES CORRECTIONS
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
SPECIFICATIONS).
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.
7. Tighten to correct torque
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.
(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9 -
ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
3. Crankshaft seal flange.
Scratched, nicked or grooved.
3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Timing chain cover seal, damaged
or misaligned.
5. Replace seal (Refer to 9 -
ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - FRONT -
REMOVAL).
6. Scratched or damaged vibration
damper hub.
6. Polish or replace damper.
WJ ENGINE - 4. 7L 9 - 67
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9 -
ENGINE/LUBRICATION/OIL
PRESSURE SENSOR/SWITCH -
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP -
REMOVAL).
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP -
REMOVAL).
9. Oil pick up tube loose, damaged
or clogged.
9. Replace as necessary.
OIL PUMPING AT RINGS;
SPARK PLUGS FOULING
1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD PROCEDURE).
3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD PROCEDURE).
4. Worn valve guides. 4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
5. Leaking valve guide seals. 5. Replace valve guide seals.
COMPRESSION PRESSURE
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sabl e the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY - DESCRI PTI ON).
(5) Remove the ASD rel ay (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/AUTO SHUT DOWN
RELAY - REMOVAL).
(6) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(7) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
(8) (Refer to 9 - ENGI NE - SPECI FI CATI ONS) for
the correct engi ne compressi on pressures.
9 - 68 ENGINE - 4. 7L WJ
COMBUSTION PRESSURE LEAKAGE
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(3) Remove the spark pl ugs.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Set pi ston of cyl i nder to be tested at TDC compres-
si on,Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to CYLI NDER COMBUSTI ON PRESSURE
LEAKAGE DI AGNOSI S CHART .
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
WJ ENGINE - 4. 7L 9 - 69
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous pl aces where form-i n-pl ace
gaskets are used on the engi ne. Care must be taken
when appl yi ng form-i n-pl ace gaskets to assure
obtai ni ng the desi red resul ts. Do not use form-in-
place gasket material unless specified. Bead si ze,
conti nui ty, and l ocati on are of great i mportance. Too
thi n a bead can resul t i n l eakage whi l e too much can
resul t i n spi l l -over whi ch can break off and obstruct
fl ui d feed l i nes. A conti nuous bead of the proper
wi dth i s essenti al to obtai n a l eak-free gasket.
There are numerous types of form-i n-pl ace gasket
materi al s that are used i n the engi ne area. Mopar
Engi ne RTV GEN I I , Mopar ATF-RTV, and Mopar
Gasket Maker gasket materi al s, each have di fferent
properti es and can not be used i n pl ace of the other.
MOPAR ENGINE RTV GEN II
Mopar Engi ne RTV GEN I I i s used to seal com-
ponents exposed to engi ne oi l . Thi s materi al i s a spe-
ci al l y desi gned bl ack si l i cone rubber RTV that
retai ns adhesi on and seal i ng properti es when
exposed to engi ne oi l . Moi sture i n the ai r causes the
materi al to cure. Thi s materi al i s avai l abl e i n three
ounce tubes and has a shel f l i fe of one year. After one
year thi s materi al wi l l not properl y cure. Al ways
i nspect the package for the expi rati on date before
use.
MOPAR ATF RTV
Mopar ATF RTV i s a speci fi cal l y desi gned bl ack
si l i cone rubber RTV that retai ns adhesi on and seal -
i ng properti es to seal components exposed to auto-
mati c transmi ssi on fl ui d, engi ne cool ants, and
moi sture. Thi s materi al i s avai l abl e i n three ounce
tubes and has a shel f l i fe of one year. After one year
thi s materi al wi l l not properl y cure. Al ways i nspect
the package for the expi rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker i s an anaerobi c type gasket
materi al . The materi al cures i n the absence of ai r
when squeezed between two metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. The anaerobi c
materi al i s for use between two machi ned surfaces.
Do not use on fl exi bl e metal fl anges.
MOPAR GASKET SEALANT
Mopar Gasket Seal ant i s a sl ow dryi ng, perma-
nentl y soft seal er. Thi s materi al i s recommended for
seal i ng threaded fi tti ngs and gaskets agai nst l eakage
of oi l and cool ant. Can be used on threaded and
machi ned parts under al l temperatures. Thi s mate-
ri al i s used on engi nes wi th mul ti -l ayer steel (MLS)
cyl i nder head gaskets. Thi s materi al al so wi l l pre-
vent corrosi on. Mopar Gasket Seal ant i s avai l abl e i n
a 13 oz. aerosol can or 4oz./16 oz. can w/appl i cator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care but i ts easi er then usi ng precut gas-
kets.
Mopar Gasket Maker materi al shoul d be appl i ed
spari ngl y 1 mm (0.040 i n.) di ameter or l ess of seal ant
to one gasket surface. Be certai n the materi al sur-
rounds each mounti ng hol e. Excess materi al can eas-
i l y be wi ped off. Components shoul d be torqued i n
pl ace wi thi n 15 mi nutes. The use of a l ocati ng dowel
i s recommended duri ng assembl y to prevent smear-
i ng materi al off the l ocati on.
Mopar Engi ne RTV GEN I I or ATF RTV gasket
materi al shoul d be appl i ed i n a conti nuous bead
approxi matel y 3 mm (0.120 i n.) i n di ameter. Al l
mounti ng hol es must be ci rcl ed. For corner seal i ng, a
3.17 or 6.35 mm (1/8 or 1/4 i n.) drop i s pl aced i n the
center of the gasket contact area. Uncured seal ant
may be removed wi th a shop towel . Components
shoul d be torqued i n pl ace whi l e the seal ant i s sti l l
wet to the touch (wi thi n 10 mi nutes). The usage of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng materi al off the l ocati on.
Mopar Gasket Seal ant i n an aerosol can shoul d be
appl i ed usi ng a thi n, even coat sprayed compl etel y
over both surfaces to be joi ned, and both si des of a
gasket. Then proceed wi th assembl y. Materi al i n a
can w/appl i cator can be brushed on evenl y over the
seal i ng surfaces. Materi al i n an aerosol can shoul d be
used on engi nes wi th mul ti -l ayer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engi ne gasket seal i ng, proper surface
preparati on must be performed, especi al l y wi th the
use of al umi num engi ne components and mul ti -l ayer
steel cyl i nder head gaskets.
Never use the fol l owi ng to cl ean gasket surfaces:
Metal scraper
9 - 70 ENGINE - 4. 7L WJ
Abrasi ve pad or paper to cl ean cyl i nder bl ock
and head
Hi gh speed power tool wi th an abrasi ve pad or a
wi re brush (Fi g. 2)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Onl y use the fol l owi ng for cl eani ng gasket surfaces:
Sol vent or a commerci al l y avai l abl e gasket
remover
Pl asti c or wood scraper (Fi g. 2)
Dri l l motor wi th 3M Rol oc Bri stl e Di sc (whi te
or yel l ow) (Fi g. 2)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Usi ng a bl unt tool such as a dri ft and a hammer,
stri ke the bottom edge of the cup pl ug. Wi th the cup
pl ug rotated, grasp fi rml y wi th pl i ers or other sui t-
abl e tool and remove pl ug (Fi g. 3).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Li ghtl y coat i nsi de of cup pl ug hol e wi th Mopar
Stud and Beari ng Mount. Make certai n the new pl ug
i s cl eaned of al l oi l or grease. Usi ng proper dri ve
pl ug, dri ve pl ug i nto hol e so that the sharp edge of
the pl ug i s at l east 0.5 mm (0.020 i n.) i nsi de the
l ead-i n chamfer.
I t i s not necessary to wai t for curi ng of the seal ant.
The cool i ng system can be refi l l ed and the vehi cl e
pl aced i n servi ce i mmedi atel y.
REMOVAL
(2) Remove the front fasci a.
(4) Remove exhaust crossover pi pe from exhaust
mani fol ds.
(5) Di sconnect two ground straps from the l ower
l eft hand si de and one ground strap from the l ower
ri ght hand si de of the engi ne.
(6) Di sconnect crankshaft posi ti on sensor. (Fi g. 4)
(7) Remove structural cover (Refer to 9 - ENGI NE/
ENGI NE BLOCK/STRUCTURAL COVER - REMOV-
AL).
(8) Remove starter. (Refer to 8 - ELECTRI CAL/
STARTI NG/STARTER MOTOR - REMOVAL).
(9) Remove rubber spl ash shi el d.
(11) Remove torque converter bol ts.
(12) Remove transmi ssi on to engi ne mounti ng
bol ts.
Fig. 2 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
Fig. 3 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
WJ ENGINE - 4. 7L 9 - 71
(13) Di sconnect the engi ne bl ock heater power
cabl e from the bl ock heater.
(15) Remove throttl e body resonator assembl y and
i nl et hose.
(16) Di sconnect throttl e and speed control cabl es.
(17) Di sconnect tube from both the l eft and ri ght
si de crankcase breathers, then remove the breathers
(Fi g. 5).
(18) Di scharge A/C system (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - STAN-
DARD PROCEDURE).
(19) Remove radi ator fan (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR FAN - REMOVAL) and acces-
sory dri ve bel t (Refer to 7 - COOLI NG/ACCESSORY
DRI VE/DRI VE BELTS - REMOVAL).
(20) Remove A/C compressor (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C COM-
PRESSOR - REMOVAL).
(21) Di sconnect transmi ssi on oi l cool er l i nes at the
radi ator.
(22) Di sconnect radi ator l ower hose at the thermo-
stat housi ng.
(23) Remove A/C condenser (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C CON-
DENSER - REMOVAL).
(24) Remove radi ator (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - REMOVAL).
(25) Remove generator (Refer to 8 - ELECTRI CAL/
CHARGI NG/GENERATOR - REMOVAL).
(26) Di sconnect the two heater hoses from the ti m-
i ng chai n cover.
(27) Di sconnect engi ne harness at the fol l owi ng
poi nts :
I ntake ai r temperature (I AT) sensor (Fi g. 6)
Fuel I njectors
Throttl e Posi ti on (TPS) Swi tch
I dl e Ai r Control (I AC) Motor
Engi ne Oi l Pressure Swi tch
Engi ne Cool ant Temperature (ECT) Sensor
Mani fol d absol ute pressure (MAP) Sensor
Camshaft Posi ti on (CMP) Sensor
Coi l Over Pl ugs
(28) Rel ease fuel rai l pressure (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY - STANDARD PROCE-
DURE) then di sconnect the fuel suppl y qui ck connect
fi tti ng at the fuel rai l (Refer to 14 - FUEL SYSTEM/
FUEL DELI VERY/QUI CK CONNECT FI TTI NG -
(29) Remove power steeri ng pump and posi ti on out
of the way.
(30) Di sconnect ground straps from the l eft si de of
the engi ne.
(31) I nstal l Engi ne Li fti ng Fi xture Speci al Tool
8347 (Fi g. 7)fol l owi ng these steps.
Hol di ng the l i fti ng fi xture at a sl i ght angl e, sl i de
the l arge bore i n the front pl ate over the hex porti on
of the l i fti ng stud.
Posi ti on the two remai ni ng fi xture arms onto
the two l i fti ng studs i n the cyl i nder heads.
Pul l foward and upward on the l i fti ng fi xture so
that the l i fti ng stud rest i n the sl otted area bel ow the
l arge bore.
Secure the l i fti ng fi xture to the three studs
usi ng three 7/16 14 N/C l ocknuts.
Make sure the l i fti ng l oop i n the l i fti ng fi xture i s
i n the l ast hol e (cl osest to the throttl e body) to mi n-
i mi ze the angl e of engi ne duri ng removal .
Fig. 4 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
Fig. 5 Crankcase Breather Connection Points
1 - CRANKCASE BREATHERS
9 - 72 ENGINE - 4. 7L WJ
(32) Di sconnect body ground strap at the ri ght si de
cowl .
NOTE: It will be necessary to support the transmis-
sion in order to remove the engine.
(33) Posi ti on a sui tabl e jack under the transmi s-
si on.
(34) Remove the engi ne mount through bol ts.
(35) Rai se engi ne sl i ghtl y, then remove both l eft
and ri ght si de engi ne mounts from engi ne. (Refer to
9 - ENGI NE/ENGI NE MOUNTI NG/FRONT MOUNT
- REMOVAL).
(36) Remove engi ne from the vehi cl e.
INSTALLATION
(1) Posi ti on engi ne i n the vehi cl e.
(2) I nstal l both l eft and ri ght si de engi ne mounts
onto engi ne (Refer to 9 - ENGI NE/ENGI NE MOUNT-
I NG/FRONT MOUNT - I NSTALLATI ON).
(3) I nstal l transmi ssi on to engi ne mounti ng bol ts.
Ti ghten the bol ts to 41 Nm (30 ft. l bs.).
(4) Remove jack from under the transmi ssi on.
(5) Remove engi ne l i fti ng fi xture speci al tool 8347
(Fi g. 7).
(6) Connect ground straps on the l eft si de of the
engi ne.
(7) I nstal l power steeri ng pump (Refer to 19 -
STEERI NG/PUMP - I NSTALLATI ON).
(8) Connect fuel suppl y l i ne qui ck connect fi tti ng
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY/
QUI CK CONNECT FI TTI NG - STANDARD PROCE-
DURE).
(9) Connect engi ne harness at the fol l owi ng poi nts
(Fi g. 6):
I ntake Ai r Temperature (I AT) Sensor
Fuel I njectors
Throttl e Posi ti on (TPS) Swi tch
Engi ne Oi l Pressure Swi tch
Engi ne Cool ant Temperature (ECT) Sensor
Mani fol d Absol ute Pressure (MAP) Sensor
Fig. 6 Throttle Body Connection Points
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR (THREADED TYPE)
5 - MOUNTING SCREWS
Fig. 7 Engine Lifting Fixture Attachment Locations
1 - ATTACHING LOCATION
2 - ADJUSTABLE HOOK
3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 - ATTACHING LOCATIONS
WJ ENGINE - 4. 7L 9 - 73
Camshaft Posi ti on (CMP) Sensor
Coi l Over Pl ugs
(10) I nstal l generator (Refer to 8 - ELECTRI CAL/
CHARGI NG/GENERATOR - I NSTALLATI ON).
(11) I nstal l radi ator (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - I NSTALLATI ON).
(12) I nstal l A/C condenser (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG/A/C CON-
DENSER - I NSTALLATI ON).
(13) Connect radi ator l ower hose at the thermostat
housi ng.
(14) Connect the transmi ssi on oi l cool er l i nes to
the radi ator.
(15) I nstal l A/C compressor. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C COM-
PRESSOR - I NSTALLATI ON).
(16) I nstal l accessory dri ve bel t (Refer to 7 -
I NSTALLATI ON) and radi ator fan (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR FAN - I NSTALLA-
TI ON).
(17) I nstal l breathers, then connect tube to both
crankcase breathers (Fi g. 5).
(18) Connect throttl e and speed control cabl es.
(19) I nstal l throttl e body resonator assembl y and
i nl et hose.
(21) Connect two ground straps on the l ower l eft
hand si de of the engi ne and one ground strap on the
l ower ri ght si de.
(22) I nstal l torque converter bol ts.
(23) Connect crankshaft posi ti on sensor (Fi g. 4).
(24) I nstal l starter.
(25) I nstal l rubber spl ash shi el d.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(26) I nstal l structural cover (Refer to 9 - ENGI NE/
ENGI NE BLOCK/STRUCTURAL COVER - I NSTAL-
LATI ON).
(27) I nstal l exhaust crossover pi pe.
(28) I nstal l engi ne bl ock heater power cabl e, I f
equi pped.
(30) Check and fi l l engi ne oi l (Refer to LUBRI CA-
TI ON & MAI NTENANCE/FLUI D TYPES - SPECI FI -
CATI ONS).
(31) Recharge the A/C system (Refer to 24 - HEAT-
DARD PROCEDURE).
(32) Refi l l the engi ne cool i ng system (Refer to 7 -
(34) Start engi ne and check for l eaks.
SPECIFICATIONS
4. 7L ENGINE
GENERAL SPECIFICATIONS
Engine Type 90SOHC V-8 16-Valve
Displacement 4.7 Liters / 4701cc
(287 Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 86.5 mm (3.40 in.)
Horsepower 235 BHP @ 4800 RPM
Torque 295 LB-FT @ 3200 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-8-4-3-6-5-7-2
CYLINDER BLOCK
Bore Diameter 93.010 .0075 mm
(3.6619 0.0003 in.)
Out of Round (MAX) 0.076 mm (0.003 in.)
Taper (MAX) 0.051 mm (0.002 in.)
PISTONS
Material Aluminum Alloy
Diameter 92.975 mm (3.6605 in.)
Weight 367.5 grams (12.96 oz)
Ring Groove Diameter
No. 1 83.73 - 83.97 mm
(3.296 - 3.269 in.)
No. 2 82.833 - 83.033 mm
(3.261 - 3.310 in.)
No. 3 83.88 - 84.08 mm
(3.302 - 3.310 in.)
PISTON PINS
Type Pressed Fit
Clearance In Piston 0.010 - 0.019 mm
(0.0004 - 0.0008 in.)
Diameter 24.013 - 24.016 mm
(0.9454 - 0.9456 in.)
9 - 74 ENGINE - 4. 7L WJ
PISTON RINGS
Ring Gap
(0.0146 - 0.0249 in.)
Second Compression
Ring
0.37 - 0.63 mm
(0.0146 - 0.0249 in.)
Oil Control (Steel Rails) 0.25 - 0.76 mm
(0.0099 - 0.30 in.)
Side Clearance
Top Compression Ring .051 - .094 mm
(0.0020 - 0.0037 in.)
Second Compression
Ring
0.040 - 0.080 mm
(0.0016 - 0.0031 in.)
Oil Ring (Steel Ring) .019 - .229 mm
(.0007 - .0091 in.)
Ring Width
(0.057 - 0.058 in.)
Second Compression
Ring
1.472 - 1.490 mm
(0.057 - 0.058 in.)
Oil Ring (Steel Rails) 0.445 - 0.470 mm
(0.017 - 0.018 in.)
CONNECTING RODS
Bearing Clearance 0.010 - 0.048 mm
(0.0004 - 0.0019 in.)
Side Clearance 0.10 - 0.35 mm
(0.004 - 0.0138 in.)
Piston Pin Bore Diameter .022 - .045 mm
(Interference Fit) (0.0009 - 0.0018 in.)
Bearing Bore Out of
Round
0.004 mm
(MAX) (0.0002 in.)
Total Weight (Less
Bearing)
555 grams (19.5771
ounces)
CRANKSHAFT
Main BearingJournal
Diameter 63.488 - 63.512 mm
(2.4996 - 2.5005 in.)
(0.0008 - 0.0021 in.)
Taper (MAX) 0.008 mm (0.0004 in.)
End Play 0.052 - 0.282 mm
(0.0021 - 0.0112 in.)
End Play (MAX) 0.282 mm (0.0112 in)
Connecting Rod
Journal
Diameter 50.992 - 51.008 mm
(2.0076 - 2.0082 in.)
(0.0006 -0.0022 in.)
Taper (MAX) 0.008 mm (0.0004 in.)
CAMSHAFT
Bore Diameter 26.02 - 26.04 mm
(1.0245 - 1.0252 in.)
Bearing Journal Diameter 25.975 - 25.995 mm
(1.0227 - 1.0235 in.)
(0.001 - 0.0026 in.)
Bearing Clearance (MAX) 0.065 mm (0.0026 in.)
End Play .075 - .200 mm
(0.003 - 0.0079 in.)
End Play (MAX) .200 mm (0.0079 in.)
VALVE TIMING
Intake
Opens (ATDC) 3.6
Closes (ATDC) 247.1
Duration 243.5
Exhaust
Opens (BTDC) 232.5
Closes (ATDC) 21.2
Duration 253.70
Valve Overlap 17.6
VALVES
Face Angle 45- 45.5
Head Diameter
Intake 48.52 - 48.78 mm
(1.9103 - 1.9205 in.)
WJ ENGINE - 4. 7L 9 - 75
Exhaust 36.87 - 37.13 mm
1.4516 - 1.4618 in.)
Length (Overall)
Intake 113.45 - 114.21 mm
(4.4666 - 4.4965)
Exhaust 114.92 - 115.68 mm
(4.5244 - 4.5543 in.)
Stem Diameter
Intake 6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Exhaust 6.902 - 6.928 mm
(0.2717 - 0.2728 in.)
Stem - to - Guide
Clearance
Intake .018 - .069 mm
(0.0008 - 0.0028 in.)
Exhaust .047 - .098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem -
to -
Guide Clearance
(Rocking
Method)
Intake 0.069 mm (0.0028 in.)
Exhaust 0.098 mm (0.0039 in.)
Valve Lift (Zero Lash)
Intake 11.25 mm (0.443 in.)
Exhaust 10.90 mm (0.4292 in.)
VALVE SPRING
Free Length (Approx)
Intake and Exhaust 48.6 mm (1.9134 in.)
Spring Force (Valve
Closed)
Intake and Exhaust 315.5 - 352.5 N @ 40.89
mm
(70.92722 - 79.24515 lbs.
@ 1.6099 in.)
Spring Force (Valve
Open)
Intake and Exhaust 786.0 - 860.0 N @ 29.64
mm
176.6998 - 193.3357 lbs.
@ 1.167 in.)
Number of Coils
Intake and Exhaust 6.69
Wire Diameter
Intake and Exhaust 4.2799 - 4.3561 mm
(0.1685 - 0.1715 in.)
Installed Height (Spring
Seat to Bottom of
Retainer)
Nominal
Intake 40.97 mm (1.613 in.)
Exhaust 40.81 mm (1.606 in.)
CYLINDER HEAD
Gasket Thickness
(Compressed) .7 mm (0.0276 in.)
Valve Seat Angle 44.5- 45.0
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Valve Seat Width
Intake 1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
(Std.)
6.975 - 7.00 mm
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
(Flatness) 0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over Rotors /
End Face (MAX)
.035 - .095 mm
(0.0014 - 0.0038 in.)
Cover Out - of -Flat
(MAX)
.025 mm (0.001 in.)
Inner and Outer Rotor
Thickness 12.02 mm (0.4731 in.)
9 - 76 ENGINE - 4. 7L WJ
Outer Rotor Clearance
(MAX)
.235 mm (.0093 in.)
Outer Rotor Diameter
(MIN)
85.925 mm (0.400 in.)
Tip Clearance Between
Rotors
(MAX) .150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*
25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run
engine at 3000 rpm.
SPECIFICATIONS - 4. 7L H. O. ENGINE
GENERAL SPECIFICATIONS
Engine Type 90SOHC V-8 16-Valve
Displacement 4.7 Liters / 4701cc
(287 Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 86.5 mm (3.40 in.)
Horsepower 270 BHP @ 5100 RPM
Torque 330 LB-FT @ 3600 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-8-4-3-6-5-7-2
CYLINDER BLOCK
Bore Diameter 93.010 .0075 mm
(3.6619 0.0003 in.)
Taper (MAX) 0.051 mm (0.002 in.)
PISTONS
Material Aluminum Alloy
Diameter 92.975 mm (3.6605 in.)
Weight 383.5 grams (13.52 oz)
Ring Groove Diameter
No. 1 83.37 - 83.13 mm
(3.296 - 3.269 in.)
No. 2 82.833 - 83.033 mm
(3.261 - 3.310 in.)
No. 3 83.88 - 84.08 mm
(3.302 - 3.310 in.)
PISTON PINS
Type Full Floating
Clearance In Piston 0.010 - 0.019 mm
(0.0004 - 0.0008 in.)
Clearance in Rod 0.006 - 0.015 mm
(0.0002 - 0.0005 in.)
Diameter 24.017 - 24.020 mm
(0.9455 - 0.9456 in.)
PISTON RINGS
Ring Gap
(0.0146 - 0.0249 in.)
Second Compression
Ring
0.37 - 0.63 mm
(0.0146 - 0.0249 in.)
Oil Control (Steel Rails) 0.25 - 0.76 mm
(0.0099 - 0.30 in.)
Side Clearance
Top Compression Ring .051 - .094 mm
(0.0020 - 0.0037 in.)
Second Compression
Ring
0.040 - 0.080 mm
(0.0016 - 0.0031 in.)
Oil Ring (Steel Ring) .019 - .229 mm
(.0007 - .0091 in.)
Ring Width
(0.057 - 0.058 in.)
Second Compression
Ring
1.472 - 1.490 mm
(0.057 - 0.058 in.)
Oil Ring (Steel Rails) 0.445 - 0.470 mm
(0.017 - 0.018 in.)
CONNECTING RODS
(0.0004 - 0.0019 in.)
WJ ENGINE - 4. 7L 9 - 77
Side Clearance 0.10 - 0.35 mm
(0.004 - 0.0138 in.)
Piston Pin Bore Diameter 24.045 - 24.035 mm
(0.94665 - 0.94625 in.)
Bearing Bore Out of
Round
0.004 mm
(MAX) (0.0002 in.)
Total Weight (Less
Bearing)
555 grams (19.5771
ounces)
CRANKSHAFT
Main BearingJournal
Diameter 63.488 - 63.512 mm
(2.4996 - 2.5005 in.)
(0.0008 - 0.0021 in.)
Taper (MAX) 0.008 mm (0.0004 in.)
End Play 0.052 - 0.282 mm
(0.0021 - 0.0112 in.)
End Play (MAX) 0.282 mm (0.0112 in)
Connecting Rod
Journal
Diameter 50.992 - 51.008 mm
(2.0076 - 2.0082 in.)
(0.0006 -0.0022 in.)
Taper (MAX) 0.008 mm (0.0004 in.)
CAMSHAFT
Bore Diameter 26.02 - 26.04 mm
(1.0245 - 1.0252 in.)
Bearing Journal Diameter 25.975 - 25.995 mm
(1.0227 - 1.0235 in.)
(0.001 - 0.0026 in.)
Bearing Clearance (MAX) 0.065 mm (0.0026 in.)
End Play .075 - .200 mm
(0.003 - 0.0079 in.)
End Play (MAX) .200 mm (0.0079 in.)
VALVE TIMING
Intake
Opens (BTDC) 3.0
Closes (ATDC) 233.0
Duration 236.0
Exhaust
Opens (BTDC) 235.0
Closes (ATDC) 15.0
Duration 250.0
Valve Overlap 18.0
VALVES
Face Angle 45- 45.5
Head Diameter
Intake 48.52 - 48.78 mm
(1.9103 - 1.9205 in.)
Exhaust 36.87 - 37.13 mm
1.4516 - 1.4618 in.)
Length (Overall)
Intake 113.45 - 114.21 mm
(4.4666 - 4.4965)
Exhaust 114.92 - 115.68 mm
(4.5244 - 4.5543 in.)
Stem Diameter
Intake 6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Exhaust 6.902 - 6.928 mm
(0.2717 - 0.2728 in.)
Stem - to - Guide
Clearance
Intake .018 - .069 mm
(0.0008 - 0.0028 in.)
Exhaust .047 - .098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem -
to -
Guide Clearance
(Rocking
Method)
Intake 0.069 mm (0.0028 in.)
Exhaust 0.098 mm (0.0039 in.)
9 - 78 ENGINE - 4. 7L WJ
Valve Lift (Zero Lash)
Intake 12.00 mm (0.4724 in.)
Exhaust 10.90 mm (0.4292 in.)
VALVE SPRING
Free Length (Approx)
Intake and Exhaust 48.92 mm (1.9259 in.)
Spring Force (Valve
Closed)
Intake and Exhaust 380.0 +/- 19.0 N @ 40.12
mm
(85.4274 lbs. @ 1.5795
in.)
Spring Force (Valve
Open)
Intake and Exhaust 1030.0 +/- 46.0 N @
28.12 mm
231.5532 lbs. @ 1.107
in.)
Number of Coils
Intake and Exhaust 7.30
Wire Diameter
Intake and Exhaust 4.77 +/- 0.03 mm x
3.80+/- .03mm
Installed Height (Spring
Seat to Bottom of
Retainer)
Nominal
Intake 40.97 mm (1.613 in.)
Exhaust 40.81 mm (1.606 in.)
CYLINDER HEAD
Gasket Thickness
(Compressed) .7 mm (0.0276 in.)
Valve Seat Angle 44.5- 45.0
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Valve Seat Width
Intake 1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
(Std.)
6.975 - 7.00 mm
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
(Flatness) 0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over Rotors /
End Face (MAX)
.035 - .095 mm
(0.0014 - 0.0038 in.)
Cover Out - of -Flat
(MAX)
.025 mm (0.001 in.)
Inner and Outer Rotor
Thickness 12.02 mm (0.4731 in.)
Outer Rotor Clearance
(MAX)
.235 mm (.0093 in.)
Outer Rotor Diameter
(MIN)
85.925 mm (0.400 in.)
Tip Clearance Between
Rotors
(MAX) .150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*
25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run
engine at 3000 rpm.
TORQUE
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90
Bearing Cap Bolts 11 100
Timing Chain CoverBolts 54 40
Connecting Rod CapBolts 27 20
PLUS 90TURN
Bed PlateBolts Refer to Procedure
Crankshaft DamperBolt 175 130
Cylinder HeadBolts
M11 Bolts 81 60
M8 Bolts 26 19
Cylinder Head CoverBolts 12 105
Exhaust ManifoldBolts 25 18
WJ ENGINE - 4. 7L 9 - 79
Lbs. Lbs.
Exhaust Manifold Heat
ShieldNuts
8 72
Then loosen 45
FlexplateBolts 60 45
Engine Mount Bracket to
BlockBolts
61 45
Rear Mount to
TransmissionBolts
46 34
Generator MountingBolts
M10 Bolts 54 40
M8 Bolts 28 250
Intake ManifoldBolts 12 105
Refer to Procedure
for
Tightening Sequence
Oil PanBolts 15 130
Oil PanDrain Plug 34 25
Oil PumpBolts 28 250
Oil Pump CoverBolts 12 105
Oil Pickup TubeBolt and
Nut
28 250
Oil Dipstick Tube to Engine
BlockBolt 15 130
Oil Fill TubeBolts 12 105
Timing Chain GuideBolts 28 250
Timing Chain Tensioner
ArmSpecial
Pin Bolt 17 150
Hydraulic TensionerBolts 28 250
Timing Chain Primary
TensionerBolts
28 250
Timing Drive Idler Sprocket
Bolt
34 25
Thermostat HousingBolts 13 115
Water PumpBolts 54 40
SPECIAL TOOLS
4. 7L ENGINE
Spanner Wrench 6958
Adapter Pins 8346
Engine Lifting Studs 8400
Engine Lift Fixture 8347
9 - 80 ENGINE - 4. 7L WJ
Front Crankshaft Seal Remover 8511
Front Crankshaft Seal Installer 8348
Handle C-4171
Rear Crankshaft Seal Installer 8349
Rear Crankshaft Seal Remover 8506
Connecting Rod Guides 8507
Crankshaft Damper Installer 8512
Puller 1026
WJ ENGINE - 4. 7L 9 - 81
Crankshaft Damper Removal Insert 8513
Chain Tensioner Wedge 8379
Chain Tensioner Pins 8514
Secondary Chain Holder 8429
Remover, Rocker Arm 8516
Valve Spring Compressor 8387
Idler Shaft Remover 8517
Valve Spring Compressor Adapters 8519
9 - 82 ENGINE - 4. 7L WJ
AIR CLEANER ELEMENT
REMOVAL - 4. 7L
(1) Unl atch four cl i ps retai ni ng ai r cl eaner cover to
ai r cl eaner housi ng (Fi g. 8).
(2) Li ft cover up and posi ti on to the si de.
(3) Remove ai r cl eaner el ement.
(1) Cl ean i nsi de of ai r cl eaner housi ng before
i nstal l i ng new el ement.
(2) I nstal l ai r cl eaner el ement i nto housi ng.
(3) Latch cl i ps and cl amp cover down to secure. Be
sure ai r cl eaner cover i s properl y seated to ai r
cl eaner housi ng.
Valve Spring Tester C-647
Dial Indicator C-3339
Valve Spring Compressor C-3422-B
Bore Size Indicator C-119
Oil Pressure Gauge C-3292
Piston Ring Compressor C-385
Pressure Tester Kit 7700
BlocChekKit C-3685A
WJ ENGINE - 4. 7L 9 - 83
AIR CLEANER HOUSING
REMOVAL - 4. 7L
(1) Di sconnect ai r cl eaner cover-to-ai r duct cl amp
(Fi g. 8).
(2) Di sconnect ai r duct at housi ng.
(3) Each of the 3 air cleaner housing mount-
ing bolts is attached with 2 nuts (an upper nut
and lower nut). DO NOT REMOVE BOLTS. To
prevent stripping bolts, only remove lower
nuts. The lower housing nuts are located under
left front inner fender (Fig. 8).
(a) To gai n access to l ower nuts, rai se vehi cl e.
(b) Remove cl i ps retai ni ng rubber i nner fender
shi el d.
(c) Pry back shi el d enough to gai n access to
l ower nuts.
(d) Remove 3 nuts.
(e) Remove ai r cl eaner assembl y from vehi cl e.
(4) I f resonator i s to be removed, di sconnect
breather tube at resonator, di sconnect ai r duct cl amp
at resonator (Fi g. 8)and remove 2 resonator mount-
i ng bol ts (at si des of resonator). Remove resonator
from throttl e body by l ooseni ng cl amp at throttl e
body.
(1) Posi ti on ai r cl eaner assembl y to body and
i nstal l 3 nuts. Ti ghten nuts to 10 Nm (93 i n. l bs.)
torque. To prevent excessive vibration transmit-
ted through housing, the nuts must be properly
torqued. Do not overtighten nuts.
(2) I f resonator was removed: I nstal l resonator and
Ti ghten cl amp at throttl e body to 4 Nm (35 i n. l bs.)
torque.
(3) Posi ti on fender l i ner and i nstal l cl i ps.
(4) Connect ai r duct at housi ng (Fi g. 8).
(5) Ti ghten ai r duct cl amp.
CYLINDER HEAD - LEFT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cyl i nder heads are made of an al umi num al l oy.
The cyl i nder head features two val ves per cyl i nder
wi th pressed i n powdered metal val ve gui des. The
cyl i nder heads al so provi de encl osures for the ti mi ng
chai n drai n, necessi tati ng uni que l eft and ri ght cyl i n-
der heads.
DESCRIPTION - VALVE GUIDES
The val ve gui des are made of powered metal and
are pressed i nto the cyl i nder head. The gui des are
not repl aceabl e or servi ceabl e, and val ve gui de ream-
i ng i s not recommended. I f the gui des are worn
beyond acceptabl e l i mi ts, repl ace the cyl i nder heads.
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
Fig. 8 Air Cleaner Assembly - 4.7L
1 - AIR DUCT
2 - CLAMPS
3 - AIR CLEANER COVER
4 - CLIPS
5 - HOUSING
6 - HOUSING BOLTS (3)
7 - LOWER HOUSING NUTS (3)
8 - RESONATOR BOLTS
9 - RESONATOR
9 - 84 ENGINE - 4. 7L WJ
AIR CLEANER ELEMENT (Continued)
(3) Turn engi ne off and l et set for a few mi nutes
before restarti ng. Repeat thi s several ti mes after
engi ne has reached normal operati ng temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor i n cyl i nder head gasket or the
oi l passage to the cyl i nder head i s pl ugged wi th
debri s.
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Oi l l eak or excessi ve cam bore wear i n cyl i n-
der head.
(11) Faul ty l ash adjuster.
a. Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head and cam on camshaft at
base ci rcl e. Depress part of rocker arm over adjuster.
Normal adjusters shoul d feel very fi rm. Spongy
adjusters can be bottomed out easi l y.
b. Remove suspected l ash adjusters, and repl ace.
c. Before i nstal l ati on, make sure adjusters are at
l east parti al l y ful l of oi l . Thi s can be veri fi ed by l i ttl e
or no pl unger travel when l ash adjuster i s depressed.
DIAGNOSIS AND TESTING CYLINDER HEAD
GASKET
A cyl i nder head gasket l eak can be l ocated between
adjacent cyl i nders or between a cyl i nder and the
adjacent water jacket.
Possi bl e i ndi cati ons of the cyl i nder head gasket
l eaki ng between adjacent cyl i nders are:
Loss of engi ne power
Engi ne mi sfi ri ng
Poor fuel economy
l eaki ng between a cyl i nder and an adjacent water
jacket are:
Engi ne overheati ng
Loss of cool ant
Excessi ve steam (whi te smoke) emi tti ng from
exhaust
Cool ant foami ng
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders, fol l ow the proce-
dures i n Cyl i nder Compressi on Pressure Test (Refer
to 9 - ENGI NE - DI AGNOSI S AND TESTI NG). An
engi ne cyl i nder head gasket l eaki ng between adja-
cent cyl i nders wi l l resul t i n approxi matel y a 5070%
reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
Wi th the engi ne cool , remove the cool ant pressure
cap. Start the engi ne and al l ow i t to warm up unti l
thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
I nstal l Cool i ng System Tester 7700 or equi val ent to
pressure cap neck. Start the engi ne and observe the
testers pressure gauge. I f gauge pul sates wi th every
power stroke of a cyl i nder a combusti on pressure
l eak i s evi dent.
CHEMICAL TEST METHOD
Combusti on l eaks i nto the cool i ng system can al so
be checked by usi ng Bl oc-Chek Ki t C-3685-A or
equi val ent. Perform test fol l owi ng the procedures
suppl i ed wi th the tool ki t.
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Rai se the vehi cl e on a hoi st.
(3) Di sconnect the exhaust pi pe at the l eft si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant. (Refer to 7 - COOL-
(6) Remove the i ntake mani fol d. (Refer to 9 -
REMOVAL).
(7) Remove the cyl i nder head cover. (Refer to 9 -
(8) Remove accessory dri ve bel t. (Refer to 7 -
REMOVAL).
(9) Remove the power steeri ng pump and set
asi de.
(10) Rotate the crankshaft unti l the damper ti m-
i ng mark i s al i gned wi th TDC i ndi cator mark (Fi g.
9).
WJ ENGINE - 4. 7L 9 - 85
CYLINDER HEAD - LEFT (Continued)
(11) Veri fy the V8 mark on the camshaft sprocket
i s at the 12 ocl ock posi ti on (Fi g. 11). Rotate the
crankshaft one turn i f necessary.
(12) Remove the crankshaft damper. (Refer to 9 -
REMOVAL).
(13) Remove the ti mi ng chai n cover. (Refer to 9 -
(14) Lock the secondary ti mi ng chai ns to the i dl er
sprocket usi ng Speci al Tool 8515 (Fi g. 10).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(15) Mark the secondary ti mi ng chai n, one l i nk on
each si de of the V8 mark on the camshaft dri ve gear
(Fi g. 11).
(16) Remove the l eft si de secondary chai n ten-
si oner. (Refer to 9 - ENGI NE/VALVE TI MI NG/TI M-
I NG BELT/CHAI N AND SPROCKETS - REMOVAL).
(17) Remove the cyl i nder head access pl ug (Fi g.
12).
(18) Remove the l eft si de secondary chai n gui de.
(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
BELT/CHAI N AND SPROCKETS - REMOVAL).
(19) Remove the retai ni ng bol t and the camshaft
dri ve gear.
CAUTION: Do not allow the engine to rotate. Severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
NOTE: The cylinder head is attached to the cylinder
block with fourteen bolts.
(20) Remove the cyl i nder head retai ni ng bol ts.
(21) Remove the cyl i nder head and gasket. Di scard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, due to the design of the cylin-
der head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
CLEANING
use of al umi num engi ne components. (Refer to 9 -
ENGI NE - STANDARD PROCEDURE)
Fig. 9 Engine Top Dead Center
2 - CRANKSHAFT TIMING MARKS
Fig. 10 Using Special Tool 8515 to Hold Chains to
Idler Sprocket.
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
4 - IDLER SPROCKET
5 - LEFT CAMSHAFT CHAIN
9 - 86 ENGINE - 4. 7L WJ
INSPECTION
(1) I nspect the cyl i nder head for out-of-fl atness,
usi ng a strai ghtedge and a feel er gauge. I f tol erances
exceed 0.0508 mm (0.002 i n.) repl ace the cyl i nder
head.
(2) I nspect the val ve seats for damage. Servi ce the
val ve seats as necessary.
(3) I nspect the val ve gui des for wear, cracks or
l ooseness. I f ei ther condi ti on exi st, repl ace the cyl i n-
der head.
INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necki ng can be checked by hol di ng a strai ght edge
agai nst the threads. I f al l the threads do not contact
the scal e, the bol t shoul d be repl aced (Fi g. 13).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Cl ean the cyl i nder head and cyl i nder bl ock
mati ng surfaces (Refer to 9 - ENGI NE - STANDARD
PROCEDURE).
(2) Posi ti on the new cyl i nder head gasket on the
l ocati ng dowel s.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
Fig. 11 Camshaft Sprocket V8 Marks
1 - LEFT CYLINDER HEAD
Fig. 12 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
WJ ENGINE - 4. 7L 9 - 87
(3) Posi ti on the cyl i nder head onto the cyl i nder
bl ock. Make sure the cyl i nder head seats ful l y over
the l ocati ng dowel s.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lubri cate the cyl i nder head bol t threads wi th
cl ean engi ne oi l and i nstal l the ten M11 bol ts.
(5) Coat the four M8 cyl i nder head bol ts wi th
Mopar Lock and Seal Adhesive then i nstal l the
bol ts.
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Ti ghten the bol ts i n sequence (Fi g. 14) usi ng
the fol l owi ng steps and torque val ues:
Step 1: Ti ghten bol ts 110, 27 Nm (20 ft. l bs.).
Step 2: Veri fy that bol ts 110, al l reached 27
Nm (20 ft. l bs.), by repeati ng step-1 wi thout l oosen-
i ng the bol ts. Ti ghten bol ts 11 thru 14 to 14 Nm (10
ft. l bs.).
Step 3: Ti ghten bol ts 110, 90 degrees.
Step 4: Ti ghten bol ts 110, 90 degrees, agai n.
Ti ghten bol ts 1114, 26 Nm (19 ft. l bs.)
(7) I nstal l the secondary chai n and secondary
chai n gui de (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT/CHAI N AND SPROCKETS -
I NSTALLATI ON).
(8) I nstal l the cyl i nder head access pl ug.
(9) Re-set and I nstal l the l eft si de secondary chai n
tensi oner (Refer to 9 - ENGI NE/VALVE TI MI NG/
I NSTALLATI ON).
(10) Remove Speci al Tool 8515.
(11) I nstal l the ti mi ng chai n cover (Refer to 9 -
(12) I nstal l the crankshaft damper (Refer to 9 -
I NSTALLATI ON).
(13) I nstal l the power steeri ng pump.
(15) I nstal l the i ntake mani fol d (Refer to 9 -
I NSTALLATI ON).
(16) Refi l l the cool i ng system (Refer to 7 - COOL-
(18) I nstal l the exhaust pi pe onto the l eft exhaust
mani fol d.
(20) Connect the negati ve cabl e to the battery.
CAMSHAFT(S) - LEFT
DESCRIPTION
The camshafts consi st of powdered metal steel
l obes whi ch are si nter-bonded to a steel tube. A steel
post or nose pi ece i s fri cti on-wel ded to the steel cam-
shaft tube. Fi ve beari ng journal s are machi ned i nto
the camshaft, four on the steel tube and one on the
steel nose pi ece. Camshaft end pl ay i s control l ed by
two thrust wal l s that border the nose pi ece journal .
Engi ne oi l enters the hol l ow camshafts at the thi rd
journal and l ubri cates every i ntake l obe rocker
through a dri l l ed passage i n the i ntake l obe.
Fig. 13 Checking Cylinder Head Bolts for Stretching
(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 14 Cylinder Head Tightening Sequence
9 - 88 ENGINE - 4. 7L WJ
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use Special Tool
8350 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to
reset the tensioner ratchet.
(1) Remove cyl i nder head cover (Refer to 9 -
(2) Set engi ne to TDC cyl i nder #1, camshaft
sprocket V8 marks at the 12 ocl ock posi ti on.
(3) Mark one l i nk on the secondary ti mi ng chai n
on both si des of the V8 mark on the camshaft
sprocket to ai d i n i nstal l ati on.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.
(4) Loosen but DO NOT remove the camshaft
sprocket retai ni ng bol t. Leave the bol t snug agai nst
the sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Posi ti on Speci al Tool 8350 ti mi ng chai n wedge
between the ti mi ng chai n strands, tap the tool to
securel y wedge the ti mi ng chai n agai nst the ten-
si oner arm and gui de (Fi g. 15).
NOTE: When gripping the camshaft, place the pliers
on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.
(6) Hol d the camshaft wi th adjustabl e pl i ers whi l e
removi ng the camshaft sprocket bol t and sprocket
(Fi g. 16).
Fig. 15 Securing Timing Chain Tensioners Using Timing Chain Wedge
3 - SPECIAL TOOL 8350 WEDGE
WJ ENGINE - 4. 7L 9 - 89
CAMSHAFT(S) - LEFT (Continued)
(7) Usi ng the pl i ers, gentl y al l ow the camshaft to
rotate 15 cl ockwi se unti l the camshaft i s i n the neu-
tral posi ti on (no val ve l oad).
(8) Starti ng at the outsi de worki ng i nward, l oosen
the camshaft beari ng cap retai ni ng bol ts 1/2 turn at
a ti me. Repeat unti l al l l oad i s off the beari ng caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
(9) Remove the camshaft beari ng caps and the
camshaft.
INSTALLATION
(1) Lubri cate camshaft journal s wi th cl ean engi ne
oi l .
NOTE: Position the left side camshaft so that the
camshaft sprocket dowel is near the 1 oclock posi-
tion, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Posi ti on the camshaft i nto the cyl i nder head.
(3) I nstal l the camshaft beari ng caps, hand ti ghten
the retai ni ng bol ts.
(4) Worki ng i n
1
2 turn i ncrements, ti ghten the
beari ng cap retai ni ng bol ts starti ng wi th the mi ddl e
cap worki ng outward (Fi g. 17).
(5) Torque the camshaft beari ng cap retai ni ng
bol ts to 11 Nm (100 i n. l bs.).
(6) Posi ti on the camshaft dri ve gear i nto the ti m-
i ng chai n al i gni ng the V8 mark between the two
marked chai n l i nks (Two l i nks marked duri ng
removal ) (Fi g. 18).
Fig. 16 Camshaft Sprocket and Chain
1 - CAMSHAFT SPROCKET AND CHAIN
2 - ADJUSTABLE PLIERS
3 - CAMSHAFT
Fig. 17 Camshaft Bearing Caps Tightening
Sequence
9 - 90 ENGINE - 4. 7L WJ
(7) Usi ng the adjustabl e pl i ers, rotate the cam-
shaft unti l the camshaft sprocket dowel i s al i gned
wi th the sl ot i n the camshaft sprocket. I nstal l the
sprocket onto the camshaft (Fi g. 19).
CAUTION: Remove excess oil from camshaft
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oi l from bol t, then i nstal l the
camshaft sprocket retai ni ng bol t and hand ti ghten.
(9) Remove Speci al Tool 8350 ti mi ng chai n wedge
(Fi g. 20).
(10) Usi ng Speci al Tool 6958 spanner wrench wi th
adapter pi ns 8346 (Fi g. 21), torque the camshaft
sprocket retai ni ng bol t to 122 Nm (90 ft. l bs.).
(11) I nstal l the cyl i nder head cover.
Fig. 18 Timing Chain to Sprocket Alignment
Fig. 19 Camshaft Sprocket Installation
2 - CAMSHAFT DOWEL
WJ ENGINE - 4. 7L 9 - 91
Fig. 20 SPECIAL TOOL 8350
9 - 92 ENGINE - 4. 7L WJ
CYLINDER HEAD COVER(S) -
LEFT
DESCRIPTION
The cyl i nder head covers are made of di e cast mag-
nesi um, and are not i nterchangeabl e from si de-to-
si de. I t i s i mperati ve that nothi ng rest on the
cyl i nder head covers. Prol onged contact wi th other
i tems may wear a hol e i n the cyl i nder head cover.
REMOVAL - LEFT SIDE
(2) Remove the resonator assembl e and ai r i nl et
hose.
(3) Di sconnect i njector connectors and un-cl i p the
i njector harness.
(4) Route i njector harness i n front of cyl i nder head
cover.
(5) Di sconnect the l eft si de breather tube and
remove the breather tube.
(6) Remove the cyl i nder head cover mounti ng
bol ts.
(7) Remove cyl i nder head cover and gasket.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
Cl ean cyl i nder head cover gasket surface.
Cl ean head rai l , i f necessary.
INSTALLATION LEFT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.
(1) Cl ean cyl i nder head cover and both seal i ng sur-
faces. I nspect and repl ace gasket as necessary.
(2) I nstal l cyl i nder head cover and hand start al l
fasteners. Veri fy that al l studs are i n the correct l oca-
ti on shown i n (Fi g. 22).
(3) Ti ghten cyl i nder head cover bol ts and doubl e
ended studs to 12 Nm (105 i n. l bs.).
(4) I nstal l l eft si de breather and connect breather
tube.
(5) Connect i njector el ectri cal connectors and i njec-
tor harness retai ni ng cl i ps.
(6) I nstal l the resonator and ai r i nl et hose.
Fig. 21 Tightening Left Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
Fig. 22 Cylinder Head CoverLeft
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 Nm (105 in. lbs.)
WJ ENGINE - 4. 7L 9 - 93
SEATS
DESCRIPTION
have chrome pl ated stems to prevent scuffi ng. Each
val ve i s actuated by a rol l er rocker arm whi ch pi vots
on a stati onary l ash adjuster. Al l val ves use three
bead l ock keepers to retai n the spri ngs and promote
val ve rotati on.
STANDARD PROCEDURE REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Usi ng a sui tabl e di al i ndi cator measure the
center of the val ve seat Total run out must not
exceed 0.051 mm (0.002 i n).
(2) Appl y a smal l amount of Prussi an bl ue to the
val ve seat, i nsert the val ve i nto the cyl i nder head,
whi l e appl yi ng l i ght pressure on the val ve rotate the
val ve. Remove the val ve and exami ne the val ve face.
I f the bl ue i s transferred bel ow the top edge of the
val ve face, l ower the val ve seat usi ng a 15 degree
stone. I f the bl ue i s transferred to the bottom edge of
the val ve face, rai se the val ve seat usi ng a 65 degree
stone.
(3) When the seat i s properl y posi ti oned the wi dth
of the i ntake seat must be 1.75 2.36 mm (0.0689
0.0928 i n.) and the exhaust seat must be 1.71 2.32
mm (0.0673 0.0911 i n.).
(4) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat. The i nstal l ed hei ght for
both i ntake and exhaust val ve spri ngs must not
exceed 41.44 mm (1.6315 i n.).
(5) The val ve seat and val ve face must mai ntai n a
face angl e of 44.5 45 degrees angl e (Fi g. 23).
REMOVAL
NOTE: The cylinder heads must be removed in
order to preform this procedure.
(1) Remove rocker arms and l ash adjusters. Refer
to procedures i n thi s secti on (Fi g. 24).
camshaft.
Fig. 23 Valve Assembly Configuration
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 24 Rocker Arm Removal
1 - CAMSHAFT
9 - 94 ENGINE - 4. 7L WJ
NOTE: All eight valve springs and valves are
removed in the same manner; this procedure only
covers one valve and valve spring.
(3) Usi ng Speci al Tool C-3422B or C-3422C
Val ve Spri ng Compressor and Speci al tool 8519
Adapter, compress the val ve spri ng.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(4) Remove the two spri ng retai ner l ock hal ves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(5) Remove the val ve spri ng compressor.
(6) Remove the spri ng retai ner, and the spri ng.
NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the val ve from the cyl i nder head.
NOTE: The valve stem seals are common between
intake and exhaust.
(8) Remove the val ve stem seal . Mark the val ve for
proper i nstal l ati on.
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
I nspect the val ve spri ngs for physi cal si gns of wear
or damage. Turn tabl e of tool C-647 unti l surface i s
i n l i ne wi th the 40.69 mm (1.602 i n.) mark on the
threaded stud and the zero mark on the front. Pl ace
spri ng over the stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l Pi ng i s heard. Take readi ng on torque wrench
at thi s i nstant. Mul ti pl y thi s readi ng by two. Thi s
wi l l gi ve the spri ng l oad at test l ength. Fracti onal
measurements are i ndi cated on the tabl e for fi ner
adjustments. Refer to Speci fi cati ons Secti on to obtai n
speci fi ed hei ght and al l owabl e tensi ons. Repl ace any
spri ngs that do not meet speci fi cati ons. (Fi g. 25)
INSTALLATION
(1) coat the val ve stem wi th cl ean engi ne oi l and
i nsert i t i nto the cyl i nder head.
(2) I nstal l the val ve stem seal . make sure the seal
i s ful l y seated and that the garter spri ng at the top
of the seal i s i ntact.
(3) I nstal l the spri ng and the spri ng retai ner (Fi g.
26).
(4) Usi ng the val ve spri ng compressor, compress
the spri ng and i nstal l the two val ve spri ng retai ner
hal ves.
(5) Rel ease the val ve spri ng compressor and make
sure the two spri ng retai ner hal ves and the spri ng
retai ner are ful l y seated.
(6) l ubri cate the camshaft journal wi th cl ean
engi ne oi l then Posi ti on the camshaft (wi th the
sprocket dowel on the l eft camshaft at 11 ocl ock and
the ri ght camshaft at 12 ocl ock), then posi ti on the
camshaft beari ng caps.
(7) I nstal l the camshaft beari ng cap retai ni ng
bol ts. Ti ghten the bol ts 913 Nm (100 i n. l bs.) i n
1
2
turn i ncrements i n the sequence shown (Fi g. 27).
(8) Posi ti on the hydraul i c l ash adjusters and
rocker arms (Fi g. 24).
Fig. 25 Testing Valve Springs
1 - SPECIAL TOOL C-647
WJ ENGINE - 4. 7L 9 - 95
ASSEMBLY
DESCRIPTION
The rocker arms are steel stampi ngs wi th an i nte-
gral rol l er beari ng. The rocker arms i ncorporate a 2.8
mm (0.11 i nch) oi l hol e i n the l ash adjuster socket for
rol l er and camshaft l ubri cati on.
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
(2) For rocker arm removal on cyl i nders 3 and 5
Rotate the crankshaft unti l cyl i nder #1 i s at TDC
exhaust stroke.
compressi on stroke.
(6) Usi ng speci al tool 8516 Rocker Arm Remover,
press downward on the val ve spri ng, remove rocker
arm (Fi g. 28).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
(1) For rocker arm i nstal l ati on on cyl i nders 3 and
5 Rotate the crankshaft unti l cyl i nder #1 i s at TDC
exhaust stroke.
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Sequence
9 - 96 ENGINE - 4. 7L WJ
(5) Usi ng speci al tool 8516 press downward on the
val ve spri ng, i nstal l rocker arm (Fi g. 28).
VALVE SPRINGS
DESCRIPTION
The val ve spri ngs are made from hi gh strength
chrome si l i con steel . The spri ngs are common for
i ntake and exhaust appl i cati ons. The val ve spri ng
seat i s i ntegral wi th the val ve stem seal , whi ch i s a
posi ti ve type seal to control l ubri cati on.
VALVE STEM SEALS
DESCRIPTION
The val ve stem seal s are made of rubber and i ncor-
porate an i ntegral steel val ve spri ng seat. The i nte-
gral garter spri ng mai ntai ns consi stent l ubri cati on
control to the val ve stems.
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cyl i nder heads are made of an al umi num al l oy.
The cyl i nder head features two val ves per cyl i nder
wi th pressed i n powdered metal val ve gui des. The
cyl i nder heads al so provi de encl osures for the ti mi ng
chai n drai n, necessi tati ng uni que l eft and ri ght cyl i n-
der heads.
DESCRIPTION - VALVE GUIDES
The val ve gui des are made of powered metal and
are pressed i nto the cyl i nder head. The gui des are
not repl aceabl e or servi ceabl e, and val ve gui de ream-
i ng i s not recommended. I f the gui des are worn
beyond acceptabl e l i mi ts, repl ace the cyl i nder heads.
DIAGNOSIS AND TESTING CYLINDER HEAD
GASKET
A cyl i nder head gasket l eak can be l ocated between
adjacent cyl i nders or between a cyl i nder and the
adjacent water jacket.
l eaki ng between adjacent cyl i nders are:
Loss of engi ne power
Engi ne mi sfi ri ng
Poor fuel economy
l eaki ng between a cyl i nder and an adjacent water
jacket are:
Engi ne overheati ng
Loss of cool ant
Excessi ve steam (whi te smoke) emi tti ng from
exhaust
Cool ant foami ng
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders, fol l ow the proce-
dures i n Cyl i nder Compressi on Pressure Test (Refer
to 9 - ENGI NE - DI AGNOSI S AND TESTI NG). An
engi ne cyl i nder head gasket l eaki ng between adja-
cent cyl i nders wi l l resul t i n approxi matel y a 5070%
reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
Fig. 28 Rocker ArmRemoval
1 - CAMSHAFT
WJ ENGINE - 4. 7L 9 - 97
VISUAL TEST METHOD
Wi th the engi ne cool , remove the cool ant pressure
cap. Start the engi ne and al l ow i t to warm up unti l
thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
I nstal l Cool i ng System Tester 7700 or equi val ent to
pressure cap neck. Start the engi ne and observe the
testers pressure gauge. I f gauge pul sates wi th every
power stroke of a cyl i nder a combusti on pressure
l eak i s evi dent.
CHEMICAL TEST METHOD
Combusti on l eaks i nto the cool i ng system can al so
be checked by usi ng Bl oc-Chek Ki t C-3685-A or
equi val ent. Perform test fol l owi ng the procedures
suppl i ed wi th the tool ki t.
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
(3) Turn engi ne off and l et set for a few mi nutes
before restarti ng. Repeat thi s several ti mes after
engi ne has reached normal operati ng temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor i n cyl i nder head gasket or the
oi l passage to the cyl i nder head i s pl ugged wi th
debri s.
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Oi l l eak or excessi ve cam bore wear i n cyl i n-
der head.
(11) Faul ty l ash adjuster.
a. Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head and cam on camshaft at
base ci rcl e. Depress part of rocker arm over adjuster.
Normal adjusters shoul d feel very fi rm. Spongy
adjusters can be bottomed out easi l y.
b. Remove suspected l ash adjusters, and repl ace.
c. Before i nstal l ati on, make sure adjusters are at
l east parti al l y ful l of oi l . Thi s can be veri fi ed by l i ttl e
or no pl unger travel when l ash adjuster i s depressed.
REMOVAL
(1) Di sconnect battery negi ti ve cabl e.
(3) Di sconnect the exhaust pi pe at the ri ght si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant (Refer to 7 - COOL-
(6) Remove the i ntake mani fol d (Refer to 9 -
REMOVAL).
(8) Remove oi l fi l l housi ng from cyl i nder head.
REMOVAL).
(10) Rotate the crankshaft unti l the damper ti m-
i ng mark i s al i gned wi th TDC i ndi cator mark (Fi g.
9).
(11) Veri fy the V8 mark on the camshaft sprocket
i s at the 12 ocl ock posi ti on (Fi g. 11). Rotate the
crankshaft one turn i f necessary.
(12) Remove the crankshaft damper (Refer to 9 -
REMOVAL).
(13) Remove the ti mi ng chai n cover (Refer to 9 -
(14) Lock the secondary ti mi ng chai ns to the i dl er
sprocket usi ng Speci al Tool 8515 (Fi g. 10).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(15) Mark the secondary ti mi ng chai n, one l i nk on
each si de of the V8 mark on the camshaft dri ve gear
(Fi g. 11).
(16) Remove the ri ght si de secondary chai n ten-
si oner (Refer to 9 - ENGI NE/VALVE TI MI NG/TI M-
I NG BELT/CHAI N AND SPROCKETS - REMOVAL).
(17) Remove the cyl i nder head access pl ug (Fi g.
29).
(18) Remove the ri ght si de secondary chai n gui de
9 - 98 ENGINE - 4. 7L WJ
CYLINDER HEAD - RIGHT (Continued)
(19) Remove the retai ni ng bol t and the camshaft
dri ve gear.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder
block with fourteen bolts.
(20) Remove the cyl i nder head retai ni ng bol ts.
(21) Remove the cyl i nder head and gasket. Di scard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
CLEANING
use of al umi num engi ne components. (Refer to 9 -
ENGI NE - STANDARD PROCEDURE)
INSPECTION
(1) I nspect the cyl i nder head for out-of-fl atness,
usi ng a strai ghtedge and a feel er gauge. I f tol erances
exceed 0.0508 mm (0.002 i n.) repl ace the cyl i nder
head.
(2) I nspect the val ve seats for damage. Servi ce the
val ve seats as necessary.
(3) I nspect the val ve gui des for wear, cracks or
l ooseness. I f ei ther condi ti on exi st, repl ace the cyl i n-
der head.
INSTALLATION
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necki ng can be checked by hol di ng a strai ght edge
agai nst the threads. I f al l the threads do not contact
the scal e, the bol t shoul d be repl aced (Fi g. 13).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Cl ean the cyl i nder head and cyl i nder bl ock
mati ng surfaces (Refer to 9 - ENGI NE - STANDARD
PROCEDURE).
(2) Posi ti on the new cyl i nder head gasket on the
l ocati ng dowel s.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Posi ti on the cyl i nder head onto the cyl i nder
bl ock. Make sure the cyl i nder head seats ful l y over
the l ocati ng dowel s.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lubri cate the cyl i nder head bol t threads wi th
cl ean engi ne oi l and i nstal l the ten M10 bol ts.
(5) Coat the four M8 cyl i nder head bol ts wi th
Mopar Lock and Seal Adhesivethen i nstal l the
bol ts.
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Ti ghten the bol ts i n sequence (Fi g. 30) usi ng
the fol l owi ng steps and torque val ues:
Step 1: Ti ghten bol ts 110, 27 Nm (20 ft. l bs.).
Fig. 29 Cylinder Head Access Plugs
WJ ENGINE - 4. 7L 9 - 99
Step 2: Veri fy that bol ts 110, al l reached 27
Nm (20 ft. l bs.), by repeati ng step-1 wi thout l oosen-
i ng the bol ts. Ti ghten bol ts 11 thru 14 to 14 Nm (10
ft. l bs.).
Step 3: Ti ghten bol ts 110, 90 degrees.
Step 4: Ti ghten bol ts 110, 90 degrees, agai n.
Ti ghten bol ts 1114, 26 Nm (19 ft. l bs.)
(7) I nstal l the secondary chai n and secondary
chai n gui de (Refer to 9 - ENGI NE/VALVE TI MI NG/
I NSTALLATI ON).
(8) I nstal l the cyl i nder head access pl ug.
(9) Re-set and i nstal l the ri ght si de secondary
chai n tensi oner (Refer to 9 - ENGI NE/VALVE TI M-
I NG/TI MI NG BELT/CHAI N AND SPROCKETS -
I NSTALLATI ON).
(10) Remove Speci al Tool 8515.
(12) I nstal l the crankshaft damper (Refer to 9 -
I NSTALLATI ON).
I NSTALLATI ON).
(15) I nstal l the i ntake mani fol d (Refer to 9 -
I NSTALLATI ON).
(16) I nstal l oi l fi l l housi ng onto cyl i nder head.
(17) Refi l l the cool i ng system (Refer to 7 - COOL-
(19) I nstal l the exhaust pi pe onto the ri ght
exhaust mani fol d.
(21) Reconnect battery negi ti ve cabl e.
CAMSHAFT(S) - RIGHT
DESCRIPTION
The camshafts consi st of powdered metal steel
l obes whi ch are si nter-bonded to a steel tube. A steel
post or nose pi ece i s fri cti on-wel ded to the steel cam-
shaft tube. Fi ve beari ng journal s are machi ned i nto
the camshaft, four on the steel tube and one on the
steel nose pi ece. Camshaft end pl ay i s control l ed by
two thrust wal l s that border the nose pi ece journal .
Engi ne oi l enters the hol l ow camshafts at the thi rd
journal and l ubri cates every i ntake l obe rocker
through a dri l l ed passage i n the i ntake l obe.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use special tool 8350
will result in hydraulic tensioner ratchet over exten-
sion, Requiring timing chain cover removal to re-set
the tensioner ratchet.
(1) Remove the cyl i nder head covers (Refer to 9 -
(2) Set engi ne to TDC cyl i nder #1, camshaft
sprocket V8 marks at the 12 ocl ock posi ti on.
(3) Mark one l i nk on the secondary ti mi ng chai n
on both si des of the V8 mark on the camshaft
sprocket to ai d i n i nstal l ati on.
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft
sprocket retai ni ng bol t. Leave bol t snug agai nst
sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
Fig. 30 Cylinder Head Tightening Sequence
9 - 100 ENGINE - 4. 7L WJ
(5) Posi ti on Speci al Tool 8350 ti mi ng chai n wedge
between the ti mi ng chai n strands. Tap the tool to
securel y wedge the ti mi ng chai n agai nst the ten-
si oner arm and gui de (Fi g. 31).
(6) Remove the camshaft posi ti on sensor (Fi g. 32).
(7) Hol d the camshaft wi th adjustabl e pl i ers whi l e
removi ng the camshaft sprocket bol t and sprocket
(Fi g. 33).
(8) Usi ng the pl i ers, gentl y al l ow the camshaft to
rotate 45 counter-cl ockwi se unti l the camshaft i s i n
the neutral posi ti on (no val ve l oad).
(9) Starti ng at the outsi de worki ng i nward, l oosen
the camshaft beari ng cap retai ni ng bol ts 1/2 turn at
a ti me. Repeat unti l al l l oad i s off the beari ng caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
camshaft.
Fig. 32 Camshaft Position Sensor
WJ ENGINE - 4. 7L 9 - 101
CAMSHAFT(S) - RIGHT (Continued)
INSTALLATION
(1) Lubri cate camshaft journal s wi th cl ean engi ne
oi l .
NOTE: Position the right side camshaft so that the
camshaft sprocket dowel is near the 10 oclock
position, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Posi ti on the camshaft i nto the cyl i nder head.
(3) I nstal l the camshaft beari ng caps, hand ti ghten
the retai ni ng bol ts.
(4) Worki ng i n 1/2 turn i ncrements, ti ghten the
beari ng cap retai ni ng bol ts starti ng wi th the mi ddl e
cap worki ng outward (Fi g. 34).
(5) Torque the camshaft beari ng cap retai ni ng
(6) Posi ti on the camshaft dri ve gear i nto the ti m-
i ng chai n al i gni ng the V8 mark between the two
marked chai n l i nks (Two l i nks marked duri ng
removal ) (Fi g. 35).
(7) Usi ng the adjustabl e pl i ers, rotate the cam-
shaft unti l the camshaft sprocket dowel i s al i gned
wi th the sl ot i n the camshaft sprocket. I nstal l the
sprocket onto the camshaft (Fi g. 36).
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oi l from camshaft sprocket bol t,
then i nstal l the camshaft sprocket retai ni ng bol t and
hand ti ghten.
(9) Remove ti mi ng chai n wedge speci al tool 8350
(Fi g. 31).
(10) Usi ng Speci al Tool 6958 spanner wrench wi th
adapter pi ns 8346 (Fi g. 37), torque the camshaft
sprocket retai ni ng bol t to 122 Nm (90 ft. l bs.).
(11) I nstal l the camshaft posi ti on sensor (Fi g. 32).
Fig. 33 Camshaft Sprocket and Chain
2 - SPROCKET BOLT
4 - CAMSHAFT
Sequence
9 - 102 ENGINE - 4. 7L WJ
Fig. 35 Timing Chain to Sprocket Alignment
Fig. 36 Camshaft Sprocket Installation
2 - CAMSHAFT DOWEL
Fig. 37 Tightening Right Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
WJ ENGINE - 4. 7L 9 - 103
CYLINDER HEAD COVER(S) -
RIGHT
DESCRIPTION
The cyl i nder head covers are made of di e cast mag-
nesi um, and are not i nterchangeabl e from si de-to-
si de. I t i s i mperati ve that nothi ng rest on the
cyl i nder head covers. Prol onged contact wi th other
i tems may wear a hol e i n the cyl i nder head cover.
REMOVAL - RIGHT SIDE
(1) Di sconnect battery negati ve cabl e.
(2) Remove ai r cl eaner assembl y, resonator assem-
bl y and ai r i nl et hose.
REMOVAL).
(5) Remove ai r condi ti oni ng compressor retai ni ng
bol ts and move compressor to the l eft.
(6) Remove heater hoses.
(7) Di sconnect i njector and i gni ti on coi l connectors.
(8) Di sconnect and remove posi ti ve crankcase ven-
ti l ati on (PCV) hose.
(9) Remove oi l fi l l tube.
(10) Un-cl i p i njector and i gni ti on coi l harness and
move away from cyl i nder head cover.
(11) Remove ri ght rear breather tube and fi l ter
assembl y.
(12) Remove cyl i nder head cover retai ni ng bol ts.
(13) Remove cyl i nder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
Cl ean cyl i nder head cover gasket surface.
Cl ean head rai l , i f necessary.
INSTALLATION - RIGHT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Cl ean cyl i nder head cover and both seal i ng sur-
faces. I nspect and repl ace gasket as necessary.
(2) I nstal l cyl i nder head cover and hand start al l
fasteners. Veri fy that al l doubl e ended studs are i n
the correct l ocati on shown i n (Fi g. 38).
(3) Ti ghten cyl i nder head cover bol ts and doubl e
ended studs to 12 Nm (105 i n. l bs).
(4) I nstal l ri ght rear breather tube and fi l ter
assembl y.
(5) Connect i njector, i gni ti on coi l el ectri cal connec-
tors and harness retai ni ng cl i ps.
(6) I nstal l the oi l fi l l tube.
(7) I nstal l PCV hose.
(8) I nstal l heater hoses.
(9) I nstal l ai r condi ti oni ng compressor retai ni ng
bol ts.
I NSTALLATI ON).
(11) Fi l l Cool i ng system (Refer to 7 - COOLI NG -
(12) I nstal l ai r cl eaner assembl y, resonator assem-
bl y and ai r i nl et hose.
(13) Connect battery negati ve cabl e.
SEATS
DESCRIPTION
have chrome pl ated stems to prevent scuffi ng. Each
val ve i s actuated by a rol l er rocker arm whi ch pi vots
on a stati onary l ash adjuster. Al l val ves use three
bead l ock keepers to retai n the spri ngs and promote
val ve rotati on.
Fig. 38 Cylinder Head CoverRight
1 Cover Fasteners 12 Nm (105 in. lbs.)
9 - 104 ENGINE - 4. 7L WJ
STANDARD PROCEDURE REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Usi ng a sui tabl e di al i ndi cator measure the
center of the val ve seat Total run out must not
exceed 0.051 mm (0.002 i n).
(2) Appl y a smal l amount of Prussi an bl ue to the
val ve seat, i nsert the val ve i nto the cyl i nder head,
whi l e appl yi ng l i ght pressure on the val ve rotate the
val ve. Remove the val ve and exami ne the val ve face.
I f the bl ue i s transferred bel ow the top edge of the
val ve face, l ower the val ve seat usi ng a 15 degree
stone. I f the bl ue i s transferred to the bottom edge of
the val ve face, rai se the val ve seat usi ng a 65 degree
stone.
(3) When the seat i s properl y posi ti oned the wi dth
of the i ntake seat must be 1.75 2.36 mm (0.0689
0.0928 i n.) and the exhaust seat must be 1.71 2.32
mm (0.0673 0.0911 i n.).
(4) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat. The i nstal l ed hei ght for
both i ntake and exhaust val ve spri ngs must not
exceed 41.44 mm (1.6315 i n.).
(5) The val ve seat and val ve face must mai ntai n a
face angl e of 44.5 45 degrees angl e (Fi g. 39).
REMOVAL
NOTE: The cylinder heads must be removed in
order to preform this procedure.
(1) Remove rocker arms and l ash adjusters. Refer
to procedures i n thi s secti on (Fi g. 40).
camshaft.
NOTE: All eight valve springs and valves are
removed in the same manner; this procedure only
covers one valve and valve spring.
(3) Usi ng Speci al Tool C-3422B or C-3422C
Val ve Spri ng Compressor and Speci al tool 8519
Adapter, compress the val ve spri ng.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 40 Rocker Arm Removal
1 - CAMSHAFT
WJ ENGINE - 4. 7L 9 - 105
(4) Remove the two spri ng retai ner l ock hal ves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(5) Remove the val ve spri ng compressor.
(6) Remove the spri ng retai ner, and the spri ng.
NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the val ve from the cyl i nder head.
NOTE: The valve stem seals are common between
intake and exhaust.
(8) Remove the val ve stem seal . Mark the val ve for
proper i nstal l ati on.
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
I nspect the val ve spri ngs for physi cal si gns of wear
or damage. Turn tabl e of tool C-647 unti l surface i s
i n l i ne wi th the 40.69 mm (1.602 i n.) mark on the
threaded stud and the zero mark on the front. Pl ace
spri ng over the stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l Pi ng i s heard. Take readi ng on torque wrench
at thi s i nstant. Mul ti pl y thi s readi ng by two. Thi s
wi l l gi ve the spri ng l oad at test l ength. Fracti onal
measurements are i ndi cated on the tabl e for fi ner
adjustments. Refer to Speci fi cati ons Secti on to obtai n
speci fi ed hei ght and al l owabl e tensi ons. Repl ace any
spri ngs that do not meet speci fi cati ons. (Fi g. 41)
INSTALLATION
(1) coat the val ve stem wi th cl ean engi ne oi l and
i nsert i t i nto the cyl i nder head.
(2) I nstal l the val ve stem seal . make sure the seal
i s ful l y seated and that the garter spri ng at the top
of the seal i s i ntact.
(3) I nstal l the spri ng and the spri ng retai ner (Fi g.
42).
(4) Usi ng the val ve spri ng compressor, compress
the spri ng and i nstal l the two val ve spri ng retai ner
hal ves.
(5) Rel ease the val ve spri ng compressor and make
sure the two spri ng retai ner hal ves and the spri ng
retai ner are ful l y seated.
(6) l ubri cate the camshaft journal wi th cl ean
engi ne oi l then Posi ti on the camshaft (wi th the
sprocket dowel on the l eft camshaft at 11 ocl ock and
the ri ght camshaft at 12 ocl ock), then posi ti on the
camshaft beari ng caps.
Fig. 41 Testing Valve Springs
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 106 ENGINE - 4. 7L WJ
(7) I nstal l the camshaft beari ng cap retai ni ng
bol ts. Ti ghten the bol ts 913 Nm (100 i n. l bs.) i n
1
2
turn i ncrements i n the sequence shown (Fi g. 43).
(8) Posi ti on the hydraul i c l ash adjusters and
rocker arms (Fi g. 40).
ASSEMBLY
DESCRIPTION
The rocker arms are steel stampi ngs wi th an i nte-
gral rol l er beari ng. The rocker arms i ncorporate a 2.8
mm (0.11 i nch) oi l hol e i n the l ash adjuster socket for
rol l er and camshaft l ubri cati on.
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
exhaust stroke.
(6) Usi ng speci al tool 8516 Rocker Arm Remover,
press downward on the val ve spri ng, remove rocker
arm (Fi g. 44).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
exhaust stroke.
Sequence
Fig. 44 Rocker ArmRemoval
1 - CAMSHAFT
WJ ENGINE - 4. 7L 9 - 107
(5) Usi ng speci al tool 8516 press downward on the
val ve spri ng, i nstal l rocker arm (Fi g. 44).
VALVE SPRINGS
DESCRIPTION
The val ve spri ngs are made from hi gh strength
chrome si l i con steel . The spri ngs are common for
i ntake and exhaust appl i cati ons. The val ve spri ng
seat i s i ntegral wi th the val ve stem seal , whi ch i s a
posi ti ve type seal to control l ubri cati on.
VALVE STEM SEALS
DESCRIPTION
The val ve stem seal s are made of rubber and i ncor-
porate an i ntegral steel val ve spri ng seat. The i nte-
gral garter spri ng mai ntai ns consi stent l ubri cati on
control to the val ve stems.
ENGINE BLOCK
DESCRIPTION
The cyl i nder bl ock i s made of cast i ron. The bl ock
i s a cl osed deck desi gn wi th the l eft bank forward. To
provi de hi gh ri gi di ty and i mproved NVH an
enhanced compacted graphi te bedpl ate i s bol ted to
the bl ock. The bl ock desi gn al l ows cool ant fl ow
between the cyl i nders bores, and an i nternal cool ant
bypass to a si ngl e poppet i nl et thermostat i s i ncl uded
i n the cast al umi num front cover.
STANDARD PROCEDURE CYLINDER BORE
HONING
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823, equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round, as wel l as removi ng l i ght
scuffi ng, scori ng and scratches. Usual l y, a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). about 20-60
strokes, dependi ng on the bore condi ti on, wi l l be suf-
fi ci ent to provi de a sati sfactory surface. Usi ng honi ng
oi l C-3501-3880, or a l i ght honi ng oi l , avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 45).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
Fig. 45 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
9 - 108 ENGINE - 4. 7L WJ
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 Nm (25 ft. l bs.) torque.
INSPECTION
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter. To correctl y
sel ect the proper si ze pi ston, a cyl i nder bore gauge,
capabl e of readi ng i n 0.003 mm (.0001 i n.) I NCRE-
MENTS i s requi red. I f a bore gauge i s not avai l abl e,
do not use an i nsi de mi crometer (Fi g. 46).
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
bl ock must be repl aced. A sl i ght amount of taper
al ways exi sts i n the cyl i nder bore after the engi ne
has been i n use for a peri od of ti me.
STANDARD PROCEDURE - CONNECTING ROD
BEARING FITTING
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 47) (Fi g. 48). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 49). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(3) Use pi ston ri ng compressor and Gui de Pi ns
Speci al Tool 8507 (Fi g. 50) to i nstal l the rod and pi s-
ton assembl i es. The oi l sl i nger sl ots i n the rods must
face front of the engi ne. The Fs near the pi ston
wri st pi n bore shoul d poi nt to the front of the engi ne.
(4) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(5) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us a
90 turn. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
Fig. 46 Bore GaugeTypical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM
(1.5 in)
WJ ENGINE - 4. 7L 9 - 109
ENGINE BLOCK (Continued)
(6) Remove the beari ng cap and determi ne amount
of beari ng-to-journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 51). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(7) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(8) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, determi n whi ch servi ces beari ng set to
use the beari ng si zes are as fol l ows:
Fig. 47 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 - WEAR PATTERN ALWAYS GREATER ON UPPER
BEARING
Fig. 48 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 49 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
Fig. 50 Piston and Connecting Rod - Installation
1 - F TOWARD FRONT OF ENGINE
2 - OIL SLINGER SLOT
3 - RING COMPRESSOR
9 - 110 ENGINE - 4. 7L WJ
Bearing
Mark
SIZE USED WITH
JOURNAL SIZE
.025 US .025 mm 50.983-50.967 mm
(.001 in.) (2.0073-2.0066 in.)
Std. STANDARD 50.992-51.008 mm
(2.0076-2.0082 in.)
.250 US .250 mm 50.758-50.742 mm
(.010 in.) (1.9984-1.9978 in.)
(9) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(10) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 27 Nm (20 ft. l bs.) pl us a 90 turn.
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 52).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
CRANKSHAFT
DESCRIPTION
The 4.7L crankshaft i s constructed of nodul ar cast
i ron. The crankshaft for the 4.7L H.O. i s constructed
of forged steel. The crankshaft i s a cross shaped
four throw desi gn wi th ei ght counterwei ghts for bal -
anci ng purposes. The crankshaft i s supported by fi ve
sel ect fi t mai n beari ngs wi th the number three serv-
i ng as the thrust washer l ocati on. The mai n journal s
of the crankshaft are cross dri l l ed to i mprove rod
beari ng l ubri cati on. The number ei ght counterwei ght
has provi si ons for crankshaft posi ti on sensor target
wheel mounti ng. The sel ect fi t mai n beari ng mark-
i ngs are l ocated on the rear si de of the target wheel .
The crankshaft oi l seal s are one pi ece desi gn. The
front oi l seal i s retai ned i n the ti mi ng chai n cover,
and the rear seal i s pressed i n to a bore formed by
the cyl i nder bl ock and the bedpl ate assembl y.
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY
(1) Mount a di al i ndi cator to front of engi ne wi th
the l ocati ng probe on nose of crankshaft (Fi g. 53).
(2) Move crankshaft al l the way to the rear of i ts
travel .
(3) Zero the di al i ndi cator.
(4) Move crankshaft al l the way to the front and
read the di al i ndi cator. (Refer to 9 - ENGI NE -
SPECI FI CATI ONS) for end pl ay speci fi cati on.
Plastigage
Fig. 52 Checking Connecting Rod Side Clearance -
Typical
Fig. 53 Checking Crankshaft End PlayTypical
WJ ENGINE - 4. 7L 9 - 111
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engi ne. (Refer to 9 - ENGI NE -
REMOVAL).
(2) Remove the engi ne oi l pump.(Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove oi l pan. (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PAN - REMOVAL).
(4) Remove the oi l pump pi ckup tube and oi l pan
gasket /wi ndage tray.
(5) Remove the bedpl ate mounti ng bol ts. Note the
l ocati on of the three stud bol ts for i nstal l ati on.
(6) Remove the connecti ng rods from the crank-
shaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
sever damage to the crankshaft.
NOTE: The bedplate has pry points cast into it. Use
these points only. The pry points are on both the
left and right sides, only the left side is shown.
(7) Careful l y pry on the pry poi nts (Fi g. 54) to
l oosen the bedpl ate then remove the bedpl ate.
CAUTION: When removing the crankshaft, use care
not to damage bearing surfaces on the crankshaft.
(8) Remove the crankshaft.
(9) Remove the crankshaft target wheel .
INSPECTION
NOTE: Thoroughly inspect the connecting rod bear-
ing bores and main bearing bores for scoring, blue-
ing or severe scratches. Further disassembly may
be required.
I f connecti ng rod beari ng bores show damage, the
cyl i nder heads must be removed to servi ce the pi ston
and rod assembl i es. I f the bedpl ate or the cyl i nder
bl ock mai n beari ng bores show damage the engi ne
must be repl aced.
(1) I f requi red, remove the mai n beari ng hal ves
from the cyl i nder bl ock and bedpl ate.
(2) Thoroughl y cl ean the bedpl ate to cyl i nder bl ock
seal i ng surfaces and mai n beari ng bores. Remove al l
oi l and seal ant resi due.
(3) I nspect the bedpl ate mai n beari ng bores for
cracks, scori ng or severe bl uei ng. I f ei ther condi ti on
exi sts the engi ne must be repl aced.
(4) I nspect the crankshaft thrust washers for scor-
i ng, scratches, wear or bl uei ng. I f ei ther condi ti on
exi st repl ace the thrust washer.
(5) I nspect the oi l pan gasket/wi ndage tray for
spl i ts, tears or cracks i n the gasket seal i ng surfaces.
Repl ace gasket as necessary.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) for proper
bearing selections.
Fig. 54 Bedplate Pry Point Location
1 - CYLINDER BLOCK
2 - BEDPLATE
3 - PRY POINT
9 - 112 ENGINE - 4. 7L WJ
(1) Lubri cate upper mai n beari ng hal ves wi th
cl ean engi ne oi l .
CAUTION: When installing crankshaft, use care not
to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the target wheel retaining
screws prior to installation.
(2) I nstal l the crankshaft target wheel . Torque the
mounti ng screws to 22 Nm (21 ft. l bs.).
(3) Posi ti on crankshaft i n cyl i nder bl ock.
(4) I nstal l the thrust washers (Fi g. 55).
CAUTION: The bedplate to cylinder block mateing
surface must be coated with sealant prior to instal-
lation. Failure to do so will cause severe oil leaks.
NOTE: The installation time to install the bedplate
after the sealant has been applied is critical.
NOTE: Make sure that the bedplate and cylinder
block sealing surfaces are clean and free of oil or
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
oil leaks.
(5) Appl y a 2.5mm (0.100 i nch) (Fi g. 56) bead of
Mopar Gen I I Si l i cone Rubber Adhesi ve seal ant to
the cyl i nder bl ock-to-bedpl ate mati ng surface as
shown (Fi g. 57).
(6) Coat the crankshaft mai n beari ng journal s
wi th cl ean engi ne oi l and posi ti on the bedpl ate onto
the cyl i nder bl ock.
NOTE: Lubricate the bedplate retaining bolts with
clean engine oil prior to installation.
(7) I nstal l the bedpl ate retai ni ng bol ts, maki ng
sure to pl ace the stud bol ts i n the correct l ocati on,
Torque the bol ts i n the sequence shown (Fi g. 58).
Ti ghten bol ts A L to 54 Nm (40 ft. l bs.)
Ti ghten bol ts 110 to 2.8 Nm (25 i n. l bs.)
Turn bol ts 110 an addi ti onal 90.
Fig. 55 Crankshaft Thrust Washer Installation
1 - CRANKSHAFT THRUST WASHER
Fig. 56 Cutting Aplicator to Achieve 2.5mm (0.100
in.) Bead
1 - CUT HERE
Fig. 57 Cylinder Block-to-Bedplate Sealent Bead
Location
1 - CYLINDER BLOCK
2 - SEALANT BEAD LOCATION
WJ ENGINE - 4. 7L 9 - 113
Ti ghten bol ts A1 A6 to 27 Nm (20 ft. l bs.)
(8) Measure crankshaft end pl ay. (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT - STAN-
DARD PROCEDURE).
(9) I nstal l the connecti ng rods and measure si de
cl earance. (Refer to 9 - ENGI NE/ENGI NE BLOCK/
CONNECTI NG ROD BEARI NGS - STANDARD
PROCEDURE).
(10) Posi ti on the oi l pan gasket/wi ndage tray,
usi ng a new o-ri ng, i nstal l the oi l pi ckup tube.
Torque the bol t to 28Nn (20 ft. l bs.) torque the nuts
to 28Nm (20 ft. l bs.).
(11) I nstal l the oi l pan. Torque the retai ni ng bol ts to
15 Nm (11 ft. l bs.) i n the sequence shown (Fi g. 59).
(12) I nstal l the engi ne (Refer to 9 - ENGI NE -
I NSTALLATI ON).
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE CRANKSHAFT MAIN
BEARING - FITTING
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Crankshaft removed from the cyl i nder bl ock.
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper i s 0.008mm (0.0004
i nch.) and maxi mum out of round i s 0.005mm (0.002
i nch). Compare the measured di ameter wi th the jour-
nal di ameter speci fi cati on (Mai n Beari ng Fi tti ng
Chart). Sel ect i nserts requi red to obtai n the speci fi ed
beari ng-to-journal cl earance.
Fig. 58 Bedplate Tightening Sequence
1 - BEDPLATE
2 - CYLINDER BLOCK
Fig. 59 Oil Pan Tightening Sequence
9 - 114 ENGINE - 4. 7L WJ
CRANKSHAFT MAIN BEARING SELECTION
The mai n beari ngs are sel ect fi t to achi eve proper
oi l cl earances. For mai n beari ng sel ecti on, the crank-
shaft posi ti on sensor target wheel has grade i denti fi -
cati on marks stamped i nto i t (Fi g. 60). These marks
are read from l eft to ri ght, correspondi ng wi th jour-
nal number 1, 2, 3, 4 and 5. The crankshaft posi ti on
sensor target wheel i s mounted to the number 8
counter wei ght on the crankshaft.
NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
MAIN BEARING SELECTION CHART4.7L
GRADE SIZE mm
(in.)
FOR USE WITH
MARKING JOURNAL SIZE
A 0.008 mm
U/S
63.48863.496 mm
(0.0004 in.)
U/S
(2.49962.4999 in.)
B NOMINAL 63.49663.504 mm
(2.49992.5002 in.)
C 0.008 mm
O/S
63.50463.512 mm
(0.0004 in.)
O/S
(2.50022.5005 in.)
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 61).
NOTE: If any of the crankshaft journals are scored,
the crankshaft must be repaired or replaced.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FRONT
REMOVAL
REMOVAL).
(3) Remove A/C compressor mouni ng fasteners and
set asi de.
(5) Remove upper radi ator hose.
(6) Di sconnect el ectri cal connector for fan mounted
i nsi de radi ator shroud.
(7) Remove radi ator shroud attachi ng fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
Fig. 60 Main Bearing Markings on Target Wheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
Fig. 61 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
WJ ENGINE - 4. 7L 9 - 115
(8) Remove radi ator cool i ng fan and shroud (Refer
to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
REMOVAL).
(9) Remove crankshaft damper bol t.
(10) Remove damper usi ng Speci al Tool s 8513
I nsert and 1026 Three Jaw Pul l er (Fi g. 62).
(11) Usi ng Speci al Tool 8511, remove crankshaft
front seal (Fi g. 63).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Usi ng Speci al Tool 8348 and 8512, i nstal l
crankshaft front seal (Fi g. 64).
(2) I nstal l vi brati on damper (Refer to 9 - ENGI NE/
ENGI NE BLOCK/VI BRATI ON DAMPER - I NSTAL-
LATI ON).
(3) I nstal l radi ator cool i ng fan and shroud (Refer
to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
I NSTALLATI ON).
(4) I nstal l upper radi ator hose.
(5) I nstal l A/C compressor and ti ghten fasteners to
54 Nm (40 ft. l bs.).
(6) I nstal l accessory dri ve bel t refer (Refer to 7 -
I NSTALLATI ON).
Fig. 62 Crankshaft DamperRemoval
1 - SPECIAL TOOL 8513 INSERT
Fig. 63 Crankshaft Front SealRemoval
Fig. 64 Crankshaft Front SealInstallation
9 - 116 ENGINE - 4. 7L WJ
CRANKSHAFT OIL SEAL - FRONT (Continued)
REAR
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) I f bei ng preformed i n vehi cl e, remove the
transmi ssi on.
(2) Remove the fl expl ate (Refer to 9 - ENGI NE/
ENGI NE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Usi ng Speci al Tool 8506 (Fi g. 65), remove the
crankshaft rear oi l seal .
INSTALLATION
(1) Posi ti on the magneti c seal gui de Speci al Tool
83492 (Fi g. 66) onto the crankshaft rear face. Then
posi ti on the crankshaft rear oi l seal onto the gui de.
(2) Usi ng Speci al Tool s 8349 Crankshaft Rear Oi l
Seal I nstal l er and C-4171 Dri ver Handl e (Fi g. 67),
wi th a hammer, tap the seal i nto pl ace. Conti nue to
tap on the dri ver handl e unti l the seal i nstal l er seats
agai nst the cyl i nder bl ock crankshaft bore.
(3) I nstal l the fl expl ate.
(4) I nstal l the transmi ssi on.
Fig. 65 Crankshaft Rear Oil Seal Removal
1 - REAR CRANKSHAFT SEAL
Fig. 66 Crankshaft Rear Oil Seal Guide Special Tool
83492 and Oil
2 - SPECIAL TOOL 83492 GUIDE
Fig. 67 Crankshaft Rear Oil Seal Installation
2 - SPECIAL TOOL 83491 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
WJ ENGINE - 4. 7L 9 - 117
FLEX PLATE
REMOVAL
(1) Remove the transmi ssi on.
(2) Remove the bol ts and fl expl ate.
INSTALLATION
(1) Posi ti on the fl expl ate onto the crankshaft and
i nstal l the bol ts hand ti ght.
(2) Ti ghten the fl expl ate retai ni ng bol ts to 60 Nm
(45 ft. l bs.) i n the sequence shown (Fi g. 68).
(3) I nstal l the transmi ssi on.
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
The pi stons are made of a hi gh strength al umi num
al l oy. The anodi zed top ri ng groove and crown has
been repl aced wi th a coated top ri ng that i s bl ue i n
col or on the bottom surface. Pi ston ski rts are coated
wi th a sol i d l ubri cant (Mol ykote) to reduce fri cti on
and provi de scuff resi stance. The connecti ng rods are
made of forged powdered metal , wi th a fractured
cap desi gn. A pressed fi t pi ston pi n i s used to attach
the pi ston and connecti ng rod on the 4.7L. The 4.7L
HO uses a ful l fl oati ng pi ston pi n.
STANDARD PROCEDURE PISTON FITTING
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm (
.0001 i n.) I NCREMENTS i s requi red. I f a bore gauge
i s not avai l abl e, do not use an i nsi de mi crometer.
bore at a poi nt 38.0 mm (1.5 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 70).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 69). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
REMOVAL
(2) Remove the fol l owi ng components:
Oi l pan and gasket/wi ndage tray (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
Cyl i nder head covers (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CYLI NDER HEAD COVER(S) -
Fig. 68 Flexplate Tightening Sequence
1 - FLEXPLATE
Fig. 69 Moly Coated PistonTypical
1 - MOLY COATED
2 - MOLY COATED
9 - 118 ENGINE - 4. 7L WJ
REMOVAL) and (Refer to 9 - ENGI NE/CYLI NDER
HEAD/CYLI NDER HEAD COVER(S) - REMOVAL).
Ti mi ng chai n cover (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT / CHAI N COVER(S)
- REMOVAL).
Cyl i nder head(s) (Refer to 9 - ENGI NE/CYLI N-
DER HEAD - REMOVAL) and (Refer to 9 - ENGI NE/
CYLI NDER HEAD - REMOVAL).
(3) I f necessary, remove top ri dge of cyl i nder bores
wi th a rel i abl e ri dge reamer before removi ng pi stons
from cyl i nder bl ock. Be sure to keep tops of pis-
tons covered during this operation. Pi stons and
connecti ng rods must be removed from top of cyl i nder
bl ock. When removi ng pi ston and connecti ng rod
assembl i es from the engi ne, rotate crankshaft so the
each connecti ng rod i s centered i n cyl i nder bore.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4) Mark connecti ng rod and beari ng cap posi ti ons
usi ng a permanent i nk marker or scri be tool (Fi g.
71).
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Remove connecti ng rod cap. I nstal l Speci al Tool
8507 Connecti ng Rod Gui des i nto the connecti ng rod
bei ng removed. Remove pi ston from cyl i nder bore.
Repeat thi s procedure for each pi ston bei ng removed.
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) I mmedi atel y after pi ston and connecti ng rod
removal , i nstal l beari ng cap on the mati ng connect-
i ng rod to prevent damage to the fractured cap and
rod surfaces.
(7) Careful l y remove pi ston ri ngs from pi ston(s),
starti ng from the top ri ng down.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Usi ng a sui tabl e cl eani ng sol vent cl ean the pi s-
tons i n warm water and towel dry.
(2) Use a wood or pl asti c scraper to cl ean the ri ng
l and grooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
INSPECTION
Check the connecti ng rod journal for excessi ve
wear, taper and scori ng (Refer to 9 - ENGI NE/EN-
GI NE BLOCK/CONNECTI NG ROD BEARI NGS -
Fig. 70 Bore GaugeTypical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM
(1.5 in)
Fig. 71 Identify Connecting Rod to Cylinder
PositionTypical
WJ ENGINE - 4. 7L 9 - 119
Check the connecti ng rod for si gns of twi st or bend-
i ng.
Check the pi ston for taper and el l i pti cal shape
before i t i s fi tted i nto the cyl i nder bore (Refer to 9 -
ENGI NE/ENGI NE BLOCK/PI STON & CONNECT-
I NG ROD - STANDARD PROCEDURE).
Check the pi ston for scori ng, or scrapi ng marks i n
the pi ston ski rts. Check the ri ng l ands for cracks
and/or deteri orati on.
INSTALLATION
(1) Before i nstal l i ng pi ston and connecti ng rod
assembl i es i nto the bore, i nstal l the pi ston ri ngs.
(2) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l . Posi ti on a ri ng compressor over the pi ston
and ri ngs. Ti ghten ri ng compressor. Ensure position
of rings do not change during this operation.
(3) Posi ti on beari ng onto connecti ng rod. Ensure that
hol e i n beari ng shel l al i gns wi th hol e i n connecti ng rod.
Lubri cate beari ng surface wi th cl ean engi ne oi l .
(4) I nstal l Speci al Tool 8507 Connecti ng Rod
Gui des i nto connecti ng rod bol t threads (Fi g. 72).
(5) The pi stons are marked on the pi ston pi n bore
surface wi th an rai sed F i ndi cati ng i nstal l ati on
posi ti on. Thi s mark must be poi nti ng toward the
front of engi ne on both cyl i nder banks. The connect-
i ng rod oi l sl i nger sl ot faces the front of the engi ne
(Fi g. 73).
(6) Wi pe cyl i nder bore cl ean and l ubri cate wi th
engi ne oi l .
(7) Rotate crankshaft unti l connecti ng rod journal
i s on the center of cyl i nder bore. I nsert rod and pi s-
ton i nto cyl i nder bore and careful l y posi ti on connect-
i ng rod gui des over crankshaft journal .
(8) Tap pi ston down i n cyl i nder bore usi ng a ham-
mer handl e. Whi l e at the same ti me, gui de connect-
i ng rod i nto posi ti on on rod journal .
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
(9) Lubri cate rod bol ts and beari ng surfaces wi th
engi ne oi l . I nstal l connecti ng rod cap and beari ng.
Ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us 90.
(10) I nstal l the fol l owi ng components:
Cyl i nder head(s). (Refer to 9 - ENGI NE/CYLI N-
DER HEAD - I NSTALLATI ON).
Ti mi ng chai n and cover. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT / CHAI N COVER(S)
- I NSTALLATI ON).
Fig. 72 Piston and Connecting RodInstallation
1 - F TOWARD FRONT OF ENGINE
3 - RING COMPRESSOR
Fig. 73 Piston and Connecting Rod Orientation
1 - MAJOR THRUST SIDE OF PISTON
9 - 120 ENGINE - 4. 7L WJ
Cyl i nder head covers (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CYLI NDER HEAD COVER(S) -
I NSTALLATI ON).
Oi l pan and gasket/wi ndage tray. (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
(11) Fi l l crankcase wi th proper engi ne oi l to cor-
rect l evel .
PISTON RINGS
FITTING
Before rei nstal l i ng used ri ngs or i nstal l i ng new
ri ngs, the ri ng cl earances must be checked.
(1) Wi pe the cyl i nder bore cl ean.
(2) I nsert the ri ng i n the cyl i nder bore.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Usi ng a pi ston, to ensure that the ri ng i s
squared i n the cyl i nder bore, sl i de the ri ng downward
i nto the cyl i nder.
(4) Usi ng a feel er gauge check the ri ng end gap
(Fi g. 74). Repl ace any ri ngs not wi thi n speci fi cati on.
PISTON RING SIDE CLEARANCE
NOTE: Make sure the piston ring grooves are clean
and free of nicks and burrs.
(5) Measure the ri ng si de cl earance as shown (Fi g.
75)make sure the feel er gauge fi ts snugl y between
the ri ng l and and the ri ng. Repl ace any ri ng not
wi thi n speci fi cati on.
(6) Rotate the ri ng around the pi ston, the ri ng
must rotate i n the groove wi th out bi ndi ng.
PISTON RING SPECIFICATION CHART
Ring Position Groove Maximum
Clearance Clearance
Upper Ring .051-.094mm 0.11mm
(0.0020- .0037
in.)
(0.004 in.)
Intermediate
Ring
0.04-0.08mm 0.10mm
(0.0016-0.0031
in.)
(0.004 in.)
Oil Control Ring .019-.229mm .25mm
(Steel Rails) (.0007-.0090 in.) (0.010 in.)
Ring Position Ring Gap Wear Limit
Upper Ring 0.23-0.39mm 0.43mm
(0.009-0.015 in.) (0.0017 in.)
Intermediate
Ring
0.40-0.66mm 0.74mm
(0.015-0.026 in.) (0.029 in.)
Oil Control Ring 0.028-0.79mm 1.55mm
(Steel Rail) (0.011- 0.031
in.)
(0.061 in.)
Fig. 74 Ring End Gap Measurement - Typical
1 - FEELER GAUGE
Fig. 75 Measuring Piston Ring Side Clearance
1 - FEELER GAUGE
WJ ENGINE - 4. 7L 9 - 121
(7) The No. 1 and No. 2 pi ston ri ngs have a di ffer-
ent cross secti on. Ensure No. 2 ri ng i s i nstal l ed wi th
manufacturers I .D. mark (Dot) faci ng up, towards top
of the pi ston.
NOTE: Piston rings are installed in the following
order:
Oil ring expander.
Upper oil ring side rail.
Lower oil ring side rail.
No. 2 Intermediate piston ring.
No. 1 Upper piston ring.
(8) I nstal l the oi l ri ng expander.
(9) I nstal l upper si de rai l (Fi g. 76) by pl aci ng one
end between the pi ston ri ng groove and the expander
ri ng. Hol d end fi rml y and press down the porti on to
be i nstal l ed unti l si de rai l i s i n posi ti on. Repeat thi s
step for the l ower si de rai l .
(10) I nstal l No. 2 i ntermedi ate pi ston ri ng usi ng a
pi ston ri ng i nstal l er (Fi g. 77).
(11) I nstal l No. 1 upper pi ston ri ng usi ng a pi ston
ri ng i nstal l er (Fi g. 77).
(12) Posi ti on pi ston ri ng end gaps as shown i n
(Fi g. 78). I t i s i mportant that expander ri ng gap i s at
l east 45 from the si de rai l gaps, but not on the pi s-
ton pi n center or on the thrust di recti on.
VIBRATION DAMPER
REMOVAL
REMOVAL).
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
Fig. 76 Side RailInstallation
1 - SIDE RAIL END
Fig. 77 Upper and Intermediate RingsInstallation
Fig. 78 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
9 - 122 ENGINE - 4. 7L WJ
(3) Remove crankshaft damper bol t.
(4) Remove damper usi ng Speci al Tool s 8513
I nsert and 1026 Three Jaw Pul l er (Fi g. 79).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Al i gn crankshaft damper sl ot wi th key i n
crankshaft. Sl i de damper onto crankshaft sl i ghtl y.
CAUTION: Special Tool 8512A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assembl e Speci al Tool 8512A as fol l ows, The
nut i s threaded onto the shaft fi rst. Then the rol l er
beari ng i s pl aced onto the threaded rod (The hard-
ened beari ng surface of the beari ng MUSTface the
nut). Then the hardened washer sl i des onto the
threaded rod (Fi g. 80). Once assembl ed coat the
threaded rods threads wi th Mopar Ni ckel Anti -
Sei ze or (Locti te No. 771).
(3) Usi ng Speci al Tool 8512A, press damper onto
crankshaft (Fi g. 81).
(4) I nstal l then ti ghten crankshaft damper bol t to
175 Nm (130 ft. l bs.).
(5) I nstal l accessory dri ve bel t (Refer to 7 - COOL-
LATI ON).
Fig. 79 Crankshaft DamperRemoval
1 - SPECIAL TOOL 8513 INSERT
Fig. 80 Proper Assembly Method for Special Tool
8512A
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER
Fig. 81 Crankshaft Damper Installation
1 - SPECIAL TOOL 8512A
WJ ENGINE - 4. 7L 9 - 123
VIBRATION DAMPER (Continued)
STRUCTURAL COVER
DESCRIPTION
The structural dust cover i s made of di e cast al u-
mi num and joi ns the l ower hal f of the transmi ssi on
bel l housi ng to the engi ne bedpl ate.
OPERATION
The structural cover provi des addi ti onal power-
trai n sti ffness and reduces noi se and vi brati on.
REMOVAL
(2) Remove the l eft hand exhaust pi pe from
exhaust mani fol d.
(3) Loosen the ri ght hand exhaust mani fol d-to-ex-
haust pi pe retai ni ng bol ts.
(4) Remove the ei ght bol ts retai ni ng structural
cover (Fi g. 82) i n the sequence shown.
(5) Pi vot the exhaust pi pe downward and remove
the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Posi ti on the structural cover i n the vehi cl e.
(2) I nstal l al l four bol ts retai ni ng the cover-to-en-
gi ne. DO NOT ti ghten the bol ts at thi s ti me.
(3) I nstal l the four cover-to-transmi ssi on bol ts. Do
NOT ti ghten at thi s ti me.
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starti ng wi th the two rear cover-to-engi ne
bol ts, ti ghten bol ts (1) (Fi g. 83) to 54 Nm (40 ft. l bs.),
then ti ghten bol ts (2) (Fi g. 83) and (3) to 54 Nm ( 40
ft. l bs.) i n the sequence shown.
(5) I nstal l the exhaust pi pe on l eft hand exhaust
mani fol d.
(6) Ti ghten exhaust mani fol d-to-exhaust pi pe
retai ni ng bol ts to 2026 Nm (1520 ft. l bs.).
FRONT MOUNT
REMOVAL
CAUTION: Remove the fan blade, fan clutch and fan
shroud before raising engine. Failure to do so may
cause damage to the fan blade, fan clutch and fan
shroud.
(2) Remove the engi ne oi l fi l ter (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L FI LTER - REMOVAL).
(3) Support the engi ne wi th a sui tabl e jack and a
bl ock of wood across the ful l wi dth of the engi ne oi l
pan.
Fig. 82 Structural Cover
Fig. 83 Structural Cover
9 - 124 ENGINE - 4. 7L WJ
(4) Remove the four cyl i nder bl ock-to-i nsul ator
mount bol ts and the nut form the engi ne i nsul ator
mount through bol t (Fi g. 84) (Fi g. 85)
(5) Usi ng the jack, rai se the engi ne hi gh enough to
remove the engi ne i nsul ator mount through bol t and
the i nsul ator mount.
INSTALLATION
(1) Posi ti on the i nsul ator mount and i nstal l the
i nsul ator mount through bol t.
(2) Lower the engi ne unti l the four cyl i nder bl ock-
to-i nsul ator mount bol ts can be i nstal l ed.
(3) Remove the jack and bl ock of wood.
(4) Torque the cyl i nder bl ock-to-i nsul ator mount
bol ts to 61Nm ( 45 ft. l bs.).
(5) I nstal l and torque the through bol t retai ni ng
nut to 61Nm (45 ft. l bs.).
REAR MOUNT
REMOVAL
(2) Usi ng a sui tabl e jack, support transmi ssi on.
(3) Remove the l ock nut from the i nsul ator mount
through bol t and the four i nsul ator-to-transmi ssi on
mounti ng bol ts.
(4) Rai se the transmi ssi on enough to remove the
through bol t and i nsul ator mount (Fi g. 86) (Fi g. 87).
Fig. 84 Engine Insulator Mount 4.7 LEFT
1 - NUT
2 - BOLT
Fig. 85 Engine Insulator Mount 4.7 Right
1 - NUT
2 - BOLT
WJ ENGINE - 4. 7L 9 - 125
FRONT MOUNT (Continued)
1 NUT 45 Nm
(Qty 1) (33 ft. lbs)
2 BOLT 46 Nm
(Qty 4) (34 ft. lbs.)
3 BOLT 68 Nm
(Qty 2 Per
Side)
(50 ft. lbs.)
4 BOLT 46 Nm
(Qty 2 Per
Side)
(34 ft. lbs.)
5 BOLT 46 Nm
(Qty 4) (34 ft. lbs.)
INSTALLATION
(1) Posi ti on the i nsul ator mount and i nstal l the
through bol t.
(2) Lower the transmi ssi on enough to i nstal l the
four i nsul ator-to-transmi ssi on mounti ng bol ts. Torque
the bol ts to 46Nm (34 ft. l bs.).
(3) I nstal l the through bol t l ock nut. Torque nut to
68Nm (50 ft. l bs.).
(4) Remove jack, l ower vehi cl e.
LUBRICATION
DESCRIPTION
The l ubri cati on system (Fi g. 88) i s a ful l fl ow fi l -
trati on pressure feed type.
OPERATION
Oi l from the oi l pan i s pumped by a gerotor type oi l
pump di rectl y mounted to the crankshaft nose. Oi l
pressure i s control l ed by a rel i ef val ve mounted
i nsi de the oi l pump housi ng. For l ubri cati on fl ow
refer to (Fi g. 88).
The camshaft exhaust val ve l obes and rocker arms
are l ubri cated through a smal l hol e i n the rocker
arm; oi l fl ows through the l ash adjuster then through
the rocker arm and onto the camshaft l obe. Due to
the orentati on of the rocker arm, the camshaft i ntake
l obes are not l ubed i n the same manner as the
exhaust l obes. The i ntake l obes are l ubed through
i nternal passages i n the camshaft. Oi l fl ows through
a bore i n the number 3 camshaft beari ng bore, and
as the camshaft turns, a hol e i n the camshaft al i gns
wi th the hol e i n the camshaft bore al l owi ng engi ne
oi l to enter the camshaft tube. The oi l then exi ts
through 1.6mm (0.063 i n.) hol es dri l l ed i nto the
i ntake l obes, l ubri cati ng the l obes and the rocker
arms.
Fig. 86 Engine Rear Mount4X2
Fig. 87 Engine Rear Mount4X4
9 - 126 ENGINE - 4. 7L WJ
REAR MOUNT (Continued)
Fig. 88 Engine Oil Lubrication System
1 - LEFT CYLINDER HEAD OIL GALLERY
2 - OIL PRESSURE SENSOR LOCATION
3 - TO LEFT CYLINDER HEAD
4 - OIL FEED TO IDLER SHAFT
5 - OIL PUMP OUTLET TO BLOCK
6 - OIL PUMP
7 - TO CRANKSHAFT MAIN JOURNALS
8 - RIGHT CYLINDER HEAD OIL GALLERY
9 - TO RIGHT CYLINDER HEAD
10 - CYLINDER BLOCK MAIN GALLERY
11 - OIL FEED TO BOTH SECONDARY TENSIONERS
WJ ENGINE - 4. 7L 9 - 127
ENGINE LUBRICATION FLOW CHARTBLOCK: TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1.Front Timing Chain Idler Shaft
2.Both Secondary Chain Tensioners
Left Cylinder Head See Table 2
Right Cylinder Head See Table 2
* The cylinder head
gaskets have an oil restricter to control oil flow to the cylinder heads.
ENGINE LUBRICATION FLOW CHARTCYLINDER HEADS: TABLE 2
FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to
front)
1. Base of Camshaft Towers
2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
DIAGNOSIS AND TESTING ENGINE OIL
PRESSURE
(1) Remove oi l pressure sendi ng uni t (Fi g. 89)and
i nstal l gauge assembl y C-3292.
(2) Run engi ne unti l thermostat opens.
(3) Oi l Pressure:
Curb I dl e25 Kpa (4 psi ) mi ni mum
3000 rpm170 - 550 KPa (25 - 80 psi )
(4) I f oi l pressure i s 0 at i dl e, shut off engi ne.
Check for a cl ogged oi l pi ck-up screen or a pressure
rel i ef val ve stuck open.
DIAGNOSIS AND TESTING REAR SEAL AREA
LEAKS
area:
camshaft bore cup pl ugs, oi l gal l ey pi pe pl ugs, oi l
bl ock mati ng surfaces. See Engi ne, for proper
repai r procedures of these i tems.
(4) I f no l eaks are detected, pressuri zed the crank-
case as outl i ned i n the secti on, I nspecti on (Engi ne oi l
Leaks i n general )
9 - 128 ENGINE - 4. 7L WJ
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
seal.
assembl ed. (Refer to 9 - ENGI NE - DI AGNOSI S AND
TESTI NG), under the Oi l Leak row, for components
i nspecti ons on possi bl e causes and correcti ons.
(7) After the oi l l eak root cause and appropri ate
correcti ve acti on have been i denti fi ed, (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT OI L
SEAL - REAR - REMOVAL).
DIAGNOSIS AND TESTING ENGINE OIL LEAK
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.If the oil leak source is not pos-
itively identified at this time, proceed wi th the ai r
l eak detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Fig. 89 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
WJ ENGINE - 4. 7L 9 - 129
area:
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
seal.
assembl ed.
OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
SAE VISCOSITY
pl e vi scosi ti es such as 5W-30 or 10W-30 i n the 4.7L
engi nes. The 4.7L H.O. uses 10W-30 oil only.These
are speci fi ed wi th a dual SAE vi scosi ty grade whi ch
i ndi cates the col d-to-hot temperature vi scosi ty range.
tai ner.
cans (Fi g. 91).
OIL LEVEL INDICATOR (DIPSTICK)
The engi ne oi l l evel i ndi cator i s l ocated on the
ri ght si de of the the 4.7L engi ne. (Fi g. 92).
Engine
9 - 130 ENGINE - 4. 7L WJ
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
pressure loss or oil foaming can result.
I nspect engi ne oi l l evel approxi matel y every 800
ki l ometers (500 mi l es). Unl ess the engi ne has exhi b-
i ted l oss of oi l pressure, run the engi ne for about fi ve
mi nutes before checki ng oi l l evel . Checki ng engi ne oi l
l evel on a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng.
(6) Add oi l i f l evel i s bel ow the SAFE ZONE on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Remove oi l fi l ter (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L FI LTER - REMOVAL).
(8) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(9) I nstal l oi l fi l l cap.
(10) Start engi ne and i nspect for l eaks.
(11) Stop engi ne and i nspect oi l l evel .
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
OIL FILTER
REMOVAL
Al l engi nes are equi pped wi th a hi gh qual i ty ful l -
fl ow, di sposabl e type oi l fi l ter. Dai ml erChrysl er Cor-
porati on recommends a Mopar or equi val ent oi l
fi l ter be used.
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se (Fi g. 93)to
remove i t from the cyl i nder bl ock oi l fi l ter boss.
(4) When fi l ter separates from cyl i nder bl ock oi l
fi l ter boss, ti p gasket end upward to mi ni mi ze oi l
spi l l . Remove fi l ter from vehi cl e.
NOTE: Make sure filter gasket was removed with fil-
ter.
Fig. 91 Engine Oil Container Standard Notations
Fig. 92 Engine Oil Dipstick 4.7L Engine
1 - TRANSMISSION DIPSTICK
2 - ENGINE OIL DIPSTICK
3 - ENGINE OIL FILL CAP
WJ ENGINE - 4. 7L 9 - 131
OIL (Continued)
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface of oi l and gri me.
INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l .
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 94)hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
OIL PAN
DESCRIPTION
The engi ne oi l pan i s made of l ami nated steel and
has a si ngl e pl ane seal i ng surface. The sandwi ch
styl e oi l pan gasket has an i ntegrated wi ndage tray
and steel carri er. The seal i ng area of the gasket i s
mol ded wi th rubber and i s desi gned to be reused as
l ong as the gasket i s not cut, torn or ri pped.
REMOVAL
(3) Remove structural cover (Refer to 9 - ENGI NE/
ENGI NE BLOCK/STRUCTURAL COVER - REMOV-
AL).
(4) Remove exhaust system Y-pi pe.
(5) Remove starter (Refer to 8 - ELECTRI CAL/
STARTI NG/STARTER MOTOR - REMOVAL).
(6) Drai n engi ne oi l .
(7) Un-cl i p transmi ssi on l i nes from support on oi l
pan stud. Move l i nes for oi l pan cl earance.
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when lowering oil pan.
Gasket can not be removed with oil pan.
(8) Remove oi l pan bol ts and oi l pan.
(9) Remove oi l pump pi ckup tube.
(10) Remove oi l pan gasket.
CLEANING
(1) Cl ean oi l pan i n sol vent and wi pe dry wi th a
cl ean cl oth.
(2) Cl ean the oi l pan gasket surface. DO NOT use
a gri nder wheel or other abrasi ve tool to cl ean seal -
i ng surface.
(3) Cl ean oi l screen and tube thoroughl y i n cl ean
sol vent.
INSPECTION
(1) I nspect oi l drai n pl ug and pl ug hol e for
stri pped or damaged threads. Repai r as necessary.
(2) I nspect the oi l pan mounti ng fl ange for bends
or di storti on. Strai ghten fl ange, i f necessary.
INSTALLATION
(1) Cl ean oi l pan and al l seal i ng surfaces. I nspect
oi l pan gasket and repl ace as necessary.
(2) I nstal l oi l pan gasket.
Fig. 93 Oil Filter - 4.7L Engine
1 - ENGINE OIL FILTER
Fig. 94 Oil Filter Sealing SurfaceTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 132 ENGINE - 4. 7L WJ
OIL FILTER (Continued)
NOTE: When installing oil pan gasket/windage tray,
start four pan bolts at each corner before tightening
oil pickup tube. This will keep pan gasket in align-
ment.
(3) I nstal l oi l pump pi ck-up tube usi ng a new
O-ri ng. Fi rst ti ghten bol t at O-ri ng end of tube to 28
Nm (20 ft. l bs.). Ti ghten remai n tube support fasten-
ers to 28 Nm (20 ft. l bs.).
(4) I nstal l oi l pan and ti ghten fasteners to 15 Nm
(11 ft. l bs.) (Fi g. 95).
(5) Reconnect transmi ssi on oi l cool er l i nes to oi l
pan stud bol t.
(6) I nstal l starter (Refer to 8 - ELECTRI CAL/
STARTI NG/STARTER MOTOR - I NSTALLATI ON).
(7) I nstal l exhaust system Y-pi pe.
(8) I nstal l structural cover (Refer to 9 - ENGI NE/
ENGI NE BLOCK/STRUCTURAL COVER - I NSTAL-
LATI ON).
(10) Fi l l engi ne wi th proper amount of oi l (Refer to
LUBRI CATI ON & MAI NTENANCE/FLUI D TYPES -
SPECI FI CATI ONS).
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3wi re, sol i d-state engi ne oi l pressure sensor
(sendi ng uni t) i s l ocated i n an engi ne oi l pressure
gal l ery.
OPERATION
The oi l pressure sensor uses three ci rcui ts. They are:
A 5vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
A sensor ground through the PCMs sensor
return
A si gnal to the PCM rel ati ng to engi ne oi l pressure
The oi l pressure sensor has a 3wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
REMOVAL
(3) Remove front spl ash shi el d.
(4) Di sconnect oi l pressure sender wi re (Fi g. 96).
(5) Remove the pressure sender (Fi g. 96).
INSTALLATION
(1) I nstal l oi l pressure sender.
(2) Connect oi l pressure sender wi re.
(3) I nstal l front spl ash shi el d.
Fig. 95 Oil Pan Tightening Sequence
Fig. 96 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
WJ ENGINE - 4. 7L 9 - 133
OIL PAN (Continued)
OIL PUMP
REMOVAL
(1) Remove the oi l pan and pi ck-up tube (Refer to
9 - ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(2) Remove the ti mi ng chai n cover (Refer to 9 -
(3) Remove the ti mi ng chai ns and tensi oners
(4) Remove the four bol ts, pri mary ti mi ng chai n
tensi oner and the oi l pump.
DISASSEMBLY
(1) Remove oi l pump cover screws and l i ft off cover
pl ate.
(2) Remove pump i nner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) I f i t i s necessary to remove the pressure rel i ef
val ve, dri ve the rol l pi n from pump housi ng and
remove cup pl ug, spri ng and val ve.
CLEANING
(1) Wash al l parts i n a sui tabl e sol vent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
these components are disassembled and or
removed from the pump the entire oil pump assem-
bly must be replaced.
(1) Cl ean al l parts thoroughl y. Mati ng surface of
the oi l pump housi ng shoul d be smooth. I f the pump
cover i s scratched or grooved the oi l pump assembl y
(2) Lay a strai ght edge across the pump cover sur-
face (Fi g. 97). I f a 0.025 mm (0.001 i n.) feel er gauge
can be i nserted between the cover and the strai ght
edge the oi l pump assembl y shoul d be repl aced.
(3) Measure the thi ckness of the outer rotor (Fi g.
98). I f the outer rotor thi ckness measures at 12.005
mm (0.472 i n.) or l ess the oi l pump assembl y must be
repl aced.
(4) Measure the di ameter of the outer rotor. I f the
outer rotor di ameter measures at 85.925 mm (3.382
i n.) or l ess the oi l pump assembl y must be repl aced.
(5) Measure the thi ckness of the i nner rotor (Fi g.
99). I f the i nner rotor thi ckness measures at 12.005
mm (0.472 i n.) or l ess then the oi l pump assembl y
must be repl aced.
(6) Sl i de outer rotor i nto the body of the oi l pump.
Press the outer rotor to one si de of the oi l pump body
and measure cl earance between the outer rotor and
the body (Fi g. 100). I f the measurement i s 0.235mm
(0.009 i n.) or more the oi l pump assembl y must be
repl aced.
(7) I nstal l the i nner rotor i n the i nto the oi l pump
body. Measure the cl earance between the i nner and
outer rotors (Fi g. 101). I f the cl earance between the
rotors i s .150 mm (0.006 i n.) or more the oi l pump
assembl y must be repl aced.
(8) Pl ace a strai ght edge across the body of the oi l
pump (between the bol t hol es), i f a feel er gauge of
.095 mm (0.0038 i n.) or greater can be i nserted
between the strai ghtedge and the rotors, the pump
must be repl aced (Fi g. 102).
NOTE: The 4.7 Oil pump is released as an assem-
bly. There are no DaimlerChrysler part numbers for
Sub-Assembly components. In the event the oil
pump is not functioning or out of specification it
must be replaced as an assembly.
Fig. 97 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
9 - 134 ENGINE - 4. 7L WJ
ASSEMBLY
(1) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
(2) I nstal l i nner and outer rotors
(3) I nstal l oi l pump cover pl ate and i nstal l cover
bol ts and ti ghten them to 12 Nm (105 i n. l bs.).
(4) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
(5) I f oi l pressure i s l ow and pump i s wi thi n spec-
i fi cati ons, i nspect for worn engi ne beari ngs or other
causes for oi l pressure l oss.
INSTALLATION
(1) Posi ti on the oi l pump onto the crankshaft and
i nstal l two oi l pump retai ni ng bol ts.
(2) Posi ti on the pri mary ti mi ng chai n tensi oner
and i nstal l the two retai ni ng bol ts.
(3) Ti ghten the oi l pump and pri mary ti mi ng chai n
tensi oner retai ni ng bol ts to 28 Nm (250 i n. l bs.) i n
the sequence shown (Fi g. 103).
(4) I nstal l the secondary ti mi ng chai n tensi oners
and ti mi ng chai ns (Refer to 9 - ENGI NE/VALVE
TI MI NG/TI MI NG BELT/CHAI N AND SPROCKETS -
I NSTALLATI ON).
(6) I nstal l the pi ck-up tube and oi l pan (Refer to 9
- ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
Fig. 98 Measuring Outer Rotor Thickness
Fig. 99 Measuring Inner Rotor Thickness
Fig. 100 Measuring Outer Rotor Clearance in
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 101 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
WJ ENGINE - 4. 7L 9 - 135
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s made of a composi te mate-
ri al and features l ong runners whi ch maxi mi zes l ow
end torque. The i ntake mani fol d uses si ngl e pl ane
seal i ng whi ch consi st of ei ght i ndi vi dual press i n
pl ace port gaskets to prevent l eaks. Ei ght studs and
two bol ts are used to fasten the i ntake to the head.
DIAGNOSIS AND TESTING INTAKE
MANIFOLD LEAKAGE
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
REMOVAL
(2) Remove ai r cl eaner housi ng and throttl e body
resonator (Fi g. 104).
(3) Di sconnect throttl e and speed control cabl es.
(4) Di sconnect el ectri cal connectors for the fol l ow-
i ng components:
Throttl e Posi ti on (TPS) Sensor
Cool ant Temperature (CTS) Sensor
(5) Di sconnect vapor purge hose, brake booster
hose, speed control servo hose, posi ti ve crankcase
venti l ati on (PCV) hose.
Fig. 102 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 103 Oil Pump and Primary Timing Chain
Tensioner Tightening Sequence
Fig. 104 Throttle Body Resonator
1 - THROTTLE BODY RESONATOR
2 - BOLT
3 - BOLT
9 - 136 ENGINE - 4. 7L WJ
REMOVAL).
(7) Di sconnect generator el ectri cal connecti ons.
(8) Unbol t the generator and move i t away from
the i ntake mani fol d for cl earance.
(9) Di sconnect ai r condi ti oni ng compressor el ectri -
cal connecti ons.
(10) Unbol t the ai r condi ti oni ng compressor and
move i t away from the i ntake mani fol d for cl earance.
(11) Di sconnect l eft and ri ght radi o suppressor
straps.
(12) Di sconnect and remove i gni ti on coi l towers
(Refer to 8 - ELECTRI CAL/I GNI TI ON CONTROL/
I GNI TI ON COI L - REMOVAL).
(13) Remove top oi l di psti ck tube retai ni ng bol t
and ground strap.
(14) Bl eed pressure from fuel system (Refer to 14 -
FUEL SYSTEM/FUEL DELI VERY - STANDARD
PROCEDURE).
(15) Remove fuel rai l (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY/FUEL RAI L - REMOVAL).
(16) Remove throttl e body assembl y and mounti ng
bracket.
(17) Drai n cool i ng system bel ow cool ant tempera-
ture l evel (Refer to 7 - COOLI NG - STANDARD
PROCEDURE).
(18) Remove cool ant temperature sensor (Refer to
7 - COOLI NG/ENGI NE/ENGI NE COOLANT TEMP
SENSOR - REMOVAL).
(19) Remove cowl to hood seal . (Refer to 23 -
BODY/WEATHERSTRI P/SEALS/COWL WEATHER-
STRI P - REMOVAL).
(20) Remove ri ght si de engi ne l i fti ng stud.
(21) Remove i ntake mani fol d retai ni ng fasteners,
i n reverse order of ti ghteni ng sequence (Fi g. 105).
NOTE: Intake must be lifted upward and level in the
front and rear to clear the cowl. Interference with
the cowl will occur during removal.
(22) Remove i ntake mani fol d.
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.
Before i nstal l i ng the i ntake mani fol d thoroughl y
cl ean the mati ng surfaces. Use a sui tabl e cl eani ng
sol vent, then ai r dry.
INSPECTION
(1) I nspect the i ntake seal i ng surface for cracks,
ni cks and di storti on.
(2) I nspect the i ntake mani fol d vacuum hose fi t-
ti ngs for l ooseness or bl ockage.
(3) I nspect the mani fol d to throttl e body mati ng
surface for cracks, ni cks and di storti on.
INSTALLATION
(1) I nstal l i ntake mani fol d gaskets.
(2) I nstal l i ntake mani fol d.
(3) I nstal l i ntake mani fol d retai ni ng bol ts and
ti ghten i n sequence shown i n (Fi g. 106) to 12 Nm
(105 i n. l bs.).
(4) I nstal l l eft and ri ght radi o suppressor straps.
(5) I nstal l throttl e body assembl y.
(6) I nstal l throttl e cabl e bracket.
Fig. 105 Intake Manifold Tightening Sequence
Fig. 106 Intake Manifold Tightening Sequence
WJ ENGINE - 4. 7L 9 - 137
(7) Connect throttl e cabl e and speed control cabl e
to throttl e body.
(8) I nstal l fuel rai l (Refer to 14 - FUEL SYSTEM/
FUEL DELI VERY/FUEL RAI L - I NSTALLATI ON).
(9) I nstal l i gni ti on coi l towers (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/I GNI TI ON COI L -
I NSTALLATI ON).
(10) I nstal l cool ant temperature sensor (Refer to 7
- COOLI NG/ENGI NE/ENGI NE COOLANT TEMP
SENSOR - I NSTALLATI ON).
(11) Connect el ectri cal connectors for the fol l owi ng
components:
Throttl e Posi ti on (TPS) Sensor
Cool ant Temperature (CTS) Sensor
I gni ti on coi l towers
Fuel i njectors
(12) I nstal l top oi l di psti ck tube retai ni ng bol t and
ground strap.
(13) I nstal l ri ght si de engi ne l i fti ng stud.
(14) I nstal l generator i ncl udi ng el ectri cal connec-
ti ons (Refer to 8 - ELECTRI CAL/CHARGI NG/GEN-
ERATOR - I NSTALLATI ON).
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Posi ti ve crankcase
venti l ati on (PCV) hose.
(16) I nstal l ai r condi ti oni ng compressor i ncl udi ng
el ectri cal connecti ons.
I NSTALLATI ON).
(19) I nstal l cowl to hood seal (Refer to 23 - BODY/
WEATHERSTRI P/SEALS/COWL WEATHERSTRI P -
I NSTALLATI ON).
(20) I nstal l ai r cl eaner housi ng and throttl e body
resonator. Ti ghten resonator bol ts 4.5 Nm (40 i n.
l bs.).
EXHAUST MANIFOLD - LEFT
DESCRIPTION
The exhaust mani fol ds are l og styl e wi th a pat-
ented fl ow enhanci ng desi gn to maxi mi ze perfor-
mance. The exhaust mani fol ds are made of hi gh
si l i con mol ybdenum cast i ron. A perforated core
graphi te exhaust mani fol d gasket i s used to i mprove
seal i ng to the cyl i nder head. The exhaust mani fol ds
are covered by a three l ayer l ami nated heat shi el d
for thermal protecti on and noi se reducti on. The heat
shi el ds are fastened wi th a torque prevai l i ng nut
that i s backed off sl i ghtl y to al l ow for the thermal
expansi on of the exhaust mani fol d.
REMOVAL
(1) Di sconnect negati ve cabl e for battery.
(2) Hoi st vehi cl e.
(3) Di sconnect exhaust pi pe at mani fol d.
(5) Remove ai r cl eaner housi ng and tube.
(6) Remove the front two exhaust heat shi el d
retai ni ng fasteners. Rai se vehi cl e and remove the
fasteners at rear of heat shi el d.
(7) Remove heat shi el d (Fi g. 107).
(8) Lower vehi cl e and remove the upper exhaust
mani fol d retai ni ng bol ts (Fi g. 107).
(9) Rai se vehi cl e and remove the l ower exhaust
mani fol d retai ni ng bol ts (Fi g. 107).
(10) Remove exhaust mani fol d and gasket (Fi g.
107). Mani fol d i s removed from bel ow the engi ne
compartment.
CLEANING
(1) Cl ean the exhaust mani fol d usi ng a sui tabl e
cl eani ng sol vent, then al l ow to ai r dry.
(2) Cl ean al l gasket resi due from the mani fol d
mati ng surface.
INSPECTION
(1) I nspect the exhaust mani fol d for cracks i n the
mati ng surface and at every mounti ng bol t hol e.
(2) Usi ng a strai ght edge and a feel er gauge, check
the mati ng surface for warp and twi st.
(3) I nspect the mani fol d to exhaust pi pe mati ng
surface for cracks, gouges, or other damage that
woul d prevent seal i ng.
INSTALLATION
(1) I nstal l exhaust mani fol d and gasket from bel ow
(2) I nstal l l ower exhaust mani fol d fasteners (Fi g.
107). DO NOT ti ghten unti l al l fasteners are i n
pl ace.
(3) Lower vehi cl e and i nstal l upper exhaust mani -
fol d fasteners (Fi g. 107). Ti ghten al l mani fol d bol ts
starti ng at center and worki ng outward to 25 Nm
(18 ft. l bs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) I nstal l exhaust mani fol d heat shi el d (Fi g. 107).
Ti ghten fasteners to 8 Nm (72 i n. l bs.), then l oosen
45 degrees.
(5) I nstal l ai r cl eaner housi ng and tube.
(6) Connect exhaust pi pe to mani fol d.
9 - 138 ENGINE - 4. 7L WJ
EXHAUST MANIFOLD - RIGHT
DESCRIPTION
The exhaust mani fol ds are l og styl e wi th a pat-
ented fl ow enhanci ng desi gn to maxi mi ze perfor-
mance. The exhaust mani fol ds are made of hi gh
si l i con mol ybdenum cast i ron. A perforated core
graphi te exhaust mani fol d gasket i s used to i mprove
seal i ng to the cyl i nder head. The exhaust mani fol ds
are covered by a three l ayer l ami nated heat shi el d
for thermal protecti on and noi se reducti on. The heat
shi el ds are fastened wi th a torque prevai l i ng nut
that i s backed off sl i ghtl y to al l ow for the thermal
expansi on of the exhaust mani fol d.
REMOVAL
(1) Di sconnect negati ve cabl e for battery.
(2) Remove battery from vehi cl e.
(3) Remove Power Di stri buti on Center (PDC) fas-
teners and set asi de.
(4) Remove battery tray assembl y.
(5) Remove washer bottl e assembl y
REMOVAL).
Fig. 107 Exhaust ManifoldLeft
ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
2 Bolt (Qty 4) 5 Nut (Qty 2)
3 Stud (Qty 2)
WJ ENGINE - 4. 7L 9 - 139
EXHAUST MANIFOLD - LEFT (Continued)
(7) Remove A/C compressor from mounti ng and set
asi de.
(8) Remove A/C accumul ator support bracket fas-
tener.
(9) Drai n cool ant (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
(10) Remove heater hoses at engi ne.
(11) Remove fasteners attachi ng exhaust mani fol d
heat shi el d (Fi g. 108).
(12) Remove heat shi el d (Fi g. 108).
(13) Remove upper exhaust mani fol d attachi ng fas-
teners (Fi g. 108).
(15) Di sconnect exhaust pi pe from mani fol d.
(16) Remove fasteners attachi ng starter. Move
starter asi de.
(17) Remove l ower exhaust mani fol d attachi ng fas-
teners.
(18) Remove exhaust mani fol d and gasket (Fi g.
108). Mani fol d i s removed from bel ow the engi ne
compartment.
CLEANING
(1) Cl ean the exhaust mani fol d usi ng a sui tabl e
cl eani ng sol vent, then al l ow to ai r dry.
(2) Cl ean al l gasket resi due from the mani fol d
mati ng surface.
Fig. 108 Exhaust ManifoldRight
ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
2 Bolt (Qty 4) 5 Nut (Qty 2)
3 Stud (Qty 2)
9 - 140 ENGINE - 4. 7L WJ
EXHAUST MANIFOLD - RIGHT (Continued)
INSPECTION
(1) I nspect the exhaust mani fol d for cracks i n the
mati ng surface and at every mounti ng bol t hol e.
(2) Usi ng a strai ght edge and a feel er gauge, check
the mati ng surface for warp and twi st.
(3) I nspect the mani fol d to exhaust pi pe mati ng
surface for cracks, gouges, or other damage that
woul d prevent seal i ng.
INSTALLATION
(1) I nstal l exhaust mani fol d and gasket from bel ow
(2) I nstal l l ower exhaust mani fol d fasteners. DO
NOT ti ghten unti l al l fasteners are i n pl ace.
(3) Lower vehi cl e and i nstal l upper exhaust mani -
fol d fasteners. Ti ghten al l mani fol d bol ts starti ng at
center and worki ng outward to 25 Nm (18 ft. l bs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) I nstal l exhaust mani fol d heat shi el d. Ti ghten
fasteners to 8 Nm (72 i n. l bs.), then l oosen 45
degrees.
(5) I nstal l starter and fasteners.
(6) Connect exhaust pi pe to mani fol d.
(7) Connect heater hoses at engi ne.
(8) I nstal l fastener attachi ng A/C accumul ator.
(9) I nstal l A/C compressor and fasteners.
I NSTALLATI ON).
(11) I nstal l washer bottl e and battery tray assem-
bl y.
(12) I nstal l PDC.
(13) I nstal l battery and connect cabl es.
VALVE TIMING
DESCRIPTION - TIMING DRIVE SYSTEM
The ti mi ng dri ve system has been desi gned to pro-
vi de qui et performance and rel i abi l i ty to support a
non-free wheeling engi ne. Speci fi cal l y the i ntake
val ves are non-free wheel i ng and can be easi l y dam-
aged wi th forceful engi ne rotati on i f camshaft-to-
crankshaft ti mi ng i s i ncorrect. The ti mi ng dri ve
system consi sts of a pri mary chai n and two second-
ary ti mi ng chai n dri ves (Fi g. 109).
OPERATION - TIMING DRIVE SYSTEM
The pri mary ti mi ng chai n i s a si ngl e i nverted tooth
type. The pri mary chai n dri ves the l arge fi fty tooth
i dl er sprocket di rectl y from a 25 tooth crankshaft
sprocket. Pri mary chai n moti on i s control l ed by a
pi voti ng l eaf spri ng tensi oner arm and a fi xed gui de.
The arm and the gui de both use nyl on pl asti c wear
faces for l ow fri cti on and l ong wear. The pri mary
chai n recei ves oi l spl ash l ubri cati on from the second-
ary chai n dri ve and oi l pump l eakage. The i dl er
sprocket assembl y connects the pri mary and second-
ary chai n dri ves. The i dl er sprocket assembl y con-
si sts of two i ntegral thi rty tooth sprockets and a fi fty
tooth sprocket that i s spl i ned to the assembl y. The
spl i ne joi nt i s a non servi ceabl e press fi t anti rattl e
type. A spi ral ri ng i s i nstal l ed on the outboard si de of
the fi fty tooth sprocket to prevent spl i ne di sengage-
ment. The i dl er sprocket assembl y spi ns on a stati on-
ary i dl er shaft. The i dl er shaft i s press-fi t i nto the
cyl i nder bl ock. A l arge washer on the i dl er shaft bol t
and the rear fl ange of the i dl er shaft are used to con-
trol sprocket thrust movement. Pressuri zed oi l i s
routed through the center of the i dl er shaft to pro-
vi de l ubri cati on for the two bushi ngs used i n the
i dl er sprocket assembl y.
There are two secondary dri ve chai ns, both are
i nverted tooth type, one to dri ve the camshaft i n each
SOHC cyl i nder head. There are no shaft speed
changes i n the secondary chai n dri ve system. Each
secondary chai n dri ves a thi rty tooth cam sprocket
di rectl y from the thi rty tooth sprocket on the i dl er
sprocket assembl y. A fi xed chai n gui de and a hydrau-
l i c oi l damped tensi oner are used to mai ntai n tensi on
i n each secondary chai n system. The hydraul i c ten-
si oners for the secondary chai n systems are fed pres-
suri zed oi l from oi l reservoi r pockets i n the bl ock.
Each tensi oner al so has a mechani cal ratchet system
that l i mi ts chai n sl ack i f the tensi oner pi ston bl eeds
down after engi ne shut down. The tensi oner arms
and gui des al so uti l i ze nyl on wear faces for l ow fri c-
ti on and l ong wear. The secondary ti mi ng chai ns
recei ve l ubri cati on from a smal l ori fi ce i n the ten-
si oners. Thi s ori fi ce i s protected from cl oggi ng by a
fi ne mesh screen whi ch i s l ocated on the back of the
hydraul i c tensi oners.
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE TIMING -
VERIFICATION
CAUTION: The 4.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
WJ ENGINE - 4. 7L 9 - 141
EXHAUST MANIFOLD - RIGHT (Continued)
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
Engi ne base ti mi ng can be veri fi ed by the fol l owi ng
procedure:
(1) Remove the cyl i nder head covers (Refer to 9 -
(2) Usi ng a mi rror, l ocate the TDC arrow on the
front cover (Fi g. 110). Rotate the crankshaft unti l the
mark on the crankshaft damper i s al i gned wi th the
TDC arrow on the front cover. The engi ne i s now at
TDC.
(3) Note the l ocati on of the V8 mark stamped i nto
the camshaft dri ve gears (Fi g. 111). I f the V8 mark
on each camshaft dri ve gear i s at the twel ve ocl ock
posi ti on, the engi ne i s at TDC (cyl i nder #1) on the
exhaust stroke. I f the V8 mark on each gear i s at the
si x ocl ock posi ti on, the engi ne i s at TDC (cyl i nder
#1) on the compressi on stroke.
(4) I f both of the camshaft dri ve gears are off i n
the same or opposi te di recti ons, the pri mary chai n or
both secondary chai ns are at faul t. Refer to Ti mi ng
Chai n and Sprockets procedure i n thi s secti on.
(5) I f onl y one of the camshaft dri ve gears i s off
and the other i s correct, the probl em i s confi ned to
one secondary chai n. Refer to Si ngl e camshaft ti m-
i ng, i n thi s procedure.
(6) I f both camshaft dri ve gear V8 marks are at
the twel ve ocl ock or the si x o cl ock posi ti on the
engi ne base ti mi ng i s correct. Rei nstal l the cyl i nder
head covers.
Fig. 109 Timing Drive System
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT
SIDE NOT COMMON)
3 - SECONDARY TENSIONER ARM
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
7 - PRIMARY CHAIN
8 - IDLER SPROCKET
10 - PRIMARY CHAIN TENSIONER
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
9 - 142 ENGINE - 4. 7L WJ
VALVE TIMING (Continued)
SINGLE CAMSHAFT TIMING
NOTE: to adjust the timing on one camshaft, pre-
form the following procedure.
(1) Usi ng Chai n Tensi oner Wedge, speci al tool
8350, stabi l i ze the secondary chai n dri ve (Fi g. 112).
For reference purposes, mark the chai n-to-sprocket
posi ti on (Fi g. 112).
(2) Remove the camshaft dri ve gear retai ni ng bol t.
(3) Careful l y remove the camshaft dri ve gear from
the camshaft.
(4) Re-i ndex the camshaft dri ve gear i n the chai n
unti l the V8 mark i s at the same posi ti on as the V8
mark on the opposi te camshaft dri ve gear.
Fig. 110 Engine Top Dead Center (TDC) Indicator
Mark
WJ ENGINE - 4. 7L 9 - 143
(5) Usi ng a sui tabl e pai r of adjustabl e pl i ers,
rotate the camshaft unti l the al i gnment dowel on the
camshaft i s al i gned wi th the sl ot i n the camshaft
dri ve gear (Fi g. 113).
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(6) Posi ti on the camshaft dri ve gear onto the cam-
shaft, remove oi l from bol t then i nstal l the retai ni ng
bol t. Usi ng Speci al Tool s, Spanner Wrench 6958 wi th
Adapter Pi ns 8346 and a sui tabl e torque wrench,
Ti ghten retai ni ng bol t to 122Nm (90 ft. Lbs.) (Fi g.
114) (Fi g. 115).
(7) Remove speci al tool 8350.
(8) Rotate the crankshaft two ful l revol uti ons, then
reveri fy that the camshaft dri ve gear V8 marks are
i n fact al i gned.
(9) I nstal l the cyl i nder head covers (Refer to 9 -
Fig. 113 Camshaft Dowel
2 - CAMSHAFT DOWEL
9 - 144 ENGINE - 4. 7L WJ
STANDARD PROCEDURE MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
(1) Remove the ti mi ng chai n cover. (Refer to 9 -
(2) To determi ne i f the secondary ti mi ng chai ns
are worn, rotate the engi ne cl ockwi se unti l maxi mum
tensi oner pi ston extensi on i s obtai ned. Measure the
di stance between the secondary ti mi ng chai n ten-
si oner housi ng and the step l edge on the pi ston (Fi g.
116). The measurement at poi nt (A) must be l ess
than 15mm (0.5906 i nches).
(3) I f the measurement exceeds the speci fi cati on
the secondary ti mi ng chai ns are worn and requi re
repl acement. (Refer to 9 - ENGI NE/VALVE TI MI NG/
REMOVAL).
NOTE: If the secondary chains are to be replaced
the primary chain must also be replaced.
Fig. 114 Camshaft Sprocket Left Cylinder Head
1 - TORQUE WRENCH
Fig. 115 Camshaft Sprocket InstallationRight
Cylinder Head
1 - TORQUE WRENCH
Fig. 116 Measuring Secondary Timing Chains For
Wear
2 - SECONDARY CHAIN TENSIONER PISTON
WJ ENGINE - 4. 7L 9 - 145
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(3) Di sconnect both heater hoses at ti mi ng cover.
(4) Di sconnect l ower radi ator hose at engi ne.
(5) Remove crankshaft damper (Refer to 9 -
REMOVAL).
(6) Remove accessory dri ve bel t tensi oner assembl y
(Fi g. 117).
(7) Remove the generator and A/C compressor.
(8) Remove cover and gasket (Fi g. 118).
INSTALLATION
(1) Cl ean ti mi ng chai n cover and bl ock surface.
I nspect cover gasket and repl ace as necessary.
(2) I nstal l cover and gasket. Ti ghten fasteners i n
sequence as shown i n (Fi g. 119) to 54 Nm (40 ft.
l bs.).
(3) I nstal l the A/C compressor and generator.
(4) I nstal l crankshaft damper (Refer to 9 -
I NSTALLATI ON).
(5) I nstal l accessory dri ve bel t tensi oner assembl y.
Ti ghten fastener to 54 Nm (40 ft. l bs.).
(6) I nstal l l ower radi ator hose.
(7) I nstal l both heater hoses.
Fig. 117 Accessory Drive Belt Tensioner
1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
Fig. 118 Timing Chain Cover Fasteners
Fig. 119 Timing Chain Cover Fasteners
9 - 146 ENGINE - 4. 7L WJ
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(3) Remove ri ght and l eft cyl i nder head covers
(Refer to 9 - ENGI NE/CYLI NDER HEAD/CYLI N-
DER HEAD COVER(S) - REMOVAL).
(4) Remove radi ator fan (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR FAN - REMOVAL).
(5) Rotate engi ne unti l ti mi ng mark on crankshaft
damper al i gns wi th TDC mark on ti mi ng chai n cover
(Fi g. 120) (#1 cyl i nder exhaust stroke) and the cam-
shaft sprocket V8 marks are at the 12 ocl ock posi -
ti on (Fi g. 121).
(6) Remove power steeri ng pump.
(7) Remove access pl ugs (2) from l eft and ri ght cyl -
i nder heads for access to chai n gui de fasteners (Fi g.
122).
(8) Remove the oi l fi l l housi ng to gai n access to the
ri ght si de tensi oner arm fastener.
(9) Remove crankshaft damper (Refer to 9 -
REMOVAL) and ti mi ng chai n cover (Refer to 9 -
(10) Col l apse and pi n pri mary chai n tensi oner
(Fi g. 123).
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chai n tensi oners.
(12) Remove camshaft posi ti on sensor from ri ght
cyl i nder head (Fi g. 124).
CAUTION: Care should be taken not to damage
camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.
CAUTION: Do not forcefully rotate the camshafts or
crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.
(13) Remove l eft and ri ght camshaft sprocket bol ts.
(14) Whi l e hol di ng the l eft camshaft steel tube
wi th adjustabl e pl i ers, (Fi g. 125) remove the l eft
camshaft sprocket. Sl owl y rotate the camshaft
approxi matel y 15 degrees cl ockwi se to a neutral posi -
ti on.
(15) Whi l e hol di ng the ri ght camshaft steel tube
wi th adjustabl e pl i ers, (Fi g. 126) remove the ri ght
camshaft sprocket. Sl owl y rotate the camshaft
approxi matel y 45 degrees countercl ockwi se to a neu-
tral posi ti on.
Fig. 120 Engine Top Dead Center (TDC) Indicator
Mark
WJ ENGINE - 4. 7L 9 - 147
(16) Remove i dl er sprocket assembl y bol t.
(17) Sl i de the i dl er sprocket assembl y and crank
sprocket forward si mul taneousl y to remove the pri -
mary and secondary chai ns.
(18) Remove both pi voti ng tensi oner arms and
chai n gui des.
(19) Remove chai n tensi oner.
Fig. 122 Cylinder Head Access Plug Location
Fig. 123 Collapsing And Pinning Primary Chain
Tensioner
9 - 148 ENGINE - 4. 7L WJ
TIMING BELT/CHAIN AND SPROCKETS (Continued)
INSPECTION
I nspect the fol l owi ng components:
Sprockets for excessi ve tooth wear. Some tooth
marki ngs are normal and not a cause for sprocket
repl acement.
I dl er sprocket assembl y bushi ng and shaft for
excessi ve wear.
I dl er sprocket assembl y spl i ne joi nt. The joi nt
shoul d be ti ght wi th no backl ash or axi al movement.
Chai n gui des and tensi oner arms. Repl ace these
parts i f groovi ng i n pl asti c face i s more than 1 mm
(0.039 i n.) deep. I f pl asti c face i s severel y grooved or
mel ted, the tensi oner l ube jet may be cl ogged. The
tensi oner shoul d be repl aced.
secondary chai n tensi oner pi ston and ratcheti ng
devi ce. I nspect for evi dence of heavy contact between
tensi oner pi ston and tensi oner arm. I f thi s condi ti on
exi st the tensi oner and tensi oner arm shoul d be
repl aced.
Pri mary chai n tensi oner pl asti c faces. Repl ace as
requi red (Fi g. 127).
INSTALLATION
(1) Usi ng a vi se, l i ghtl y compress the secondary
chai n tensi oner pi ston unti l the pi ston step i s fl ush
wi th the tensi oner body. Usi ng a pi n or sui tabl e tool ,
rel ease ratchet pawl by pul l i ng pawl back agai nst
spri ng force through access hol e on si de of tensi oner.
Whi l e conti nui ng to hol d pawl back, Push ratchet
devi ce to approxi matel y 2 mm from the tensi oner
Fig. 124 Camshaft Position SensorRemoval
Fig. 125 Camshaft RotationLeft Side
3 - CAMSHAFT
Fig. 126 Camshaft RotationRight Side
2 - CAMSHAFT DOWEL
WJ ENGINE - 4. 7L 9 - 149
body. I nstal l Speci al Tool 8514 l ock pi n i nto hol e on
front of tensi oner. Sl owl y open vi se to transfer pi ston
spri ng force to l ock pi n (Fi g. 128).
(2) Posi ti on pri mary chai n tensi oner over oi l pump
and i nsert bol ts i nto l ower two hol es on tensi oner
bracket. Ti ghten bol ts to 28 Nm (250 i n. l bs.).
CAUTION: Overtightening the tensioner arm torx
bolt can cause severe damage to the cylinder head.
Tighten torx bolt to specified torque only.
(3) I nstal l ri ght si de chai n tensi oner arm. Appl y
Mopar Lock N, Seal to torx bol t, ti ghten bol t to 17
Nm (150 i n. l bs.).
NOTE: The silver bolts retain the guides to the cyl-
inder heads and the black bolts retain the guides to
the engine block.
(4) I nstal l the l eft si de chai n gui de. Ti ghten the
CAUTION: Overtightening the tensioner arm torx
bolt can cause severe damage to the cylinder head.
Tighten torx bolt to specified torque only.
(5) I nstal l l eft si de chai n tensi oner arm. Appl y
Mopar Lock N, Seal to torx bol t, ti ghten bol t to 17
Nm (150 i n. l bs.).
(6) I nstal l the ri ght si de chai n gui de. Ti ghten the
(7) I nstal l both secondary chai ns onto the i dl er
sprocket. Al i gn two pl ated l i nks on the secondary
chai ns to be vi si bl e through the two l ower openi ngs
on the i dl er sprocket (4 ocl ock and 8 ocl ock). Once
the secondary ti mi ng chai ns are i nstal l ed, posi ti on
speci al tool 8515 to hol d chai ns i n pl ace for i nstal l a-
ti on (Fi g. 129).
Fig. 127 Timing Chain System
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT
SIDE NOT COMMON)
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
7 - PRIMARY CHAIN
8 - IDLER SPROCKET
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
9 - 150 ENGINE - 4. 7L WJ
(8) Al i gn pri mary chai n doubl e pl ated l i nks wi th
the ti mi ng mark at 12 ocl ock on the i dl er sprocket.
Al i gn the pri mary chai n si ngl e pl ated l i nk wi th the
ti mi ng mark at 6 ocl ock on the crankshaft sprocket
(Fi g. 127).
(9) Lubri cate i dl er shaft and bushi ngs wi th cl ean
engi ne oi l .
(10) I nstal l al l chai ns, crankshaft sprocket, and
i dl er sprocket as an assembl y (Fi g. 130). After gui d-
i ng both secondary chai ns through the bl ock and cyl -
i nder head openi ngs, affi x chai ns wi th a el asti c strap
or the equi val ent, Thi s wi l l mai ntai n tensi on on
chai ns to ai d i n i nstal l ati on.
NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
(11) Al i gn l eft camshaft sprocket L dot to pl ated
l i nk on chai n.
(12) Al i gn ri ght camshaft sprocket R dot to
pl ated l i nk on chai n.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
Fig. 128 Resetting Secondary Chain Tensioners
1 - VISE
2 - INSERT LOCK PIN
3 - RATCHET PAWL
4 - RATCHET
5 - PISTON
Fig. 129 Installing Secondary Timing Chains on
Idler Sprocket
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
4 - IDLER SPROCKET
5 - LEFT CAMSHAFT CHAIN
Fig. 130 Installing Idler Gear, Primary and
Secondary Timing Chains
2 - PRIMARY CHAIN IDLER SPROCKET
WJ ENGINE - 4. 7L 9 - 151
(13) Remove Speci al Tool 8515, then attach both
sprockets to camshafts. Remove excess oi l from bol ts,
then I nstal l sprocket bol ts, but do not ti ghten at thi s
ti me.
(14) Veri fy that al l pl ated l i nks are al i gned wi th
the marks on al l sprockets and the V8 marks on
camshaft sprockets are at the 12 ocl ock posi ti on (Fi g.
127).
CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.
(15) I nstal l both secondary chai n tensi oners.
Ti ghten bol ts to 28 Nm (250 i n. l bs.).
NOTE: Left and right secondary chain tensioners
are not common.
(16) Before i nstal l i ng i dl er sprocket bol t, l ubri cate
washer wi th oi l , and ti ghten i dl er sprocket assembl y
retai ni ng bol t to 34 Nm (25 ft. l bs.).
(17) Remove al l l ocki ng pi ns (3) from tensi oners.
CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.
(18) Usi ng Speci al Tool 6958, Spanner wi th Adap-
tor Pi ns 8346, ti ghten l eft (Fi g. 131) and ri ght (Fi g.
132). camshaft sprocket bol ts to 122 Nm (90 ft. l bs.).
(19) Rotate engi ne two ful l revol uti ons. Veri fy ti m-
i ng marks are at the fol l ow l ocati ons:
pri mary chai n i dl er sprocket dot i s at 12 ocl ock
(Fi g. 127)
pri mary chai n crankshaft sprocket dot i s at 6
ocl ock (Fi g. 127)
secondary chai n camshaft sprockets V8 marks
are at 12 ocl ock (Fi g. 127)
(20) Lubri cate al l three chai ns wi th engi ne oi l .
(21) After i nstal l i ng al l chai ns, i t i s recommended
that the i dl er gear end pl ay be checked (Fi g. 133).
The end pl ay must be wi thi n 0.100.25 mm (0.004
0.010 i n.). I f not wi thi n speci fi cati on, the i dl er gear
must be repl aced.
Fig. 131 Tightening Left Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
9 - 152 ENGINE - 4. 7L WJ
(22) I nstal l ti mi ng chai n cover (Refer to 9 -
COVER(S) - I NSTALLATI ON) and crankshaft
damper (Refer to 9 - ENGI NE/ENGI NE BLOCK/VI -
BRATI ON DAMPER - I NSTALLATI ON).
(23) I nstal l cyl i nder head covers (Refer to 9 -
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.
(24) Coat the l arge threaded access pl ug wi th
Mopar Thread Sealant with Teflon, then i nstal l
i nto the ri ght cyl i nder head and ti ghten to 81 Nm
(60 ft. l bs.) (Fi g. 122).
(25) I nstal l the oi l fi l l housi ng.
(26) I nstal l access pl ug i n l eft cyl i nder head (Fi g.
122).
(27) I nstal l power steeri ng pump.
(28) I nstal l radi ator fan (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR FAN - I NSTALLATI ON).
Fig. 132 Tightening Right Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
Fig. 133 Measuring Idler Gear End Play
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
WJ ENGINE - 4. 7L 9 - 153
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION - EXHAUST SYSTEM . . . . . . . . . 1
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CATALYTIC CONVERTER - 4.0L
DESCRIPTION - CATALYTIC CONVERTER
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION - CATALYTIC CONVERTER . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST PIPE - 4.0L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EXHAUST PIPE - 4.7L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
HEAT SHIELDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
MUFFLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
TAILPIPE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EXHAUST SYSTEM
DESCRIPTION - EXHAUST SYSTEM
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan heat shields. Light overspray near the
edges is permitted. Application of coating will result
in excessive floor pan temperatures and objection-
able fumes.
The exhaust system uses a si ngl e muffl er wi th a
wel ded tai l pi pe.
The 50 State Emi ssi ons vehi cl es use two mi ni cat-
al yti c converters i nl i ne wi th the exhaust pi pe bel ow
the exhaust mani fol ds.
The exhaust mani fol ds are equi pped wi th bal l
fl ange outl ets to assure a ti ght seal and strai n free
connecti ons.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. I f the sys-
tem contacts any body panel , i t may ampl i fy objec-
ti onabl e noi ses ori gi nati ng from the engi ne or body.
When i nspecti ng an exhaust system, cri ti cal l y
i nspect for cracked or l oose joi nts, stri pped screw or
bol t threads, corrosi on damage and worn, cracked or
broken hangers. Repl ace al l components that are
badl y corroded or damaged. DO NOT attempt to
repai r.
When repl acement i s requi red, use ori gi nal equi p-
ment parts (or thei r equi val ent). Thi s wi l l assure
proper al i gnment and provi de acceptabl e exhaust
noi se l evel s.
The basi c exhaust system consi sts of exhaust man-
i fol d(s), exhaust pi pe wi th oxygen sensors, catal yti c
converter(s), heat shi el d(s), muffl er and tai l pi pe (Fi g.
1) and (Fi g. 2).
WJ EXHAUST SYSTEM 11 - 1
Fig. 1 Exhaust System4.0L
1 - MINI CONVERTERS (2)
2 - CATALYTIC CONVERTER TO EXHAUST PIPE FLANGE JOINT
3 - CATALYTIC CONVERTER
4 - MUFFLER
5 - TAILPIPE
6 - TAILPIPE HANGER REAR MOUNT INSULATOR
7 - EXHAUST PIPE HANGER AND MOUNT INSULATOR
Fig. 2 Exhaust System4.7L
1 - EXHAUST PIPE WITH CATALYTIC CONVERTERS
2 - EXHAUST PIPE TO CATALYTIC CONVERTER FLANGE JOINT
4 - MUFFLER
5 - TAILPIPE
6 - TAILPIPE HANGER REAR MOUNT INSULATOR
7 - EXHAUST PIPE HANGER AND MOUNT INSULATOR
11 - 2 EXHAUST SYSTEM WJ
EXHAUST SYSTEM (Continued)
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps to specified
torque at leaking joints (Refer to 11
- EXHAUST SYSTEM -
SPECIFICATIONS).
2. Burned or blown out muffler. 2. Replace muffler assembly (Refer
to 11 - EXHAUST SYSTEM/
MUFFLER - REMOVAL). Check
exhaust system.
3. Burned or rusted-out exhaust
pipe.
3. Replace exhaust pipe (Refer to
11 - EXHAUST SYSTEM/EXHAUST
PIPE - REMOVAL).
4. Exhaust pipe leaking at manifold
flange.
4. Tighten connection attaching nuts
(Refer to 11 - EXHAUST SYSTEM -
SPECIFICATIONS).
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold (Refer
to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD -
REMOVAL).
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head stud nuts or bolts
(Refer to 9 - ENGINE -
SPECIFICATIONS).
7. Restriction in muffler or tailpipe. 7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
8. Exhaust system contacting body
or chassis.
8. Re-align exhaust system to clear
surrounding components.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten/replace clamps at leaking
joints (Refer to 11 - EXHAUST
SYSTEM - SPECIFICATIONS).
SPECIFICATIONS
TORQUE
Lbs. Lbs.
Catalytic Converter-to-
Exhaust PipeNuts
28 250
Exhaust Pipe-to-Manifold
Nuts
31 23
Heat Shield Retaining
Nuts
2.0 20
Lbs. Lbs.
Muffler-to-Catalytic
Converter
U-bolt clamp 47 35
Rear Tailpipe Hanger
Bolts
22 192
EXHAUST SYSTEM (Continued)
DESCRIPTION - CATALYTIC CONVERTER 4. 0L
ENGINE
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emi ssi on vehi cl es i ncorporate two mi ni
catal yti c converters l ocated after the exhaust mani -
fol ds and before the i nl i ne catal yti c converter (Fi g. 3).
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
Fig. 3 4.0L Catalytic Converter and O2 Sensor Configuration - 50 State Emissions
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove nuts from the catal yti c converter and
exhaust pi pe fl ange connecti on (Fi g. 4).
(4) Loosen exhaust cl amp from the catal yti c con-
verter and muffl er connecti on (Fi g. 4).
(5) Di sconnect oxygen sensor wi ri ng (Fi g. 4).
(6) Heat the catal yti c converter to muffl er connec-
ti on wi th a torch unti l the metal becomes cherry red.
(7) Whi l e the metal i s sti l l cherry red, twi st the
catal yti c converter back and forth to separate i t from
the exhaust pi pe and the muffl er (Fi g. 5).
INSPECTION
Look at the stai nl ess steel body of the converter,
i nspect for bul gi ng or other di storti on that coul d be a
resul t of overheati ng. I f the converter has a heat
shi el d attached make sure i t i s not bent or l oose.
I f you suspect i nternal damage to the catal yst, tap-
pi ng the bottom of the catal yst wi th a rubber mal l et
may i ndi cate a damaged core.
INSTALLATION
(1) Posi ti on the catal yti c converter onto the
exhaust pi pe fl ange connecti on (Fi g. 4). Ti ghten the
nuts to 28 Nm (250 i n. l bs.) torque.
(2) I nstal l the muffl er onto the catal yti c converter
unti l the al i gnment tab i s i nserted i nto the al i gn-
ment sl ot.
(3) I nstal l the exhaust cl amp at the muffl er and
catal yti c converter connecti on (Fi g. 4). Ti ghten the
cl amp nuts to 47 Nm (35 ft. l bs.) torque.
(4) Connect oxygen sensor wi ri ng (Fi g. 4).
(6) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
Fig. 4 Exhaust Pipe-to-Catalytic Converter-to-Muffler
Connection
1 - EXHAUST CLAMP ASSEMBLY
2 - OXYGEN SENSOR
3 - MUFFLER
5 - EXHAUST PIPE WITH FLANGE JOINT
6 - NUTS (3)
Fig. 5 Catalytic ConverterRemoval
1 - EXHAUST PIPE WITH FLANGE
2 - NUTS (3)
CATALYTIC CONVERTER - 4.0L (Continued)
DESCRIPTION - CATALYTIC CONVERTER
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emi ssi on vehi cl es i ncorporate two mi ni
catal yti c converters l ocated after the exhaust mani -
fol ds and before the i nl i ne catal yti c converter (Fi g. 6).
REMOVAL
(3) Remove nuts from the catal yti c converter and
exhaust pi pe fl ange connecti on (Fi g. 7).
(4) Loosen exhaust cl amp from the catal yti c con-
verter and muffl er connecti on (Fi g. 7).
(5) Di sconnect oxygen sensor wi ri ng (Fi g. 7).
(6) Heat the catal yti c converter to muffl er connec-
(7) Whi l e the metal i s sti l l cherry red, twi st the
catal yti c converter back and forth to separate i t from
the muffl er (Fi g. 8).
INSPECTION
Look at the stai nl ess steel body of the converter,
i nspect for bul gi ng or other di storti on that coul d be a
resul t of overheati ng. I f the converter has a heat
shi el d attached make sure i t i s not bent or l oose.
I f you suspect i nternal damage to the catal yst, tap-
pi ng the bottom of the catal yst wi th a rubber mal l et
may i ndi cate a damaged core.
INSTALLATION
exhaust pi pe fl ange connecti on (Fi g. 7). Ti ghten the
nuts to 28 Nm (250 i n. l bs.) torque.
(2) I nstal l the muffl er onto the catal yti c converter
unti l the al i gnment tab i s i nserted i nto the al i gn-
ment sl ot.
(3) I nstal l the exhaust cl amp at the muffl er and
catal yti c converter connecti on (Fi g. 7). Ti ghten the
cl amp nuts to 47 Nm (35 ft. l bs.) torque.
(4) Connect oxygen sensor wi ri ng (Fi g. 7).
Fig. 7 Exhaust Pipe-to-Catalytic Converter-to-Muffler
Connection
1 - EXHAUST CLAMP ASSEMBLY
2 - OXYGEN SENSOR
3 - MUFFLER
5 - EXHAUST PIPE WITH FLANGE JOINT
6 - NUTS (3)
2 - NUTS (3)
CATALYTIC CONVERTER - 4.7L (Continued)
EXHAUST PIPE - 4.0L
REMOVAL
(3) Remove the oxygen sensor from the exhaust
pi pe (Fi g. 9).
(4) Remove the nuts from the exhaust pi pe to cat-
al yti c converter fl ange connecti on (Fi g. 10).
(5) Di sconnect the exhaust pi pe from the exhaust
INSPECTION
Di scard rusted cl amps, broken or worn supports
and attachi ng parts. Repl ace a component wi th ori g-
i nal equi pment parts, or equi val ent. Thi s wi l l assure
proper al i gnment wi th other parts i n the system and
provi de acceptabl e exhaust noi se l evel s.
INSTALLATION
(1) Connect the exhaust pi pe to the engi ne exhaust
mani fol d. Ti ghten the nuts to 31 Nm (23 ft. l bs.)
(Fi g. 11).
Fig. 9 O2 Sensor Location 4.0L
NOTE: When servicing the exhaust system, replace
the factory installed uni-clamp with standard u-bolt
clamps.
exhaust pi pe fl ange connecti on. Ti ghten retai ni ng
nuts to 28 Nm (250 i n. l bs.) (Fi g. 12).
(3) Coat the oxygen sensor wi th anti -sei ze com-
pound. I nstal l the sensor and ti ghten the nut to 48
Nm (35 ft. l bs.) torque (Fi g. 9).
(6) After i ni ti al start-up, check the engi ne exhaust
mani fol d to exhaust pi pe nuts for proper torque.
2 - NUTS (3)
Fig. 11 Exhaust Pipe 4.0L
1 - NUT
2 - EXHAUST MANIFOLD
3 - TRANSMISSION SUPPORT
4 - EXHAUST PIPE
5 - MINI CATALYTIC CONVERTER
6 - BOLT
Fig. 12 Installing Exhaust Clamps
2 - MUFFLER
EXHAUST PIPE - 4.0L (Continued)
EXHAUST PIPE - 4.7L
REMOVAL
(3) Remove the oxygen sensor from the exhaust
pi pe (Fi g. 13).
(4) Remove the retai ni ng nuts hol di ng catal yti c
converter to exhaust pi pe (Fi g. 14).
(5) Di sconnect the exhaust pi pe from the exhaust
mani fol d. (Fi g. 15)
INSPECTION
Di scard rusted cl amps, broken or worn supports
and attachi ng parts. Repl ace a component wi th ori g-
i nal equi pment parts, or equi val ent. Thi s wi l l assure
proper al i gnment wi th other parts i n the system and
provi de acceptabl e exhaust noi se l evel s.
INSTALLATION
(1) Connect the exhaust pi pe to the engi ne exhaust
mani fol d. Ti ghten the nuts (A) to 31 Nm (23 ft. l bs.)
(Fi g. 15).
NOTE: When servicing the exhaust system, replace
the factory installed uni-clamp with standard u-bolt
clamps.
exhaust pi pe fl ange connecti on. Ti ghten retai ni ng
nuts to 28 Nm (250 i n. l bs.). (Fi g. 16)
(3) Coat the oxygen sensor wi th anti -sei ze com-
pound. I nstal l the sensor and ti ghten the nut to 48
Nm (35 ft. l bs.) torque (Fi g. 13).
(6) After i ni ti al start-up, check the engi ne exhaust
mani fol d to exhaust pi pe nuts for proper torque.
2 - NUTS (3)
Fig. 15 Exhaust Pipe 4.7L
1 - EXHAUST PIPE HANGER
A - NUTS (4)
3 - EXHAUST PIPE
B - BOLTS (4)
2 - MUFFLER
EXHAUST PIPE - 4.7L (Continued)
HEAT SHIELDS
DESCRIPTION
Heat shi el ds are needed to protect both the vehi cl e
and the envi ronment from the hi gh temperatures
devel oped by the catal yti c converter. The catal yti c
converter rel eases addi ti onal heat i nto the exhaust
system. Under severe operati ng condi ti ons, the tem-
perature i ncreases i n the area of the converter. Such
condi ti ons can exi st when the engi ne mi sfi res or oth-
erwi se does not operate at peak effi ci ency (Fi g. 17).
MUFFLER
DESCRIPTION
Both the 4.0L and 4.7L engi nes use a stai nl ess
steel muffl er to control exhaust noi se l evel s and
exhaust back pressure. The muffl er and tai l pi pe are
a one pi ece assembl y (Fi g. 18).
REMOVAL
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the tai l pi pe wel ded to the muffl er. Ser-
vi ce repl acement muffl ers and tai l pi pes are ei ther
cl amped together or wel ded together.
(3) Loosen the exhaust cl amp on the catal yti c con-
verter to muffl er connecti on (Fi g. 19).
(4) Heat the catal yti c converter-to-muffl er connec-
(5) Whi l e the metal i s sti l l cherry red, remove the
tai l pi pe/muffl er assembl y from the catal yti c con-
verter.
(6) Remove the tai l pi pe from the tai l pi pe hanger
(Fi g. 20).
(7) Remove the tai l pi pe/muffl er assembl y (Fi g. 20).
INSTALLATION
(1) I f the tai l pi pe hanger assembl y was removed,
i nstal l the hanger to the frame. Ti ghten the bol ts to
(2) Posi ti on the tai l pi pe and muffl er onto the
tai l pi pe hanger (Fi g. 20) .
(3) I nstal l the muffl er onto the catal yti c converter.
Make sure that the tai l pi pe has suffi ci ent cl earance
from the fl oor pan. I nstal l exhaust cl amp and ti ghten
the nuts to 47 Nm (35 ft. l bs.) torque (Fi g. 19) .
Fig. 17 Front and Rear Floor Pan Heat Shields
Typical
1 - REAR FLOOR PAN HEAT SHIELD
2 - HEAT SHIELD RETAINING NUTS (QTY 8)
3 - FRONT FLOOR PAN HEAT SHIELD
Fig. 18 Muffler and Tailpipe
2 - TAILPIPE HANGER
3 - TAILPIPE
4 - MUFFLER
TAILPIPE
DESCRIPTION
The tai l pi pe i s al so made of stai nl ess steel . (Fi g.
18) .
OPERATION
The Tai l pi pe channel s the exhaust out of the muf-
fl er and out from under the vehi cl e to control noi se
and prevent exhaust gas fumes from enteri ng the
passenger compartment
2 - MUFFLER
Fig. 20 Muffler and Tailpipe
2 - TAILPIPE HANGER
3 - TAILPIPE
4 - MUFFLER
MUFFLER (Continued)
FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRONT ABSORBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT FASCIA
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REAR ABSORBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR FASCIA
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRAME
SPECIFICATIONS
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . 4
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . 4
FRONT SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT TOW HOOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL TANK SKID PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR TOW HOOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRAILER HITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSFER CASE SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT ABSORBER
REMOVAL
(1) Remove front fasci a, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCI A
- REMOVAL).
(2) Remove the retai ner attachi ng the absorber to
the fasci a.
(3) Separate the absorber from the fasci a.
INSTALLATION
(1) Posi ti on the absorber on the fasci a.
(2) I nstal l the retai ner attachi ng the absorber to
the fasci a.
(3) I nstal l front fasci a. Refer to (Refer to 13 -
- I NSTALLATI ON).
FRONT FASCIA
REMOVAL
(2) Turn front wheel s to access ri vets and remove
pl asti c ri vets attachi ng fasci a to wheel l i ner.
(3) Remove bol ts attachi ng fasci a to fender (Fi g. 1).
(4) Remove pl asti c push pi n fasteners attachi ng
front fasci a to l ower radi ator crossmember spl ash
shi el d (Fi g. 2).
(5) Di sengage fog l amp connectors, i f equi pped.
(6) Remove screws attachi ng fasci a/gri l l e to upper
radi ator crossmember (Fi g. 3).
(7) Sl i de fasci a forward to separate from vehi cl e.
INSTALLATION
(1) Sl i de fasci a onto vehi cl e engagi ng fasci a wi th
tabs on bottom of front fenders.
(2) I nstal l screws attachi ng fasci a/gri l l e to upper
radi ator crossmember (Fi g. 3).
(3) I nstal l bol ts attachi ng fasci a to fender (Fi g. 1).
(4) Engage fog l amp connectors, i f equi pped.
(5) I nstal l pl asti c ri vets attachi ng fasci a to wheel
l i ner.
(6) I nstal l pl asti c push pi n fasteners attachi ng
front fasci a to l ower radi ator crossmember spl ash
shi el d (Fi g. 2).
WJ FRAME & BUMPERS 13 - 1
REAR ABSORBER
REMOVAL
(1) Remove rear fasci a, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCI A -
REMOVAL).
(2) Remove ri vets attachi ng absorber to rear cross-
member (Fi g. 5).
(3) Separate absorber from vehi cl e.
INSTALLATION
(1) Posi ti on absorber on vehi cl e.
(2) I nstal l ri vets attachi ng absorber to rear cross-
member (Fi g. 2).
(3) I nstal l rear fasci a, refer to (Refer to 13 -
I NSTALLATI ON).
REAR FASCIA
REMOVAL
(2) Remove wheel s.
(3) Remove pl asti c push pi ns attachi ng fasci a to
fuel tank ski d pl ate.
(4) Remove pl asti c ri vets attachi ng fasci a to wheel
l i ner.
Fig. 1 Front Fascia
1 - BODY
2 - FASCIA
Fig. 2 Front Fascia
1 - WHEEL LINER
2 - FASCIA
3 - FOG LAMP CONNECTOR
4 - PLASTIC PUSH PIN
5 - PLASTIC RIVET
Fig. 3 Front Fascia
1 - SCREW
2 - FASCIA
13 - 2 FRAME & BUMPERS WJ
FRONT FASCIA (Continued)
(5) Remove nuts attachi ng upper edge of fasci a to
quarter panel and wheel l i ner (Fi g. 4).
(6) Remove pl asti c push pi ns attachi ng fasci a to
l i ftgate openi ng (Fi g. 5).
(7) Remove screws attachi ng fasci a to l i ftgate
openi ng.
(8) Remove D pi l l ar tri m and scuff pl ate outboard
screws.
(9) Remove the rearward ti e down screws and the
aperture tri m panel .
(10) Careful l y peel back the rubber body seal er
patch to access the retai ner cl i ps.
(11) Rel ease the forward and rearward retai ner
cl i ps on both si des of the fasci a.
(12) Grasp forward edges of fasci a and pul l out-
ward to di sengage retai ners attachi ng fasci a to quar-
ter panel (Fi g. 6).
(13) Separate fasci a from vehi cl e.
Fig. 5 Rear Fascia
1 - ABSORBER
2 - RIVET
3 - FASCIA
Fig. 4 Rear Fascia Attachment
1 - FASCIA
REAR FASCIA (Continued)
INSTALLATION
(1) Posi ti on fasci a on vehi cl e al i gni ng retai ners
wi th sl ots i n quarter panel (Fi g. 7).
(2) Press forward edges of fasci a i nward to engage
retai ners.
(3) I nstal l screws attachi ng fasci a to l i ftgate open-
i ng.
(4) I nstal l pl asti c push pi ns attachi ng fasci a to l i ft-
gate openi ng.
(5) I nstal l nuts attachi ng upper edge of fasci a to
quarter panel and wheel l i ner.
(6) I nstal l pl asti c ri vets attachi ng fasci a to wheel
l i ner.
(7) I nstal l support l ower vehi cl e.
(8) I nstal l pl asti c push pi ns attachi ng fasci a to fuel
tank ski d pl ate.
(9) I nstal l the i nteri or tri m panel s removed to
access fasci a retai ners.
(10) I nstal l ti e down l oop screws.
(11) I nstal l the wheel s, refer to secti on 22 for
ti ghteni ng sequence and torque speci fi cati ons.
FRAME
SPECIFICATIONS
SPECIFICATIONS - TORQUE
DESCRIPTION Nm
Ft.
Lbs.
In.
Lbs.
Front Tow Hook Bolt 54 40
Front Skid Plate Bolt 54 40
Rear Tow Hook Bolt 68 50
Trailer Hitch Bolts 68 50
Transfer Case Skid Plate
Bolts
34 25
FRAME DIMENSIONS
INDEX
DESCRIPTION FIGURE
SIDE VIEW 8
BOTTOM VIEW 9
Fig. 6 Rear Fascia Retainers
1 - RETAINER
2 - FASCIA
Fig. 7 Fascia Attachment
1 - SLOT
2 - QUARTER PANEL
REAR FASCIA (Continued)
F
i
g
.
8
S
I
D
E
V
I
E
W
FRAME (Continued)
F
i
g
.
9
B
O
T
T
O
M
V
I
E
W
FRAME (Continued)
FRONT SKID PLATE
REMOVAL
(1) Posi ti on a support under ski d pl ate.
(2) Remove bol ts attachi ng ski d pl ate to frame
(Fi g. 10).
(3) Separate ski d pl ate from frame.
INSTALLATION
(1) Posi ti on ski d pl ate on a support.
(2) Rai se i t i nto posi ti on
(3) I nstal l bol ts attachi ng ski d pl ate to frame.
Ti ghten bol ts to 54 Nm (40 ft. l bs.) torque.
FRONT TOW HOOK
REMOVAL
(1) Remove bol ts that attach tow hook bracket to
the l ower crossmember (Fi g. 11).
(2) Separate tow hook bracket from l ower cross-
member.
INSTALLATION
(1) Posi ti on tow hook bracket at the l ower cross-
member.
(2) I nstal l bol ts attachi ng tow hook bracket to
crossmember. Ti ghten bol ts to 54 Nm (40 ft. l bs.)
torque.
FUEL TANK SKID PLATE
DESCRIPTION
The fuel tank ski d pl ate i s i ntegrated wi th the fuel
tank. Refer to Fuel Tank for servi ce procedures
REAR TOW HOOK
REMOVAL
(1) Remove rear tow hook to frame brace.
(2) Remove bol ts attachi ng the tow hook bracket to
frame (Fi g. 12).
(3) Separate tow hook bracket from frame.
INSTALLATION
(1) posi ti on tow hook bracket on frame.
(2) I nstal l bol ts attachi ng tow hook bracket to
frame. Ti ghten bol ts to 68 Nm (50 ft. l bs.) torque.
(3) I nstal l rear tow hook to frame brace.
Fig. 10 Front Skid Plate
1 - SKID PLATE
Fig. 11 Front Tow Hook
1 - TAPPING PLATE
2 - CROSSMEMBER
3 - BRACKET
4 - TOW HOOK
Fig. 12 Rear Tow Hook
1 - TOW HOOK BRACE
2 - TOW HOOK
3 - BRACKET
4 - FUEL TANK
TRAILER HITCH
REMOVAL
(1) Remove rear fasci a, refer to (Refer to 13 -
REMOVAL).
(2) Remove screws attachi ng trai l er harness pl ug
to trai l er hi tch.
(3) Di sconnect harness connector from harness
pl ug.
(4) Posi ti on support stands under trai l er hi tch.
(5) Remove bol ts attachi ng trai l er hi tch to frame
rai l s (Fi g. 13).
(6) Separate trai l er hi tch from vehi cl e.
INSTALLATION
(1) Posi ti on trai l er hi tch on support stands.
(2) Posi ti on trai l er hi tch on vehi cl e.
(3) I nstal l bol ts attachi ng trai l er hi tch to frame
rai l s. Ti ghten bol ts to 68 Nm (50 l bs.) torque.
(4) Connect harness connector to harness pl ug.
(5) Posi ti on harness pl ug i n trai l er hi tch and
i nstal l screws.
(6) I nstal l rear fasci a, refer to (Refer to 13 -
I NSTALLATI ON).
TRANSFER CASE SKID PLATE
REMOVAL
(1) Support ski d pl ate.
(2) Remove bol ts that attach ski d pl ate to trans-
mi ssi on support crossmember and frame si l l (Fi g.
14).
(3) Remove support and ski d pl ate from vehi cl e.
INSTALLATION
(1) I nstal l nutserts, i f removed.
(2) Posi ti on and support ski d pl ate at the frame
si l l and transmi ssi on support crossmember.
(3) Attach ski d pl ate to frame si l l and crossmem-
ber wi th the bol ts. Ti ghten bol ts to 34 Nm (25 ft. l bs)
torque.
Fig. 13 Trailer Hitch
1 - FUEL TANK
2 - TRAILER HITCH
Fig. 14 Transfer Case Skid Plate
1 - TRANSFER CASE
2 - NUTSERT
3 - SKID PLATE
4 - CROSSMEMBER
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 31
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL PRESSURE LEAK DOWN TEST . . . . . . 2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . 4
TORQUE - FUEL DELIVERY . . . . . . . . . . . . . . 4
SPECIAL TOOLS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST . . . . . . . . . . . . . . . . . . . . . . . 9
AMPERAGE TEST . . . . . . . . . . . . . . . . . . . . . . 9
FUEL PUMP PRESSURE TEST . . . . . . . . . . . 11
FUEL PUMP MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL RAIL
DESCRIPTION
DESCRIPTION - 4.7L . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . . 15
OPERATION
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . 15
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . 15
REMOVAL
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 18
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 18
FUEL TANK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
INLET FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
QUICK CONNECT FITTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
WJ FUEL SYSTEM 14 - 1
FUEL DELIVERY
DESCRIPTION
The fuel del i very system consi sts of:
the fuel pump modul e contai ni ng the el ectri c
fuel pump, fuel gauge sendi ng uni t (fuel l evel sensor)
and a separate fuel fi l ter l ocated at bottom of pump
modul e
a separate combi nati on fuel fi l ter/fuel pressure
regul ator
fuel tubes/l i nes/hoses
qui ck-connect fi tti ngs
fuel i njector rai l
fuel i njectors
fuel tank
fuel tank fi l l er/vent tube assembl y
fuel tank fi l l er tube cap
accel erator pedal
throttl e cabl e
OPERATION
The fuel tank assembl y consi sts of: the fuel tank,
fuel tank shi el d, fuel tank straps, fuel pump modul e
assembl y, fuel pump modul e l ocknut/gasket, and fuel
tank check val ve (refer to Emi ssi on Control System
for fuel tank check val ve i nformati on).
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum, 1/4 turn fuel fi l l er cap i s used. The fuel
fi l l er tube contai ns a fl ap door l ocated bel ow the fuel
fi l l cap.
Al so to be consi dered part of the fuel system i s the
evaporati on control system. Thi s i s desi gned to
reduce the emi ssi on of fuel vapors i nto the atmo-
sphere. The descri pti on and functi on of the Evapora-
ti ve Control System i s found i n Emi ssi on Control
Systems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
FUEL PRESSURE LEAK DOWN TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Pressure Test and Fuel Pump Capaci ty Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Abnormal l y l ong peri ods of cranki ng to restart a
hot engi ne that has been shut down for a short
peri od of ti me may be caused by:
Fuel pressure bl eedi ng past a fuel i njector(s).
Fuel pressure bl eedi ng past the check val ve i n
the fuel pump modul e.
A defecti ve fuel fi l ter/pressure regul ator.
Two #6539, 5/16, Fuel Li ne Pressure Test Adapter
Hose Tool s are requi red for the fol l owi ng tests.
(1) Rel ease fuel system pressure. Refer to Fuel
Pressure Rel ease Procedure.
Fuel Line Identification: The fuel fi l ter/pressure
regul ator i s l ocated i n front of the fuel tank and
above the rear axl e. I t i s transversel y mounted to a
chassi s crossmember (l eft-to-ri ght). The fi l ter/regul a-
tor i s equi pped wi th 3 fuel l i ne fi tti ngs (2 at one end
and 1 at the other end). The si ngl e fi tti ng faci ng the
l eft si de of the vehi cl e i s the suppl y l i ne to the fuel
rai l (Fi g. 1) . The 2 fi tti ngs faci ng the ri ght si de of
the vehi cl e are connected to the fuel tank. Of these 2
fi tti ngs, the fi tti ng towards the front i s used for fuel
return to the fuel tank. The fi tti ng towards the rear
i s a pressure l i ne. Thi s rear fi tti ng must be di scon-
nected for the fol l owi ng step.
(3) See previ ous step. Di sconnect fuel pressure l i ne
at rear of fi l ter/regul ator. Thi s i s a 5/16 qui ck-con-
nect fi tti ng (Fi g. 1) . Refer to Qui ck-Connect Fi tti ngs
for procedures.
(4) Obtai n correct Fuel Li ne Pressure Test Adapter
Hose Tool # 6539 for 5/16 fuel l i nes. Connect one
end of thi s Speci al Tool i nto the di sconnected fuel
pressure l i ne. Connect the other end of the Tool i nto
fi tti ng on fi l ter/regul ator.
(6) Di sconnect the fuel i nl et l i ne at fuel rai l . Refer
to Qui ck-Connect Fi tti ngs for procedures. On some
engi nes, ai r cl eaner housi ng removal may be neces-
sary before fuel l i ne di sconnecti on.
(7) Obtai n a second Fuel Li ne Pressure Test
Adapter Hose Tool #6539 for 5/16 fuel l i nes. Con-
nect thi s tool between di sconnected fuel l i ne and fuel
rai l (Fi g. 2) .
(8) Connect the 0-414 kPa (0-60 psi ) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropri ate Adaptor Tool . NOTE: The DRB III
Scan Tool along with the PEP module, the 500
psi pressure transducer, and the transducer-to-
test port adapter may also be used in place of
the fuel pressure gauge.
14 - 2 FUEL DELIVERY WJ
CAUTION: The fittings on both tools must be in
good condition and free from any small leaks
before performing the proceeding test.
(9) Start engi ne and bri ng to normal operati ng
temperature.
(10) Observe fuel pressure test gauge (or DRB
screen). Normal operati ng pressure shoul d be 339
kPa 34 kPa (49.2 psi 5 psi ).
(11) Shut engi ne off.
(12) Pressure shoul d not fal l bel ow 30 psi for five
minutes.
(13) I f pressure fal l s bel ow 30 psi , i t must be
determi ned i f a fuel i njector, the suppl y check val ve
wi thi n the fuel pump modul e, the fuel fi l ter/pressure
regul ator, or a fuel tube/l i ne i s l eaki ng.
(14) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(16) Testing for fuel injector or fuel rail leak-
age: Cl amp off the rubber hose porti on of the 6539
Adaptor Tool between the fuel rai l and the test port
T on Adapter Tool (be sure cl ampi ng pressure i s
suffi ci ent). I f pressure now hol ds at or above 30 psi , a
fuel i njector or the fuel rai l i s l eaki ng.
(17) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(20) Testing for fuel filter/pressure regulator
leakage: Whi l e conti nui ng to securel y cl amp
between the fuel rai l and the test port T on Adaptor
Tool 6539, securel y cl amp off any rubber hose por-
ti on of the Adaptor Tool 6539 that was i nstal l ed
between the fuel pressure l i ne and the fi l ter/regul a-
tor fi tti ng (by restri cti ng the pump modul e suppl y
l i nes backfl ow, you i sol ate any l eakdown ori gi nati ng
from the fi l ter/regul ator vi a the tank return l i ne.) I f
the pressure fal l s bel ow 30 psi wi thi n 5 mi nutes, the
fi l ter/regul ator i s l eaki ng. I f i t now hol ds at or above
30 psi , the el ectri c fuel pump check val ve i s l eaki ng
or a fuel tube/l i ne i s l eaki ng. A fuel odor presence
woul d i ndi cate the l atter.
The el ectri c fuel pump i s not servi ced separatel y. I f
repl acement i s necessary, repl ace the fuel pump mod-
ul e assembl y. The fi l ter/regul ator may be repl aced
separatel y. Refer to Fuel Fi l ter/Fuel Pressure Regu-
l ator Removal /I nstal l ati on for addi ti onal i nformati on.
Fig. 1 Disconnect Fuel Pressure Line at Filter/
Regulator
1 - FUEL SUPPLY LINE (TO FUEL RAIL)
2 - EVAP LINE
3 - FUEL RETURN LINE (MALE)
4 - FUEL PRESSURE LINE (FEMALE)
5 - FUEL FILTER/PRESSURE REGULATOR
6 - FUEL TANK
Fig. 2 Connecting Adapter ToolTypical
1 - VEHICLE FUEL LINE
2 - TEST PORT T
3 - SPECIAL TOOL 6923, 6631, 6541 OR 6539
4 - FUEL PRESSURE TEST GAUGE
5 - FUEL LINE CONNECTION AT RAIL
6 - FUEL RAIL
WJ FUEL DELIVERY 14 - 3
FUEL DELIVERY (Continued)
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fi l l cap.
(2) Remove fuel pump rel ay from Power Di stri bu-
ti on Center (PDC). For l ocati on of rel ay, refer to l abel
on undersi de of PDC cover.
(3) Start and run engi ne unti l i t stal l s.
(4) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(5) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unpl ug connector from any fuel i njector.
(7) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(8) Connect other end of jumper wi re to posi ti ve
si de of battery.
(9) Connect one end of a second jumper wi re to
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentari l y touch other end of jumper wi re
to negati ve termi nal of battery for no more than a
few seconds.
(11) Pl ace a rag or towel bel ow fuel l i ne qui ck-con-
nect fi tti ng at fuel rai l .
(12) Di sconnect qui ck-connect fi tti ng at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs.
(13) Return fuel pump rel ay to PDC.
(14) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n PCM memory due to fuel
pump rel ay removal . The DRB scan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa 34 kPa (49. 2 psi 5 psi).
TORQUE - FUEL DELIVERY
Accelerator Pedal Bracket Mounting Nuts
(without adjustable pedals)
12 2 - 105 20
Fuel Filter/Fuel Press. Reg. Bolts 3 - 26
Fuel Hose Clamps 3 - 26
Fuel Injector Rail Mounting Bolts -4.0L Engine 11 - 100
Fuel Injector Rail Mounting Bolts -4.7L V-8
Engine
11 - 100
Fuel Pump Module Locknut 74 55 -
Fuel Tank Filler Tube-to-Body Mounting Bolts 2 - 15
Fuel Tank-to-Body Mounting Bolts 88 65 -
Fuel Tank Support Bracket Bolts (large brackets) 88 65 -
Fuel Tank Support Bracket Bolts (small bracket) 5 - 45
Fuel Tank Support Bracket Nuts (large brackets) 61 45 -
Fuel Tank Heat Shield Nuts (shield-to-tank) 9 - 85
Fuel Tank Heat Shield Nuts (shield-to-body) 3 - 25
SPECIAL TOOLS
FUEL SYSTEM
FUEL FILTER/PRESSURE
REGULATOR
DESCRIPTION
The combi nati on fuel fi l ter/pressure regul ator i s
l ocated i n front of the fuel tank and above the rear
axl e (Fi g. 3). I t i s transversel y mounted to a chassi s
crossmember (l eft-to-ri ght). Fuel Line Identifica-
tion: The fi l ter/regul ator i s equi pped wi th 3 fuel l i ne
fi tti ngs (2 at one end and 1 at the other end). The
si ngl e fi tti ng faci ng the l eft si de of the vehi cl e i s the
suppl y l i ne to the fuel rai l (Fi g. 3). The 2 fi tti ngs fac-
i ng the ri ght si de of the vehi cl e are connected to the
fuel tank. Of these 2 fi tti ngs, the fi tti ng towards the
front i s used for fuel return to the fuel tank. The fi t-
ti ng towards the rear i s a pressure l i ne.
OPERATION
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the Powertrai n Control
Modul e (PCM).
Spanner Wrench6856
FITTING, AIR METERING - 6714
Adapters, Fuel Pressure Test6539 and/or 6631
O2S (Oxygen Sensor) Remover/InstallerC-4907
Test Kit, Fuel Pressure5069
Test Kit, Fuel PressureC-4799-B
Fuel Line Removal Tool6782
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 kPa 34
kPa (49.2 psi 5 psi ) at the fuel i njectors. I t contai ns
a di aphragm, cal i brated spri ngs and a fuel return
val ve. The i nternal fuel fi l ter i s al so part of the
assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump. The regul ator acts as a check val ve to
mai ntai n some fuel pressure when the engi ne i s not
operati ng. Thi s wi l l hel p to start the engi ne. A second
check val ve i s l ocated at the outl et end of the el ectri c
fuel pump.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 49 psi , an i nternal di aphragm cl oses.
Excess fuel i s then routed i nto a separate fuel return
l i ne and returned to the fuel tank through the top of
the fuel pump modul e.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
REMOVAL
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s remotel y mounted to the vehi cl e body, above
the rear axl e and near the front of the fuel tank (Fi g.
4) or (Fi g. 5).
(1) Perform Fuel System Pressure Rel ease Proce-
dure.
(4) Cl ean area around 3 fi l ter/regul ator fi tti ngs.
(5) Di sconnect fuel suppl y, fuel return and fuel
pressure l i nes at fi l ter/regul ator (Fi g. 4) . Refer to
Qui ck-Connect Fi tti ngs.
(6) Remove 2 mounti ng bol ts (Fi g. 5) and remove
fi l ter/regul ator.
INSTALLATION
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s remotel y mounted to the vehi cl e body, above
the rear axl e and near the front of the fuel tank (Fi g.
4) or (Fi g. 5).
(1) Before i nstal l i ng fi l ter/regul ator, be sure al l fi t-
ti ngs are cl eaned of al l di rt and contami nants.
(2) Be sure o-ri ng i s posi ti oned i nto fuel return fi t-
ti ng i n fi l ter/regul ator.
Fig. 3 Fuel Filter/Fuel Pressure Regulator Location
2 - EVAP LINE
6 - FUEL TANK
2 - EVAP LINE
6 - FUEL TANK
FUEL FILTER/PRESSURE REGULATOR (Continued)
(3) Appl y a smal l amount of cl ean engi ne oi l to
o-ri ngs.
(4) Posi ti on fi l ter/regul ator to body and i nstal l 2
(5) Connect 3 fi tti ngs. Refer to Qui ck-Connect Fi t-
ti ngs.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor track (card).
OPERATION
The fuel pump modul e has 4 di fferent ci rcui ts
(wi res). Two of these ci rcui ts are used for the fuel
gauge sendi ng uni t for fuel gauge operati on, and for
certai n OBD I I emi ssi on requi rements. The other 2
wi res are used for el ectri c fuel pump operati on.
For Fuel Gauge Operation: A constant i nput
vol tage source of about 12 vol ts (battery vol tage) i s
suppl i ed to the resi stor track on the fuel gauge send-
i ng uni t. Thi s i s fed di rectl y from the Powertrai n
Control Modul e (PCM). NOTE: For diagnostic pur-
poses, this 12V power source can only be veri-
fied with the circuit opened (fuel pump module
electrical connector unplugged). With the con-
nectors plugged, output voltages will vary from
about 0.6 volts at FULL, to about 8.6 volts at
EMPTY (about 8.6 volts at EMPTY for J eep
models, and about 7.0 volts at EMPTY for
Dodge Truck models). The resi stor track i s used to
vary the vol tage (resi stance) dependi ng on fuel tank
fl oat l evel . As fuel l evel i ncreases, the fl oat and arm
move up, whi ch decreases vol tage. As fuel l evel
decreases, the fl oat and arm move down, whi ch
i ncreases vol tage. The vari ed vol tage si gnal i s
returned back to the PCM through the sensor return
ci rcui t.
Both of the el ectri cal ci rcui ts between the fuel
gauge sendi ng uni t and the PCM are hard-wi red (not
mul ti -pl exed). After the vol tage si gnal i s sent from
the resi stor track, and back to the PCM, the PCM
wi l l i nterpret the resi stance (vol tage) data and send
a message across the mul ti -pl ex bus ci rcui ts to the
i nstrument panel cl uster. Here i t i s transl ated i nto
the appropri ate fuel gauge l evel readi ng. Refer to
I nstrument Panel for addi ti onal i nformati on.
For OBD II Emission Monitor Requirements:
The PCM wi l l moni tor the vol tage output sent from
the resi stor track on the sendi ng uni t to i ndi cate fuel
l evel . The purpose of thi s feature i s to prevent the
OBD I I system from recordi ng/setti ng fal se mi sfi re
and fuel system moni tor di agnosti c troubl e codes.
The feature i s acti vated i f the fuel l evel i n the tank
i s l ess than approxi matel y 15 percent of i ts rated
capaci ty. I f equi pped wi th a Leak Detecti on Pump
(EVAP system moni tor), thi s feature wi l l al so be acti -
vated i f the fuel l evel i n the tank i s more than
approxi matel y 85 percent of i ts rated capaci ty.
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT
The fuel l evel sendi ng uni t contai ns a vari abl e
resi stor (track). As the fl oat moves up or down, el ec-
tri cal resi stance wi l l change. Refer to I nstrument
Panel and Gauges for Fuel Gauge testi ng. To test the
gauge sendi ng uni t onl y, i t must be removed from
vehi cl e. The uni t i s part of the fuel pump modul e.
Refer to Fuel Pump Modul e Removal /I nstal l ati on for
procedures. Measure the resi stance across the send-
i ng uni t termi nal s. Wi th fl oat i n up posi ti on, resi s-
tance shoul d be 20 ohms (+/- 5%). Wi th fl oat i n down
posi ti on, resi stance shoul d be 270 ohms (+/- 5%).
REMOVAL
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 6). The fuel pump modul e i s l ocated
wi thi n the fuel tank.
Fig. 5 Fuel Filter/Fuel Pressure Regulator Removal/
Installation
1 - FUEL FILTER/FUEL PRESSURE REGULATOR
FUEL FILTER/PRESSURE REGULATOR (Continued)
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press upward on rel ease tab (Fi g. 7) to remove
sendi ng uni t from pump modul e.
INSTALLATION
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 6). The fuel pump modul e i s l ocated
wi thi n the fuel tank.
(1) Posi ti on sendi ng uni t to pump modul e and
snap i nto pl ace.
(2) Connect el ectri cal connector to termi nal s.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
(4) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL LINES
DESCRIPTION
Al so refer to Qui ck-Connect Fi tti ngs.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
FUEL PUMP
DESCRIPTION
The el ectri c fuel pump i s l ocated i nsi de of the fuel
pump modul e. A 12 vol t, permanent magnet, el ectri c
motor powers the fuel pump. The el ectri c fuel pump
i s not a separate, servi ceabl e component.
Fig. 6 Fuel Gauge Sending Unit Location
1 - FUEL PUMP MODULE
2 - FUEL GAUGE FLOAT
3 - ELECTRIC FUEL PUMP
4 - INLET FILTER
5 - FUEL GAUGE SENDING UNIT
6 - PIGTAIL HARNESS
Fig. 7 Fuel Gauge Sending Unit Release Tab
3 - RELEASE TAB
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
OPERATION
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
Fuel i s drawn i n through a fi l ter at the bottom of
the modul e and pushed through the el ectri c motor
gearset to the pump outl et.
Check Valve Operation: The pump outl et con-
tai ns a one-way check val ve to prevent fuel fl ow back
i nto the tank and to mai ntai n fuel suppl y l i ne pres-
sure (engi ne warm) when pump i s not operati onal . I t
i s al so used to keep the fuel suppl y l i ne ful l of gaso-
l i ne when pump i s not operati onal . After the vehi cl e
has cool ed down, fuel pressure may drop to 0 psi
(col d fl ui d contracts), but l i qui d gasol i ne wi l l remai n
i n fuel suppl y l i ne between the check val ve and fuel
i njectors. Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition. Refer to the Fuel Pressure Leak
Down Test for more i nformati on.
The el ectri c fuel pump i s not a separate, servi ce-
abl e component.
CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
Pressure Rel ease Procedure.
(2) Di sconnect fuel suppl y l i ne at fuel rai l . Refer to
Qui ck-Connect Fi tti ngs. Some engi nes may requi re
ai r cl eaner housi ng removal before l i ne di sconnecti on.
(3) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(4) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose i nto di sconnected fuel suppl y l i ne.
I nsert other end of Adaptor Tool Hose i nto a gradu-
ated contai ner.
(5) Remove fuel fi l l cap.
(6) To acti vate fuel pump and pressuri ze system,
obtai n DRB scan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump wi l l del i ver at l east 1/4 l i ter
of fuel i n 7 seconds. Do not operate fuel pump for
l onger than 7 seconds wi th fuel l i ne di sconnected as
fuel pump modul e reservoi r may run empty.
(a) I f capaci ty i s l ower than speci fi cati on, but
fuel pump can be heard operati ng through fuel fi l l
cap openi ng, check for a ki nked/damaged fuel sup-
pl y l i ne somewhere between fuel rai l and fuel
pump modul e.
(b) I f l i ne i s not ki nked/damaged, and fuel pres-
sure i s OK, but capaci ty i s l ow, repl ace fuel fi l ter/
fuel pressure regul ator. The fi l ter/regul ator may be
servi ced separatel y on certai n appl i cati ons. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for addi ti onal i nformati on.
(c) I f both fuel pressure and capaci ty are l ow,
repl ace fuel pump modul e assembl y. Refer to Fuel
Pump Modul e Removal /I nstal l ati on.
AMPERAGE TEST
Thi s amperage (current draw) test i s to be done i n
conjuncti on wi th the Fuel Pump Pressure Test, Fuel
Pump Capaci ty Test and Fuel Pressure Leak Down
Test. Before performi ng the amperage test, be sure
the temperature of the fuel tank i s above 50 F (10
C).
The DRB Scan Tool al ong wi th the DRB Low Cur-
rent Shunt (LCS) adapter (Fi g. 8) and i ts test l eads
wi l l be used to check fuel pump amperage speci fi ca-
ti ons.
(1) Be sure fuel tank contai ns fuel before starti ng
test. I f tank i s empty or near empty, amperage read-
i ngs wi l l be i ncorrect.
(2) Obtai n LCS adapter.
(3) Pl ug cabl e from LCS adapter i nto DRB scan
tool at SET 1 receptacl e.
(4) Pl ug DRB i nto vehi cl e 16way connector (data
l i nk connector).
Fig. 8 LOW CURRENT SHUNT
1 - LOW CURRENT SHUNT ADAPTER
2 - PLUG TO DRB
3 - TEST LEAD RECEPTACLES
FUEL PUMP (Continued)
(5) Connect (-) and (+) test cabl e l eads i nto LCS
adapter receptacl es. Use 10 amp (10A +) receptacl e
and common (-) receptacl es.
(6) Gai n access to MAI N MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Usi ng l eft/ri ght arrow keys, hi ghl i ght CHAN-
NEL 1 functi on on DRB screen.
(9) Press ENTER three ti mes.
(10) Usi ng up/down arrow keys, hi ghl i ght RANGE
on DRB screen (screen wi l l defaul t to 2 amp scal e).
(11) Press ENTER to change 2 amp scal e to 10
amp scal e. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Di stri buti on Center
(PDC).
(13) Remove fuel pump rel ay from PDC. Refer to
l abel on PDC cover for rel ay l ocati on.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Dependi ng upon vehi cl e model , year or engi ne con-
fi gurati on, three di fferent types of rel ays may be
used: Type-1, type-2 and type3.
(14) I f equi pped wi th type1 relay (Fi g. 9), attach
test l eads from LCS adapter i nto PDC rel ay cavi ti es
number 30 and 87. For l ocati on of these cavi ti es,
refer to numbers stamped to bottom of rel ay (Fi g. 9).
(15) I f equi pped wi th type2 relay (Fi g. 10),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 10).
(16) I f equi pped wi th type3 relay (Fi g. 11),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 3 and 5. For l ocati on of these cavi -
ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 11).
(17) When LCS adapter test l eads are attached
i nto rel ay cavi ti es, fuel pump will be activated.
Determi ne fuel pump amperage on DRB screen.
Amperage shoul d be bel ow 10.0 amps. I f amperage i s
bel ow 10.0 amps, and speci fi cati ons for the Fuel
Pump Pressure, Fuel Pump Capaci ty and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ul e i s OK.
(18) I f amperage i s more than 10.0 amps, repl ace
fuel pump modul e assembl y. The el ectri c fuel pump
i s not servi ced separatel y.
Fig. 9 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
(19) Di sconnect test l eads from rel ay cavi ti es
i mmedi atel y after testi ng.
FUEL PUMP PRESSURE TEST
Use thi s test i n conjuncti on wi th other fuel system
tests. Refer to the Fuel Pump Capaci ty Test, Fuel
Pressure Leak Down Test and Fuel Pump Amperage
Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
The fuel system i s equi pped wi th a combi nati on
fuel fi l ter/fuel pressure regul ator. The fuel pressure
regul ator i s not control l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove pressure test port cap at fuel rai l test
port (Fi g. 12) or (Fi g. 13) . Connect 0414 kPa (0-60
psi ) fuel pressure gauge (from gauge set 5069) to test
port pressure fi tti ng on fuel rai l (Fi g. 14) . The DRB
III Scan Tool along with the PEP module, the
500 psi pressure transducer, and the transduc-
er-to-test port adapter may also be used in
place of the fuel pressure gauge.
(2) Start and warm engi ne and note pressure
gauge readi ng. The DRB scan tool may al so be used
to power fuel pump. Fuel pressure shoul d be 339 kPa
34 kPa (49.2 psi 5 psi ) at i dl e.
(3) I f engi ne runs, but pressure i s bel ow 44.2 psi ,
determi ne i f fuel pump or fi l ter/regul ator i s defecti ve.
Proceed to next step:
(a) Check for a ki nked fuel suppl y l i ne some-
where between fuel rai l and fuel pump modul e.
TERMINAL LEGEND
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
Fig. 12 Test Port Cap Location4.0L Engine
1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
7 - FUEL INJECTOR RAIL
8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
11 - QUICK-CONNECT FITTING
(b) I f l i ne i s not ki nked and pressure i s l ow,
rai se vehi cl e and di sconnect fuel pressure l i ne at
fuel fi l ter/fuel pressure regul ator (Fi g. 15) . Three
fuel l i nes are attached to fi l ter/regul ator. The fuel
pressure line i s attached to the ri ght si de of fi l -
ter/regul ator. I t i s al so the most rearward of the
two (Fi g. 15) .
(c) I nstal l Speci al 5/16 Fuel Li ne Adapter Tool #
6539 between di sconnected fuel l i ne and fi l ter/reg-
ul ator fi tti ng
(d) Attach 060 psi fuel pressure test gauge to
T fi tti ng on tool 6539.
Fig. 13 Test Port Cap Location4.7L V-8 Engine
2 - INJ.#7
3 - INJ.#5
5 - INJ.#3
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
Fig. 14 Fuel Pressure Test Gauge (Typical Gauge
Installation at Test Port)
1 - SERVICE (TEST) PORT
2 - FUEL PRESSURE TEST GAUGE
3 - FUEL RAIL
2 - EVAP LINE
6 - FUEL TANK
(e) Use DRB scan tool to power fuel pump. I f
pressure i s now wi thi n speci fi cati ons, repl ace fuel
fi l ter/fuel pressure regul ator.
(f) I f pressure i s sti l l l ow, repl ace fuel pump
modul e.
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator.
(5) I nstal l test port cap to fuel rai l test port.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 16). The fuel pump modul e (Fi g. 17)
contai ns the fol l owi ng components:
A separate fuel pi ck-up fi l ter (strai ner)
An el ectri c fuel pump
A threaded l ocknut to retai n modul e to tank
A gasket between tank fl ange and modul e
Fuel gauge sendi ng uni t (fuel l evel sensor)
Fuel suppl y tube (l i ne) connecti on
Fuel return tube (l i ne) connecti on
The fuel gauge sendi ng uni t and pi ck-up fi l ter may
be servi ced separatel y. I f the el ectri cal fuel pump
requi res servi ce, the enti re fuel pump modul e must
be repl aced.
OPERATION
Refer to Fuel Pump, Fuel Fi l ter/Fuel Pressure Reg-
ul ator and Fuel Gauge Sendi ng Uni t.
REMOVAL
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING FUEL PUMP MODULE, FUEL
SYSTEM PRESSURE MUST BE RELEASED.
dure.
Fig. 16 FUEL TANK AND COMPONENTS
1 - FUEL PUMP MODULE 9 - TANK SUPPORT BRACKET (SMALL/FRONT)
2 - MODULE LOCK RING 10 - MODULE PIGTAIL HARNESS
3 - TANK SUPPORT BRACKETS (REAR) 11 - FUEL SUPPLY (PRESSURE) LINE
4 - CHECK VALVE 12 - FUEL RETURN LINE
5 - FUEL FILL HOSE 13 - SKID PLATE
6 - ORVR COMPONENTS 14 - TANK STRAPS (2)
7 - ORVR CONTROL VALVE 15 - FUEL TANK
8 - CONTROL VALVE LOCK RING
(2) Drai n fuel tank and remove tank. Refer to Fuel
Tank Removal /I nstal l ati on.
(3) Thoroughl y wash and cl ean area around pump
modul e to prevent contami nants from enteri ng tank.
(4) Di sconnect fuel return and pressure l i nes from
fuel pump modul e fi tti ngs (Fi g. 16). Refer to Qui ck-
Connect Fi tti ngs for procedures.
(5) The pl asti c fuel pump modul e l ocknut i s
threaded onto fuel tank (Fi g. 16). I nstal l Speci al Tool
6856 to fuel pump modul e l ocknut and remove l ock-
nut (Fi g. 18). The fuel pump modul e wi l l spri ng up
sl i ghtl y after l ocknut i s removed.
(6) Remove modul e from fuel tank.
INSTALLATION
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
CAUTION: Whenever fuel pump module is serviced,
module gasket must be replaced.
(1) Thoroughl y cl ean l ocknut threads and mati ng
fuel tank threads. Use a soap/water sol uti on. Do not
use carburetor cl eaner to cl ean threads.
(2) Usi ng new gasket, posi ti on fuel pump modul e
i nto openi ng i n fuel tank.
(3) Appl y cl ean water to l ocknut threads.
(4) Posi ti on l ocknut over top of fuel pump modul e.
(5) Rotate modul e unti l i ndexi ng arrow at top of
modul e (Fi g. 19)i s poi nted toward rear of vehi cl e.
Al i gn arrow to ti ck mark on top of fuel tank. This
step must be done to prevent float/float rod
assembly from contacting sides of fuel tank.
(6) I nstal l Speci al Tool 6856 to l ocknut.
(7) Ti ghten l ocknut to 74 Nm (55 ft. l bs.) torque.
Fig. 17 FUEL PUMP MODULE
2 - FUEL GAUGE FLOAT
3 - ELECTRIC FUEL PUMP
4 - INLET FILTER
6 - PIGTAIL HARNESS
Fig. 18 LOCKNUT REMOVAL/INSTALLATION -
TYPICAL
2 - LOCKNUT
Fig. 19 FUEL PUMP MODULE INDEXING ARROW
2 - INDEXING ARROW
3 - FUEL SUPPLY (PRESSURE) FITTING
4 - FUEL RETURN FITTING
FUEL PUMP MODULE (Continued)
(8) Connect fuel return and pressure l i nes to fuel
pump modul e fi tti ngs (Fi g. 16). Refer to Qui ck-Con-
nect Fi tti ngs.
(9) I nstal l fuel tank. Refer to Fuel Tank I nstal l a-
ti on.
FUEL RAIL
DESCRIPTION
DESCRIPTION - 4. 7L
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne. I t i s mounted to the i ntake
DESCRIPTION - 4. 0L
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne (Fi g. 21). On the 4.0L 6cyl i n-
der engi ne, a fuel damper i s l ocated near the center
of the fuel rai l (Fi g. 21).
OPERATION
OPERATION - 4. 7L
Hi gh pressure fuel from the fuel pump i s routed to
the fuel rai l . The fuel rai l then suppl i es the neces-
sary fuel to each i ndi vi dual fuel i njector.
A fuel pressure test port i s l ocated on the fuel rai l
(Fi g. 20). A qui ck-connect fi tti ng wi th a safety l atch
i s used to attach the fuel l i ne to the fuel rai l .
The fuel rai l i s not repai rabl e.
OPERATION - 4. 0L
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
Hi gh pressure fuel from the fuel pump i s routed to
the fuel rai l . The fuel rai l then suppl i es the neces-
sary fuel to each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated near the front of the fuel tank above the rear
axl e. Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n
thi s group for i nformati on.
A fuel pressure test port i s l ocated on the fuel rai l
(Fi g. 21). A qui ck-connect fi tti ng wi th a safety l atch
i s used to attach the fuel l i ne to the fuel rai l .
The fuel rai l i s not repai rabl e.
REMOVAL
REMOVAL - 4. 7L
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
Fig. 20 Fuel Injector Rail4.7L V-8 Engine
2 - INJ.#7
3 - INJ.#5
5 - INJ.#3
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
FUEL PUMP MODULE (Continued)
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tube (Fig. 22). Due to design of
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care-
ful not to bend or kink tube.
(1) Remove fuel tank fi l l er tube cap.
dure.
(3) Remove negati ve battery cabl e at battery.
(4) Remove ai r duct at throttl e body ai r box.
(5) Remove ai r box at throttl e body.
(6) Remove wi ri ng at rear of generator.
(7) Di sconnect fuel l i ne l atch cl i p and fuel l i ne at
fuel rai l . A speci al tool wi l l be necessary for fuel l i ne
di sconnecti on. Refer to Qui ck-Connect Fi tti ngs.
(8) Remove vacuum l i nes at throttl e body.
(9) Di sconnect el ectri cal connectors at al l 8 fuel
i njectors. To remove connector refer to (Fi g. 23). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(10) Di sconnect el ectri cal connectors at throttl e
body.
(11) Di sconnect el ectri cal connectors at MAP and
I AT sensors.
Fig. 21 Fuel Injector Rail/Fuel Damper4.0L Engine
1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
8 - FUEL DAMPER
Fig. 22 FUEL INJECTOR RAIL - 4.7L V-8 EN
2 - INJ.#7
3 - INJ.#5
5 - INJ.#3
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
FUEL RAIL (Continued)
(12) Remove fi rst three i gni ti on coi l s on each bank
(cyl i nders #1, 3, 5, 2, 4 and 6). Refer to I gni ti on Coi l
(13) Remove 4 fuel rai l mounti ng bol ts (Fi g. 22).
(14) Gentl y rock and pul l left si de of fuel rai l unti l
fuel i njectors just start to cl ear machi ned hol es i n
cyl i nder head. Gentl y rock and pul l right si de of rai l
unti l i njectors just start to cl ear cyl i nder head hol es.
Repeat thi s procedure (l eft/ri ght) unti l al l i njectors
have cl eared cyl i nder head hol es.
(15) Remove fuel rai l (wi th i njectors attached)
from engi ne.
(16) I f fuel i njectors are to be removed, refer to
Fuel I njector Removal /I nstal l ati on.
REMOVAL - 4. 0L
The fuel damper i s not servi ced separatel y.
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
dure.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Di sconnect el ectri cal connectors at al l 6 fuel
i njectors. To remove connector refer to (Fi g. 25). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(6) Remove oxygen sensor wi ri ng cl i p nuts at fuel
rai l mounti ng studs (certai n emi ssi ons packages
onl y).
(7) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(8) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on.
Fig. 23 Remove/Install Injector Connector4.7L V-8
Engine
Fig. 24 Fuel Rail Mounting4.0L Engine
1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
8 - FUEL DAMPER
(9) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e.
(10) Di sconnect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(11) Remove cabl e routi ng bracket at i ntake mani -
fol d.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
24).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
fuel i njectors have cl eared machi ned hol es at i ntake
mani fol d.
(15) I f fuel i njectors are to be removed, refer to
Fuel I njector Removal /I nstal l ati on.
INSTALLATION
(1) I f fuel i njectors are to be i nstal l ed, refer to Fuel
I njector Removal /I nstal l ati on.
(2) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(3) Posi ti on fuel rai l /fuel i njector assembl y to
machi ned i njector openi ngs i n cyl i nder head.
(4) Gui de each i njector i nto cyl i nder head. Be care-
ful not to tear i njector o-ri ngs.
(5) Push right si de of fuel rai l down unti l fuel
i njectors have bottomed on cyl i nder head shoul der.
Push left fuel rai l down unti l i njectors have bot-
tomed on cyl i nder head shoul der.
(6) I nstal l 4 fuel rai l mounti ng bol ts and ti ghten to
27 Nm (20 ft. l bs.).
(7) I nstal l i gni ti on coi l s. Refer to I gni ti on Coi l
(8) Connect el ectri cal connectors to throttl e body.
(9) Connect el ectri cal connectors to MAP and I AT
sensors.
(10) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 23). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(11) Connect vacuum l i nes to throttl e body.
(12) Connect fuel l i ne l atch cl i p and fuel l i ne to
fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(13) Connect wi ri ng to rear of generator.
(14) I nstal l ai r box to throttl e body.
(15) I nstal l ai r duct to ai r box.
(16) Connect battery cabl e to battery.
(1) I f fuel i njectors are to be i nstal l ed, refer to Fuel
I njector Removal /I nstal l ati on.
(2) Cl ean each i njector bore at i ntake mani fol d.
(3) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(4) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(5) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 3 Nm (100 25 i n. l bs.) torque.
(6) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 25). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs.
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(13) I nstal l oxygen sensor wi ri ng cl i p nuts to fuel
rai l mounti ng studs (certai n emi ssi ons packages
onl y).
Fig. 25 Remove/Install Injector Connector4.0L
Engine
(14) I nstal l ai r tube (or duct) at top of throttl e
body.
(15) I nstal l fuel tank cap.
(17) Start engi ne and check for fuel l eaks.
FUEL TANK
DESCRIPTION
The fuel tank i s constructed of a pl asti c materi al .
I ts mai n functi ons are for fuel storage and for pl ace-
ment of the fuel pump modul e and certai n ORVR
components.
OPERATION
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
A fuel tank check val ve(s) i s mounted i nto the top
of the fuel tank (or pump modul e). Refer to Fuel
Tank Check Val ve for addi ti onal i nformati on.
An evaporati on control system i s connected to the
check val ve(s) to reduce emi ssi ons of fuel vapors i nto
the atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng a Leak
Detecti on Pump (LDP). Refer to Emi ssi on Control
System for addi ti onal i nformati on.
Refer to ORVR for On-Board Refuel i ng Vapor
Recovery system i nformati on.
REMOVAL
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
PRESSURE MUST BE RELEASED BEFORE SERVIC-
ING FUEL TANK.
Two di fferent procedures may be used to drai n fuel
tank (through ORVR control val ve openi ng at top of
fuel tank, or usi ng DRB scan tool ). The qui ckest i s
drai ni ng through ORVR control val ve openi ng at top
of fuel tank (Fi g. 26).
As an al ternati ve procedure, the el ectri c fuel pump
may be acti vated al l owi ng tank to be drai ned at fuel
rai l connecti on. Refer to DRB scan tool for fuel pump
acti vati on procedures. Before di sconnecti ng fuel l i ne
at fuel rai l , rel ease fuel pressure. Refer to the Fuel
System Pressure Rel ease Procedure for procedures.
Attach end of Speci al Adapter Hose Tool number
6539 at fuel rai l di sconnecti on. Posi ti on opposi te end
of 6539 to an approved gasol i ne drai ni ng stati on.
Acti vate fuel pump wi th DRB and drai n tank unti l
empty.
I f el ectri c fuel pump i s not operati ng, tank MUST
be drai ned through ORVR control val ve openi ng at
top of fuel tank (Fi g. 26).
System Pressure Rel ease Procedure.
(4) Remove l eft rear wheel /ti re.
CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR /
VACUUM LINES VERY CAREFULLY. THESE LINES
AND HOSES MUST BE FIRMLY CONNECTED.
CHECK THE VAPOR/VACUUM LINES AT THE LDP,
LDP FILTER, EVAP CANISTER, EVAP CANISTER
PURGE SOLENOID AND ORVR COMPONENTS FOR
DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A
DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
(5) Cl ean top of fuel tank at ORVR control val ve
(Fi g. 26) or (Fi g. 27).
(6) Press rel ease tab i n di recti on of arrow i n (Fi g.
27) and remove ORVR control val ve l ock ri ng
(counter-cl ockwi se). Li ft up ORVR control sl i ghtl y.
Usi ng an approved gasol i ne drai ni ng stati on, drai n
tank unti l empty through thi s openi ng.
(7) Remove stone shi el d behi nd l eft/rear wheel
(Fi g. 28). Dri l l out pl asti c ri vets for removal .
(8) Remove 3 LDP mounti ng bol ts (Fi g. 29).
(9) Remove support bracket brace bol t (Fi g. 30).
(10) Loosen, but do not remove 2 support bracket
nuts at frame rai l (Fi g. 29).
(11) To separate and l ower front secti on of two-
pi ece support bracket, remove 3 attachi ng bol ts on
bottom of support bracket (Fi g. 30). Whi l e l oweri ng
support bracket, di sconnect LDP wi ri ng cl i p (Fi g. 31).
(12) Remove hose cl amp (Fi g. 32) and remove fuel
fi l l hose from fuel fi l l tube.
(13) Cut and di scard ti e wrap from axl e vent hose
(Fi g. 32).
(14) Di sconnect fuel vent hose from fuel vent tube
(Fi g. 32).
(15) Di sconnect ORVR hose el bow (Fi g. 33) at top
of EVAP cani ster.
(16) Pl ace hydraul i c jack to bottom of fuel tank.
(17) Remove fuel tank-to-rear bumper fasci a cl i ps
(Fi g. 34).
(18) Remove fuel tank heat shi el d mounti ng bol ts
(Fi g. 35).
CAUTION: To protect fuel tank from exhaust heat,
shield must re-installed after tank installation.
WARNING: PLACE SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
(19) Di sconnect fuel return l i ne at fuel fi l ter/fuel
pressure regul ator (Fi g. 36). Refer to Qui ck-Connect
Fi tti ngs for procedures.
(20) Di sconnect fuel pressure l i ne at fuel fi l ter/fuel
pressure regul ator (Fi g. 36). Refer to Qui ck-Connect
Fi tti ngs for procedures.
(21) Di sconnect EVAP cani ster vent l i ne near front
of tank (Fi g. 36).
(22) Di sconnect fuel pump modul e el ectri cal con-
nector (pi gtai l harness) near front of tank (Fi g. 36).
Harness connector i s cl i pped to body.
(23) Remove l eft / front tank support bracket bol t
at frame (Fi g. 37).
(24) WITHOUT TRAILER HITCH: Remove tank-
to-frame mounti ng bol ts (Fi g. 39). Remove rear tank
support bracket bol ts at frame (Fi g. 38). Careful l y
l ower tank unti l cl ear of vehi cl e. Pl ace tank on fl oor.
(25) WITH TRAILER HITCH: Remove tank /
hi tch mounti ng bol ts (Fi g. 40). Careful l y l ower tank
unti l cl ear of vehi cl e. Pl ace tank on fl oor.
(26) I f necessary, separate ski d pl ate from fuel
tank by removi ng 2 fuel tank strap nuts (Fi g. 39) and
remove 2 tank straps.
(27) I f fuel pump modul e removal i s necessary,
refer to Fuel Pump Modul e Removal /I nstal l ati on.
(28) I f hoses are to be removed at fuel tank end,
note pai nted al i gnment (i ndexi ng) marki ngs on
hoses, and mol ded i ndexi ng tangs on tank before
removal . Remove hoses.
(29) I f necessary, remove 3 fuel fi l l er tube assem-
bl y mounti ng bol ts (Fi g. 41) and remove fuel fi l l er
tube.
INSTALLATION
CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR /
VACUUM LINES VERY CAREFULLY. THESE LINES
AND HOSES MUST BE FIRMLY CONNECTED.
CHECK THE VAPOR/VACUUM LINES AT THE LDP,
LDP FILTER, EVAP CANISTER, EVAP CANISTER
PURGE SOLENOID AND ORVR COMPONENTS FOR
DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A
DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
(1) I f necessary, posi ti on fuel fi l l er tube assembl y
to body. I nstal l 3 bol ts and ti ghten to 2 Nm (15 i n.
l bs.) torque.
(2) I f necessary, connect qui ck-connect fi tti ngs to
fuel pump modul e.
(3) I f fuel pump modul e i s bei ng i nstal l ed, refer to
Fuel Pump Modul e Removal /I nstal l ati on.
(4) I nstal l fuel fi l l /vent hoses to tank fi tti ngs. To
prevent hoses from ki nki ng, rotate each hose unti l
pai nted i ndexi ng mark on hose i s al i gned to mol ded
i ndexi ng tang on tank.
(5) I nstal l hose cl amps to hoses. Refer to Torque
Speci fi cati ons.
(6) I f necessary, posi ti on fuel tank i nto ski d pl ate.
I nstal l 2 tank straps and 2 strap nuts (Fi g. 39). Refer
to Torque Speci fi cati ons.
(7) Posi ti on fuel tank / ski d pl ate assembl y to
hydraul i c jack.
(8) Rai se tank i nto posi ti on to frame.
(9) WITH TRAILER HITCH: Posi ti on trai l er
hi tch and tow hooks (Fi g. 40) to bottom of fuel tank.
I nstal l bol ts and nuts l oosel y.
(10) WITHOUT TRAILER HITCH: I nstal l 2 rear
tank support brackets and bol ts (Fi g. 38). I nstal l
tank-to-frame bol ts. Do not ti ghten bol ts / nuts at
thi s ti me.
(11) I nstal l 1 l eft / front tank support bracket and
bol ts / nuts (Fi g. 37). Do not ti ghten bol ts / nuts at
thi s ti me.
(12) Be sure fuel tank i s properl y al i gned to frame
and body. Ti ghten al l tank, tow hook and trai l er
hi tch bol ts / nuts except for 3 support brackets.
Ti ghten al l 3 (2 rear and 1 l eft / front) support
bracket bol ts / nuts l ast. Refer to Torque Speci fi ca-
ti ons.
(13)
(14) Connect fuel pump modul e pi gtai l harness
el ectri cal connector near front of tank.
(15) Connect both fuel l i nes to fuel fi l ter/fuel pres-
sure regul ator. Refer to Qui ck-Connect Fi tti ngs for
procedures.
(16) Connect EVAP hose near front of tank.
(17) Posi ti on rear axl e vent hose and i nstal l new
ti e strap (Fi g. 32).
(18) I nstal l heat shi el d nuts /bol ts (Fi g. 35). Refer
to Torque Speci fi cati ons.
(19) Connect ORVR hose el bow (Fi g. 33) to top of
EVAP cani ster.
(20) Connect fuel vent hose to fuel vent tube (Fi g.
32).
(21) I nstal l fuel fi l l hose and cl amp to fuel fi l l tube
(Fi g. 32).
(22) I nstal l 3 LDP mounti ng bol ts (Fi g. 29).
(23) Whi l e rai si ng support bracket, connect LDP
wi ri ng cl i p (Fi g. 31). I nstal l front secti on of two-pi ece
support bracket to rear secti on wi th 3 attachi ng bol ts
l ocated on bottom of support bracket (Fi g. 30).
(24) I nstal l support bracket brace bol t (Fi g. 30).
(25) Ti ghten 2 support bracket nuts at frame rai l
(Fi g. 29).
(26) I nstal l fuel tank-to-rear bumper fasci a cl i ps
(Fi g. 34).
(27) Usi ng new pl asti c ri vets, i nstal l stone shi el d
behi nd l eft/rear wheel (Fi g. 28).
(28) I nstal l l eft rear wheel /ti re.
(29) Lower vehi cl e and connect negati ve battery
cabl e to battery.
(30) Fi l l tank wi th fuel and check for l eaks.
FUEL TANK (Continued)
Fig. 26 FUEL TANK AND COMPONENTS
1 - FUEL PUMP MODULE 9 - TANK SUPPORT BRACKET (SMALL/FRONT)
2 - MODULE LOCK RING 10 - MODULE PIGTAIL HARNESS
3 - TANK SUPPORT BRACKETS (REAR) 11 - FUEL SUPPLY (PRESSURE) LINE
4 - CHECK VALVE 12 - FUEL RETURN LINE
5 - FUEL FILL HOSE 13 - SKID PLATE
6 - ORVR COMPONENTS 14 - TANK STRAPS (2)
7 - ORVR CONTROL VALVE 15 - FUEL TANK
8 - CONTROL VALVE LOCK RING
Fig. 27 ORVR CONTROL VALVE / LOCK RING
1 - ORVR CONTROL VALVE
2 - LOCK RING
3 - ORVR HOSE
4 - RELEASE TAB
5 - TOP OF FUEL TANK
Fig. 28 STONE SHIELD
1 - LEFT-REAR WHEELHOUSE
2 - STONE SHIELD
3 - PLASTIC RIVETS
Fig. 29 LDP MOUNTING BOLTS
1 - SUPPORT BRACKET NUTS (2)
2 - SUPPORT BRACKET (FRONT)
3 - SUPPORT BRACKET BRACE BOLT
4 - LDP MOUNTING BOLTS (3)
Fig. 30 TWO-PIECE SUPPORT BRACKET
1 - TWO-PIECE SUPPORT BRACKET (FRONT)
2 - SUPPORT BRACKET BRACE
3 - TWO-PIECE SUPPORT BRACKET (REAR)
4 - SUPPORT BRACKET ATTACHING BOLTS (3)
Fig. 31 LDP REMOVAL / INSTALLATION
1 - LDP
2 - ELEC. CONNECT.
3 - VAPOR / VACUUM LINES
4 - WIRING CLIP
Fig. 32 FUEL FILL TUBE/HOSE/CLAMP
1 - AXLE VENT HOSE
2 - FUEL VENT TUBE
3 - FUEL FILL TUBE
4 - PLASTIC TIE WRAP
5 - HOSE CLAMP
6 - FUEL FILL HOSE
7 - FUEL VENT HOSE
Fig. 33 ORVR HOSE ELBOW
1 - FUEL FILL HOSE
2 - ELBOW (TO TOP OF EVAP CANISTER)
Fig. 34 BUMPER FASCIA CLIPS
1 - CLIPS
2 - FUEL TANK
Fig. 35 FUEL TANK HEAT SHIELD BOLTS
1 - FUEL TANK
2 - HEAT SHIELD BOLTS
Fig. 36 FUEL FILTER/FUEL PRESSURE REGULATOR
1 - FUEL RETURN LINE
4 - FUEL PRESSURE LINE
5 - REAR AXLE
6 - ELEC. CONNECTOR
7 - EVAP LINE
Fig. 37 BRACKET, TANK SUPPORT - FRONT
1 - FUEL TANK SUPPORT BRACKET (LEFT FRONT)
2 - BRACKET BOLT
3 - LEFT SIDE OF TANK
Fig. 38 BRACKETS, TANK SUPPORT - REAR
1 - TOW HOOKS
2 - REAR SUPPORT BRACKETS (2)
3 - TANK SUPPORT BRACKET NUTS
4 - TANK SUPPORT BRACKET BOLTS
Fig. 39 FUEL TANK MOUNTING - NO TRAILER
HITCH
1 - TANK MOUNTING BOLTS
2 - STRAP NUTS
3 - FUEL TANK/SHIELD ASSEMBLY
Fig. 40 FUEL TANK MOUNTING - WITH TRAILER HITCH
1 - TRAILER HITCH
2 - FUEL TANK
3 - FUEL TANK / HITCH MOUNTING BOLTS
Fig. 41 FUEL FILLER TUBE
1 - FUEL FILLER TUBE
INLET FILTER
REMOVAL
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of fuel pump modul e (Fi g. 42). The fuel
pump modul e i s l ocated on top of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
(3) Remove fi l ter by pryi ng from bottom of modul e
wi th 2 screwdri vers. Fi l ter i s snapped to modul e.
(4) Cl ean bottom of pump modul e.
INSTALLATION
(1) Snap new fi l ter to bottom of modul e.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
(3) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
QUICK CONNECT FITTING
DESCRIPTION
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and tubes.
These are: a si ngl e-tab type, a two-tab type or a pl asti c
retai ner ri ng type. Some are equi pped wi th safety l atch
cl i ps. Some may requi re the use of a speci al tool for di s-
connecti on and removal . Refer to Qui ck-Connect Fi t-
ti ngs Removal /I nstal l ati on for more i nformati on.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Al so refer to Fuel Tubes/Li nes/Hoses and Cl amps.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Safety l atch cl i ps are
used on certai n components/l i nes. Certai n fi tti ngs
may requi re use of a speci al tool for di sconnecti on.
DISCONNECTING
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) 2Button Type Fitting: Thi s type of fi tti ng i s
equi pped wi th a push-button l ocated on each si de of
qui ck-connect fi tti ng (Fi g. 43). Press on both buttons
si mul taneousl y for removal . Speci al tool s are not
requi red for di sconnecti on.
Fig. 42 Fuel Pump Inlet Filter
2 - FUEL PUMP INLET FILTER
(5) Pinch-Type Fitting: Thi s fi tti ng i s equi pped
wi th two fi nger tabs. Pi nch both tabs together whi l e
removi ng fi tti ng (Fi g. 44). Speci al tool s are not
requi red for di sconnecti on.
(6) Single-Tab Type Fitting: Thi s type of fi tti ng
i s equi pped wi th a si ngl e pul l tab (Fi g. 45). The tab
i s removabl e. After tab i s removed, qui ck-connect fi t-
ti ng can be separated from fuel system component.
Speci al tool s are not requi red for di sconnecti on.
(a) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 46). If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use screwdri ver to pry up pul l tab (Fi g. 46).
(c) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 47).
(7) Two-Tab Type Fitting: Thi s type of fi tti ng i s
equi pped wi th tabs l ocated on both si des of fi tti ng
(Fi g. 48). The tabs are suppl i ed for di sconnecti ng
qui ck-connect fi tti ng from component bei ng servi ced.
(a) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 48) agai nst si des of
qui ck-connect fi tti ng wi th your fi ngers. Tool use i s
not requi red for removal and may damage pl asti c
retai ner.
(b) Pul l fi tti ng from fuel system component
bei ng servi ced.
(c) The pl asti c retai ner wi l l remai n on compo-
nent bei ng servi ced after fi tti ng i s di sconnected.
The o-ri ngs and spacer wi l l remai n i n qui ck-con-
nect fi tti ng connector body.
(8) Plastic Retainer Ring Type Fitting: Thi s
type of fi tti ng can be i denti fi ed by the use of a ful l -
round pl asti c retai ner ri ng (Fi g. 49) usual l y bl ack i n
col or.
(a) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 49). Wi th pl asti c ri ng
Fig. 43 2-BUTTON TYPE FITTING
2 - PUSH-BUTTONS (2)
Fig. 44 PINCH TYPE QUICK-CONNECT FITTING
1 - QUICK-CONNECT FITTINGS
2 - PINCH TABS
Fig. 45 SINGLE-TAB TYPE FITTING
1 - PULL TAB
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
QUICK CONNECT FITTING (Continued)
depressed, pul l fi tti ng from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
(c) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage.
Repl ace as necessary.
(9) Latch Clips: Dependi ng on vehi cl e model and
engi ne, 2 di fferent types of safety l atch cl i ps are used
(Fi g. 50) or (Fi g. 51). Type-1 i s tethered to fuel l i ne
and type-2 i s not. A speci al tool wi l l be necessary to
di sconnect fuel l i ne after l atch cl i p i s removed. The
l atch cl i p may be used on certai n fuel l i ne/fuel rai l
connecti on, or to joi n fuel l i nes together.
Fig. 46 DISCONNECTING SINGLE-TAB TYPE
FITTING
1 - PULL TAB
2 - SCREWDRIVER
Fig. 47 REMOVING PULL TAB
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
4 - FUEL TUBE STOP
Fig. 48 TYPICAL 2TAB TYPE FITTING
1 - TAB(S)
Fig. 49 PLASTIC RETAINER RING TYPE FITTING
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
(a) Type 1: Pry up on l atch cl i p wi th a screw-
dri ver (Fi g. 50).
(b) Type 2: Separate and unl atch 2 smal l arms
on end of cl i p (Fi g. 51) and swi ng away from fuel
l i ne.
(c) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
(d) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne
(Fi g. 52). Use tool to rel ease l ocki ng fi ngers i n end
of l i ne.
(e) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
(f) After di sconnecti on, l ocki ng fi ngers wi l l
remai n wi thi n qui ck-connect fi tti ng at end of fuel
l i ne.
(10) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
CONNECTING
(1) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(2) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(3) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(4) Conti nue pushi ng unti l a cl i ck i s fel t.
(5) Si ngl e-tab type fi tti ng: Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
(6) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(7) Latch Cl i p Equi pped: I nstal l l atch cl i p (snaps
i nto posi ti on). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
Fig. 50 LATCH CLIP-TYPE 1
1 - TETHER STRAP
2 - FUEL LINE
3 - SCREWDRIVER
4 - LATCH CLIP
5 - FUEL RAIL
Fig. 51 LATCH CLIP-TYPE 2
1 - LATCH CLIP
Fig. 52 FUEL LINE DISCONNECTION USING
SPECIAL TOOL
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
FUEL INJ ECTION
TABLE OF CONTENTS
page page
FUEL INJECTION
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . 32
SPECIFICATIONS
TORQUE - FUEL INJECTION . . . . . . . . . . . . . 39
ACCELERATOR PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
CRANKSHAFT POSITION SENSOR
DESCRIPTION
DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION - 4.7L . . . . . . . . . . . . . . . . . . . 40
OPERATION
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . 40
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . 41
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 42
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 43
FUEL INJECTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION - PCM OUTPUT . . . . . . . . . . . . 43
DIAGNOSIS AND TESTING - FUEL INJECTOR . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
FUEL PUMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
IDLE AIR CONTROL MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 46
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 46
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 47
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 47
MAP SENSOR
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 48
DESCRIPTION - 4.7L . . . . . . . . . . . . . . . . . . . 48
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 48
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 49
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 49
O2S HEATER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
O2S SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
THROTTLE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 53
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 54
THROTTLE CONTROL CABLE
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 54
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION
INSTALLATION 4.0L . . . . . . . . . . . . . . . . . . 55
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 56
THROTTLE POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL - 4.7L . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 58
INSTALLATION - 4.7L . . . . . . . . . . . . . . . . . . 58
WJ FUEL INJECTION 14 - 31
FUEL INJ ECTION
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res, vacuum l i nes and hoses shoul d
be made. Thi s shoul d be done before attempti ng to
di agnose or servi ce the fuel i njecti on system. A vi sual
check wi l l hel p spot these faul ts and save unneces-
sary test and di agnosti c ti me. A thorough vi sual
i nspecti on wi l l i ncl ude the fol l owi ng checks:
(1) Veri fy three 32way el ectri cal connectors are
ful l y i nserted i nto connector of Powertrai n Control
Modul e (PCM) (Fi g. 1).
(2) I nspect battery cabl e connecti ons. Be sure they
are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ai r condi ti oni ng
compressor cl utch rel ay (i f equi pped). I nspect ASD
and oxygen sensor heater rel ay connecti ons. I nspect
starter motor rel ay connecti ons. I nspect rel ays for
si gns of physi cal damage and corrosi on. The rel ays
are l ocated i n the Power Di stri buti on Center (PDC)
(Fi g. 2). Refer to l abel on PDC cover for rel ay l oca-
ti on.
(4) I nspect i gni ti on coi l connecti ons (Fi g. 3)or (Fi g.
4).
(5) Veri fy camshaft posi ti on sensor wi re connector
i s fi rml y connected (Fi g. 5) or (Fi g. 6).
(6) Veri fy crankshaft posi ti on sensor wi re connec-
tor i s fi rml y connected (Fi g. 7) or (Fi g. 8).
Fig. 1 Powertrain Control Module (PCM) Location
1 - PCM
2 - COOLANT TANK
Fig. 2 Power Distribution Center (PDC) Location
1 - POWER DISTRIBUTION CENTER (PDC)
2 - BATTERY
Fig. 3 Ignition Coil Connector4.0L Engine
1 - REAR OF VALVE COVER
2 - COIL RAIL
3 - COIL CONNECTOR
4 - RELEASE LOCK
5 - SLIDE TAB
14 - 32 FUEL INJECTION WJ
(7) Veri fy generator output wi re (B+ wi re) and
generator fi el d connector are fi rml y connected to gen-
erator.
Fig. 4 Ignition Coil Connector4.7L V-8 Engine
1 - IGNITION COIL
Fig. 5 Camshaft Position Sensor4.0L Engine
1 - OIL FILTER
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP
6 - ELEC. CONNECTOR
Fig. 6 Camshaft Position Sensor4.7L V-8 Engine
3 - MOUNTING BOLT
4 - ELEC. CONNECTOR
Fig. 7 Crankshaft Position Sensor4.0L Engine
1 - SLOTTED HOLE
3 - WIRE SHIELD
4 - MOUNTING BOLT
5 - TRANSMISSION HOUSING
6 - PAPER SPACER
FUEL INJ ECTION (Continued)
(8) I nspect system body grounds for l oose or di rty
connecti ons. Refer to Group 8, Wi ri ng for ground
l ocati ons.
(9) Veri fy crankcase venti l ati on (CCV) operati on.
Refer to Emi ssi on Control System for addi ti onal
i nformati on.
(10) I nspect al l fuel l i ne qui ck-connect fi tti ngs for
damage or l eaks.
(11) Veri fy hose connecti ons to al l ports of vacuum
fi tti ngs on i ntake mani fol d, and for emi ssi on system
are ti ght and not l eaki ng.
(12) I nspect accel erator cabl e, transmi ssi on throt-
tl e cabl e (i f equi pped) and speed control cabl e connec-
ti ons (i f equi pped). Check thei r connecti ons to
throttl e body l i nkage for any bi ndi ng or restri cti ons.
(13) Veri fy vacuum booster hose i s fi rml y con-
nected to fi tti ng on i ntake mani fol d. Al so check con-
necti on to brake vacuum booster.
(14) I nspect ai r cl eaner i nl et and ai r cl eaner el e-
ment for di rt or restri cti ons.
(15) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(16) 4.0L Engi ne: Veri fy MAP, I ntake Mani fol d Ai r
Temperature (I AT) sensor, TPS and I dl e Ai r Control
(I AC) motor connectors are fi rml y connected (Fi g. 9).
Be sure throttl e body mounti ng bol ts (Fi g. 9)are
ti ght.
(17) 4.7L Engi ne: Veri fy I ntake Mani fol d Ai r Tem-
perature (I AT) sensor, TPS and I dl e Ai r Control (I AC)
motor connectors are fi rml y connected (Fi g. 10). Be
sure throttl e body mounti ng bol ts (Fi g. 10)are ti ght.
Fig. 8 Crankshaft Position Sensor4.7L V-8 Engine
2 - STARTER
3 - ELEC. CONNECTOR
Fig. 9 IAT, MAP, IAC, TPS Sensor Locations4.0L
Engine
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.
(18) 4.0L Engi ne: Veri fy wi re harness connector i s
fi rml y connected to Engi ne Cool ant Temperature
(ECT) sensor (Fi g. 11).
(19) 4.7L Engi ne: Veri fy MAP and Engi ne Cool ant
Temperature (ECT) sensor el ectri cal connectors are
fi rml y connected to sensors (Fi g. 12).
(20) Veri fy fuel i njector wi re harness connectors
are fi rml y connected to i njectors i n correct order.
Each harness connector i s numeri cal l y tagged wi th
i njector number (I NJ 1, I NJ 2 etc.) of i ts correspond-
i ng fuel i njector and cyl i nder number.
(22) Veri fy al l oxygen sensor wi re connectors are
fi rml y connected to sensors. I nspect sensors and con-
nectors for damage (Fi g. 13)or (Fi g. 14).
Fig. 10 IAT, IAC, TPS Sensor Locations4.7L V-8
Engine
2 - THROTTLE BODY
3 - IAT SENSOR CONNECTOR
4 - IAC MOTOR CONNECTOR
5 - TPS CONNECTOR
Fig. 11 ECT Sensor Location4.0L Engine
2 - ENGINE COOLANT TEMPERATURE SENSOR
Fig. 12 MAP and ECT Sensor Locations4.7L V-8
Engine
1 - ECT SENSOR
3 - MAP SENSOR
4 - INTAKE MANIFOLD
Fig. 13 Oxygen Sensor Locations4.0L Engine
Fig. 14 Oxygen Sensor Locations4.7L V-8 Engine
(23) I nspect for pi nched or l eaki ng fuel tubes/l i nes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(24) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(25) I f equi pped wi th automati c transmi ssi on, ver-
i fy el ectri cal harness i s fi rml y connected to park/neu-
tral swi tch and to transmi ssi on components.
(26) Veri fy fuel pump modul e pi gtai l harness el ec-
tri cal connector (Fi g. 15) i s fi rml y connected to body
harness connector.
(27) I nspect fuel l i ne harness (from fuel pump
modul e) at fuel fi l ter/fuel pressure regul ator (Fi g. 15)
for chaffi ng, cracks or l eaks.
(28) Veri fy battery cabl e and sol enoi d feed wi re
connecti ons to starter sol enoi d are ti ght and cl ean.
(29) I nspect for chaffed wi res or wi res rubbi ng up
agai nst other components.
(30) I nspect for chaffed vacuum l i nes or l i nes rub-
bi ng up agai nst other components.
1 - FUEL RETURN LINE
4 - FUEL PRESSURE LINE
5 - REAR AXLE
6 - ELEC. CONNECTOR
7 - EVAP LINE
SPECIFICATIONS
TORQUE - FUEL INJECTION
Air Cleaner Housing Mount. Nuts 10 93
Air Cleaner Air Duct Clamps 4 35
Air Cleaner Resonator Bolts 4 35
Engine Coolant Temperature Sensor4.0L Engine 11 96
Engine Coolant Temperature Sensor4.7L Engine 11 96
Fuel Hose Clamps 1 10
IAC Motor-To-Throttle Body Bolts4.0L Engine 7 60
IAC Motor-To-Throttle Body Bolts4.7L Engine 7 60
Intake Manifold Air Temp. Sensor4.0L Engine 28 20
Intake Manifold Air Temp. Sensor4.7L Engine 28 20
MAP Sensor Mounting Screws4.0L Engine 3 25
MAP Sensor Mounting Screws4.7L Engine 3 25
Oxygen SensorAll Engines 30 22
PCM-to-Mounting Bracket Screws 3 25
PCM-to-Mounting Bracket Screws 9 80
Radiator Cooling Fan Relay Bolts 3 25
Throttle Body Mounting Bolts4.0L Engine 11 100
Throttle Body Mounting Bolts4.7L Engine 12 105
TPS Mounting Screws4.0L Engine 7 60
TPS Mounting Screws4.7L Engine 7 60
ACCELERATOR PEDAL
REMOVAL
The accel erator pedal i s connected to the throttl e
body l i nkage by the throttl e cabl e. The cabl e i s pro-
tected by a pl asti c sheathi ng and i s connected to the
throttl e body l i nkage by a bal l socket. I t i s connected
to the accel erator pedal arm by a pl asti c retai ner
(cl i p) (Fi g. 16). Thi s retai ner (cl i p) snaps i nto the top
of the accel erator pedal arm. A retai ner cl i p (Fi g. 16)
i s al so used to fasten cabl e to dash panel .
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of pedal arm. Pl asti c cabl e
retai ner (cl i p) snaps i nto pedal arm.
(2) Remove accel erator pedal bracket nuts. Remove
accel erator pedal assembl y.
INSTALLATION
The accel erator pedal i s connected to the throttl e
body l i nkage by the throttl e cabl e. The cabl e i s pro-
tected by a pl asti c sheathi ng and i s connected to the
throttl e body l i nkage by a bal l socket. I t i s connected
to the accel erator pedal arm by a pl asti c retai ner
(cl i p) (Fi g. 16) . Thi s retai ner (cl i p) snaps i nto the top
of the accel erator pedal arm. A retai ner cl i p (Fi g. 16)
i s al so used to fasten cabl e to dash panel .
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
12 Nm 2 Nm (105 i n. l bs. 20 i n. l bs.) torque.
(2) Sl i de throttl e cabl e i nto openi ng i n top of pedal
arm. Push pl asti c cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i nto pl ace.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
DESCRIPTION - 4. 0L
The Crankshaft Posi ti on Sensor (CKP) i s mounted
to the transmi ssi on bel l housi ng at the l eft/rear si de
of the engi ne bl ock (Fi g. 17).
DESCRIPTION - 4. 7L
The Crankshaft Posi ti on Sensor (CKP) i s mounted
i nto the engi ne bl ock above the starter motor (Fi g.
18).
OPERATION
OPERATION - 4. 0L
Engi ne speed and crankshaft posi ti on are provi ded
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the pow-
ertrai n control modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
Fig. 16 Accelerator Pedal Mounting
1 - CLIP
3 - CABLE CONNECTOR
4 - MOUNTING NUTS (2)
5 - PEDAL/BRACKET ASSEMBLY
6 - MOUNTING STUDS (2)
Fig. 17 CKP Sensor Location4.0L 6-Cyl. Engine
1 - SLOTTED HOLE
3 - WIRE SHIELD
4 - MOUNTING BOLT
6 - PAPER SPACER
Fig. 18 CKP Sensor Location4.7L V8 Engine
2 - STARTER
3 - ELEC. CONNECTOR
ACCELERATOR PEDAL (Continued)
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
On 4.0L 6-cyl i nder engi nes, the fl ywheel /dri ve
pl ate has 3 sets of four notches at i ts outer edge (Fi g.
19).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on there are 3
sets of four pul ses generated.
The trai l i ng edge of the fourth notch, whi ch causes
the pul se, i s four degrees before top dead center
(TDC) of the correspondi ng pi ston.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
OPERATION - 4. 7L
Engi ne speed and crankshaft posi ti on are provi ded
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the pow-
ertrai n control modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
On the 4.7L V8 engi ne, a tonewheel i s bol ted to
the engi ne crankshaft (Fi g. 20). Thi s tonewheel has
sets of notches at i ts outer edge (Fi g. 20).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM.
REMOVAL
REMOVAL - 4. 0L
The Crankshaft Posi ti on (CKP) sensor i s mounted
of the engi ne bl ock (Fi g. 21). The sensor is adjust-
able and i s attached wi th one bol t. A wi re shi el d/
router i s attached to the sensor (Fi g. 21).
(1) Di sconnect sensor pi gtai l harness (3way con-
nector) from mai n engi ne wi ri ng harness.
(2) Remove sensor mounti ng bol t.
(3) Remove wi re shi el d and sensor.
REMOVAL - 4. 7L
The Crankshaft Posi ti on (CKP) sensor i s bol ted to
the si de of the engi ne cyl i nder bl ock above the
starter motor (Fi g. 22). I t i s posi ti oned i nto a
machi ned hol e at the si de of the engi ne bl ock.
(1) Remove starter motor. Refer to Starter Remov-
al /I nstal l ati on.
Fig. 19 CKP Sensor Operation4.0L 6-Cyl. Engine
2 - FLYWHEEL
3 - FLYWHEEL NOTCHES
Fig. 20 CKP Sensor Operation and Tonewheel4.7L
V8 Engine
1 - TONEWHEEL
2 - NOTCHES
4 - CRANKSHAFT
CRANKSHAFT POSITION SENSOR (Continued)
(2) Di sconnect CKP el ectri cal connector at sensor
(Fi g. 22).
(3) Remove CKP mounti ng bol t (Fi g. 23).
(4) Careful l y twi st sensor from cyl i nder bl ock.
(5) Remove sensor from vehi cl e.
INSTALLATION
The Crankshaft Posi ti on (CKP) sensor i s mounted
of the engi ne bl ock (Fi g. 21). The sensor is adjust-
able and i s attached wi th one bol t. A wi re shi el d/
router i s attached to the sensor (Fi g. 21).
New repl acement sensors wi l l be equi pped wi th a
paper spacer gl ued to bottom of sensor. I f i nstal l i ng
(returni ng) a used sensor to vehi cl e, a new paper
spacer must be i nstal l ed to bottom of sensor. Thi s
spacer wi l l be ground off the fi rst ti me engi ne i s
started. I f spacer i s not used, sensor wi l l be broken
the fi rst ti me engi ne i s started.
(1) New Sensors: Be sure paper spacer i s i nstal l ed
to bottom of sensor. I f not, obtai n spacer
PN05252229.
(2) Used Sensors: Cl ean bottom of sensor and
i nstal l spacer PN05252229.
(3) I nstal l sensor i nto transmi ssi on bel l housi ng
hol e.
(4) Posi ti on sensor wi re shi el d to sensor (Fi g. 21).
Fig. 21 CKP Sensor4.0L 6-Cylinder Engine
1 - SLOTTED HOLE
3 - WIRE SHIELD
4 - MOUNTING BOLT
6 - PAPER SPACER
Fig. 22 CKP Sensor Location4.7L V8 Engine
2 - STARTER
3 - ELEC. CONNECTOR
Fig. 23 CKP Sensor Removal/Installation4.7L V8
Engine
2 - MOUNTING BOLT
(5) Push sensor agai nst fl ywheel /dri ve pl ate. Wi th
sensor pushed agai nst fl ywheel /dri ve pl ate, ti ghten
mounti ng bol t to 7 Nm (60 i n. l bs.) torque.
(6) Route sensor wi ri ng harness i nto wi re shi el d.
(7) Connect sensor pi gtai l harness el ectri cal con-
nector to mai n wi ri ng harness.
(1) Cl ean out machi ned hol e i n engi ne bl ock.
(2) Appl y a smal l amount of engi ne oi l to sensor
o-ri ng.
(3) I nstal l sensor i nto engi ne bl ock wi th a sl i ght
rocki ng acti on. Do not twi st sensor i nto posi ti on as
damage to o-ri ng may resul t.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) I nstal l mounti ng bol t and ti ghten to 28 Nm
(6) I nstal l starter motor. Refer to Starter Removal /
I nstal l ati on.
FUEL INJ ECTOR
DESCRIPTION
A separate fuel i njector (Fi g. 24) i s used for each
i ndi vi dual cyl i nder.
OPERATION
OPERATION
The fuel i njectors are el ectri cal sol enoi ds. The
i njector contai ns a pi ntl e that cl oses off an ori fi ce at
the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and needl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out
the ori fi ce. Because the fuel i s under hi gh pressure, a
fi ne spray i s devel oped i n the shape of a penci l
stream. The sprayi ng acti on atomi zes the fuel , add-
i ng i t to the ai r enteri ng the combusti on chamber.
The top (fuel entry) end of the i njector (Fi g. 24) i s
attached i nto an openi ng on the fuel rai l .
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are el ectri cal l y energi zed, i ndi vi du-
al l y and i n a sequenti al order by the Powertrai n Con-
trol Modul e (PCM). The PCM wi l l adjust i njector
pul se wi dth by swi tchi ng the ground path to each
i ndi vi dual i njector on and off. I njector pul se wi dth i s
the peri od of ti me that the i njector i s energi zed. The
PCM wi l l adjust i njector pul se wi dth based on vari -
ous i nputs i t recei ves.
Battery vol tage i s suppl i ed to the i njectors through
the ASD rel ay.
The PCM determi nes i njector pul se wi dth based on
vari ous i nputs.
OPERATION - PCM OUTPUT
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the Powertrai n Control Modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage (12 vol ts +) i s suppl i ed to the i njec-
tors through the ASD rel ay. The ASD rel ay wi l l shut-
down the 12 vol t power source to the fuel i njectors i f
the PCM senses the i gni ti on i s on, but the engi ne i s
not runni ng. Thi s occurs after the engi ne has not
been runni ng for approxi matel y 1.8 seconds.
Fig. 24 Fuel Injector4.0L/4.7L Engines
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
The PCM determi nes i njector on-ti me (pul se wi dth)
based on vari ous i nputs.
DIAGNOSIS AND TESTING - FUEL INJECTOR
To perform a compl ete test of the fuel i njectors and
thei r ci rcui try, use the DRB scan tool and refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual . To test the i njector onl y, refer to the fol l owi ng:
Di sconnect the fuel i njector wi re harness connector
from the i njector. The i njector i s equi pped wi th 2
el ectri cal termi nal s (pi ns). Pl ace an ohmmeter across
the termi nal s. Resi stance readi ng shoul d be approxi -
matel y 12 ohms 1.2 ohms at 20C (68F).
REMOVAL
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL INJECTOR(S), FUEL
SYSTEM PRESSURE MUST BE RELEASED.
To remove one or more fuel i njectors, the fuel rai l
assembl y must be removed from engi ne.
dure.
(2) Remove fuel i njector rai l . Refer to Fuel I njector
Rai l Removal /I nstal l ati on.
(3) Remove cl i p(s) retai ni ng i njector(s) to fuel rai l
(Fi g. 25).
(4) Remove i njector(s) from fuel rai l .
INSTALLATION
(1) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(2) I nstal l i njector(s) and i njector cl i p(s) to fuel
rai l .
(3) I nstal l fuel rai l assembl y. Refer to Fuel I njector
Rai l Removal /I nstal l ati on.
FUEL PUMP RELAY
DESCRIPTION
The 5pi n, 12vol t, fuel pump rel ay i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
l abel on the PDC cover for rel ay l ocati on.
OPERATION
The Powertrai n Control Modul e (PCM) energi zes
the el ectri c fuel pump through the fuel pump rel ay.
The fuel pump rel ay i s energi zed by fi rst appl yi ng
battery vol tage to i t when the i gni ti on key i s turned
ON, and then appl yi ng a ground si gnal to the rel ay
from the PCM.
Whenever the i gni ti on key i s turned ON, the el ec-
tri c fuel pump wi l l operate. But, the PCM wi l l shut-
down the ground ci rcui t to the fuel pump rel ay i n
approxi matel y 13 seconds unl ess the engi ne i s oper-
ati ng or the starter motor i s engaged.
IDLE AIR CONTROL MOTOR
DESCRIPTION
The I AC stepper motor i s mounted to the throttl e
body, and regul ates the amount of ai r bypassi ng the
control of the throttl e pl ate. As engi ne l oads and
ambi ent temperatures change, engi ne rpm changes.
A pi ntl e on the I AC stepper motor protrudes i nto a
passage i n the throttl e body, control l i ng ai r fl ow
through the passage. The I AC i s control l ed by the
Powertrai n Control Modul e (PCM) to mai ntai n the
target engi ne i dl e speed.
OPERATION
At i dl e, engi ne speed can be i ncreased by retract-
i ng the I AC motor pi ntl e and al l owi ng more ai r to
pass through the port, or i t can be decreased by
restri cti ng the passage wi th the pi ntl e and di mi ni sh-
i ng the amount of ai r bypassi ng the throttl e pl ate.
The I AC i s cal l ed a stepper motor because i t i s
moved (rotated) i n steps, or i ncrements. Openi ng the
I AC opens an ai r passage around the throttl e bl ade
whi ch i ncreases RPM.
Fig. 25 Fuel Injector MountingTypical (4.7L V-8
Engine Shown)
1 - INLET FITTING
3 - CLIP
4 - FUEL INJECTOR
FUEL INJ ECTOR (Continued)
The PCM uses the I AC motor to control i dl e speed
(al ong wi th ti mi ng) and to reach a desi red MAP dur-
i ng decel (keep engi ne from stal l i ng).
The I AC motor has 4 wi res wi th 4 ci rcui ts. Two of
the wi res are for 12 vol ts and ground to suppl y el ec-
tri cal current to the motor wi ndi ngs to operate the
stepper motor i n one di recti on. The other 2 wi res are
al so for 12 vol ts and ground to suppl y el ectri cal cur-
rent to operate the stepper motor i n the opposi te
di recti on.
To make the I AC go i n the opposi te di recti on, the
PCM just reverses pol ari ty on both wi ndi ngs. I f onl y
1 wi re i s open, the I AC can onl y be moved 1 step
(i ncrement) i n ei ther di recti on. To keep the I AC
motor i n posi ti on when no movement i s needed, the
PCM wi l l energi ze both wi ndi ngs at the same ti me.
Thi s l ocks the I AC motor i n pl ace.
I n the I AC motor system, the PCM wi l l count
every step that the motor i s moved. Thi s al l ows the
PCM to determi ne the motor pi ntl e posi ti on. I f the
memory i s cl eared, the PCM no l onger knows the
posi ti on of the pi ntl e. So at the fi rst key ON, the
PCM dri ves the I AC motor cl osed, regardl ess of
where i t was before. Thi s zeros the counter. From
thi s poi nt the PCM wi l l back out the I AC motor and
keep track of i ts posi ti on agai n.
When engi ne rpm i s above i dl e speed, the I AC i s
used for the fol l owi ng:
Off-i dl e dashpot (throttl e bl ade wi l l cl ose qui ckl y
but i dl e speed wi l l not stop qui ckl y)
Decel erati on ai r fl ow control
A/C compressor l oad control (al so opens the pas-
sage sl i ghtl y before the compressor i s engaged so
that the engi ne rpm does not di p down when the
compressor engages)
Power steeri ng l oad control
The PCM can control pol ari ty of the ci rcui t to con-
trol di recti on of the stepper motor.
IAC Stepper Motor Program: The PCM i s al so
equi pped wi th a memory program that records the
number of steps the I AC stepper motor most recentl y
advanced to duri ng a certai n set of parameters. For
exampl e: The PCM was attempti ng to mai ntai n a
1000 rpm target duri ng a col d start-up cycl e. The l ast
recorded number of steps for that may have been
125. That val ue woul d be recorded i n the memory
cel l so that the next ti me the PCM recogni zes the
i denti cal condi ti ons, the PCM recal l s that 125 steps
were requi red to mai ntai n the target. Thi s program
al l ows for greater customer sati sfacti on due to
greater control of engi ne i dl e.
Another functi on of the memory program, whi ch
occurs when the power steeri ng swi tch (i f equi pped),
or the A/C request ci rcui t, requi res that the I AC step-
per motor control engi ne rpm, i s the recordi ng of the
l ast targeted steps i nto the memory cel l . The PCM
can anti ci pate A/C compressor l oads. Thi s i s accom-
pl i shed by del ayi ng compressor operati on for approx-
i matel y 0.5 seconds unti l the PCM moves the I AC
stepper motor to the recorded steps that were l oaded
i nto the memory cel l . Usi ng thi s program hel ps el i m-
i nate i dl e-qual i ty changes as l oads change. Fi nal l y,
the PCM i ncorporates a No-Load engi ne speed l i m-
i ter of approxi matel y 1800 - 2000 rpm, when i t rec-
ogni zes that the TPS i s i ndi cati ng an i dl e si gnal and
I AC motor cannot mai ntai n engi ne i dl e.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the I AC motor through the PCM.
REMOVAL
REMOVAL - 4. 0L
The I AC motor i s l ocated on the throttl e body.
(1) Remove ai r duct and ai r resonator box at throt-
tl e body.
(2) Di sconnect el ectri cal connector from I AC motor
(Fi g. 40).
(3) Remove two mounti ng bol ts (screws) (Fi g. 26).
(4) Remove I AC motor from throttl e body.
REMOVAL - 4. 7L
tl e body.
(2) Di sconnect el ectri cal connector from I AC motor
(Fi g. 36).
(3) Remove two mounti ng bol ts (screws) (Fi g. 42).
(4) Remove I AC motor from throttl e body.
Fig. 26 Mounting Bolts (Screws)IAC
1 - IDLE AIR CONTROL MOTOR
2 - MOUNTING SCREWS
IDLE AIR CONTROL MOTOR (Continued)
INSTALLATION
The I AC motor i s l ocated on the throttl e body.
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r cl eaner duct/ai r box to throttl e body.
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
(4) I nstal l ai r duct/ai r box to throttl e body.
INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
The 2wi re I ntake Mani fol d Ai r Temperature (I AT)
sensor i s i nstal l ed i n the i ntake mani fol d wi th the
sensor el ement extendi ng i nto the ai r stream.
The I AT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as i ntake mani -
fol d temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
The I AT sensor provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM) i ndi cati ng the
densi ty of the ai r enteri ng the i ntake mani fol d based
upon i ntake mani fol d temperature. At key-on, a
5vol t power ci rcui t i s suppl i ed to the sensor from
the PCM. The sensor i s grounded at the PCM
through a l ow-noi se, sensor-return ci rcui t.
The PCM uses thi s i nput to cal cul ate the fol l owi ng:
Adjustment of spark ti mi ng (to hel p prevent
spark knock wi th hi gh i ntake mani fol d ai r-charge
temperatures)
The resi stance val ues of the I AT sensor i s the same
as for the Engi ne Cool ant Temperature (ECT) sensor.
REMOVAL
REMOVAL - 4. 0L
The I ntake Mani fol d Ai r Temperature (I AT) sensor
i s i nstal l ed i nto the i ntake mani fol d pl enum near the
front of the throttl e body (Fi g. 27).
(1) Di sconnect el ectri cal connector from sensor.
(2) Remove sensor from i ntake mani fol d.
REMOVAL - 4. 7L
i s l ocated on the l eft si de of the i ntake mani fol d.
Threaded Type Sensor
(1) Di sconnect el ectri cal connector from sensor.
(2) Remove sensor from i ntake mani fol d (Fi g. 28).
Snap-In Type Sensor
(1) Di sconnect el ectri cal connector from I AT sen-
sor.
(2) Cl ean di rt from i ntake mani fol d at sensor base.
(3) Gentl y l i ft on smal l pl asti c rel ease tab (Fi g. 30)
or (Fi g. 29) and rotate sensor about 1/4 turn counter-
cl ockwi se for removal .
Fig. 27 Intake Manifold Air Sensor Location4.0L
Engine
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.
IDLE AIR CONTROL MOTOR (Continued)
INSTALLATION
i s i nstal l ed i nto the i ntake mani fol d pl enum near the
front of the throttl e body (Fi g. 27).
(1) I nstal l sensor i nto i ntake mani fol d. Ti ghten
sensor to 28 Nm (20 ft. l bs.) torque.
Threaded Type Sensor
(1) I nstal l sensor (Fi g. 28) i nto i ntake mani fol d.
Ti ghten sensor to 28 Nm (20 ft. l bs.) torque.
Snap-In Type Sensor
(1) Check condi ti on of sensor o-ri ng (Fi g. 30).
(2) Cl ean sensor mounti ng hol e i n i ntake mani fol d.
(3) Posi ti on sensor (Fi g. 29) i nto i ntake mani fol d
and rotate cl ockwi se unti l past rel ease tab.
Fig. 28 IAT - 4.7L (THREADED TYPE)
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
5 - MOUNTING SCREWS
Fig. 29 IAT SENSOR - 4.7L (SNAP-IN TYPE)
1 - LEFT SIDE OF THROTTLE BODY
2 - ELEC. CONNECT.
3 - IAT SENSOR
4 - RELEASE TAB
Fig. 30 IAT SENSOR TAB / O-RING - 4.7L (SNAP-IN
TYPE)
1 - IAT SENSOR
2 - SENSOR O-RING
3 - RELEASE TAB
INTAKE AIR TEMPERATURE SENSOR (Continued)
MAP SENSOR
DESCRIPTION
DESCRIPTION
On the 4.0L si x-cyl i nder engi ne the MAP sensor i s
mounted to the engi ne throttl e body. On the 4.7L V-8
engi ne the MAP sensor i s mounted to front of the
i ntake mani fol d.
DESCRIPTION - 4. 7L
The MAP sensor i s l ocated on the front of the
i ntake mani fol d. An o-ri ng seal s the sensor to the
i ntake mani fol d.
OPERATION
The MAP sensor i s used as an i nput to the Power-
trai n Control Modul e (PCM). I t contai ns a si l i con
based sensi ng uni t to provi de data on the mani fol d
vacuum that draws the ai r/fuel mi xture i nto the com-
busti on chamber. The PCM requi res thi s i nformati on
to determi ne i njector pul se wi dth and spark advance.
When mani fol d absol ute pressure (MAP) equal s
Barometri c pressure, the pul se wi dth wi l l be at max-
i mum.
A 5 vol t reference i s suppl i ed from the PCM and
returns a vol tage si gnal to the PCM that refl ects
mani fol d pressure. The zero pressure readi ng i s 0.5V
and ful l scal e i s 4.5V. For a pressure swi ng of 015
psi , the vol tage changes 4.0V. To operate the sensor,
i t i s suppl i ed a regul ated 4.8 to 5.1 vol ts. Ground i s
provi ded through the l ow-noi se, sensor return ci rcui t
at the PCM.
The MAP sensor i nput i s the number one contri b-
utor to fuel i njector pul se wi dth. The most i mportant
functi on of the MAP sensor i s to determi ne baromet-
ri c pressure. The PCM needs to know i f the vehi cl e i s
at sea l evel or at a hi gher al ti tude, because the ai r
densi ty changes wi th al ti tude. I t wi l l al so hel p to cor-
rect for varyi ng barometri c pressure. Barometri c
pressure and al ti tude have a di rect i nverse correl a-
ti on; as al ti tude goes up, barometri c goes down. At
key-on, the PCM powers up and l ooks at MAP vol t-
age, and based upon the vol tage i t sees, i t knows the
current barometri c pressure (rel ati ve to al ti tude).
Once the engi ne starts, the PCM l ooks at the vol tage
agai n, conti nuousl y every 12 mi l l i seconds, and com-
pares the current vol tage to what i t was at key-on.
The di fference between current vol tage and what i t
was at key-on, i s mani fol d vacuum.
Duri ng key-on (engi ne not runni ng) the sensor
reads (updates) barometri c pressure. A normal range
can be obtai ned by moni tori ng a known good sensor.
As the al ti tude i ncreases, the ai r becomes thi nner
(l ess oxygen). I f a vehi cl e i s started and dri ven to a
very di fferent al ti tude than where i t was at key-on,
the barometri c pressure needs to be updated. Any
ti me the PCM sees Wi de Open Throttl e (WOT), based
upon Throttl e Posi ti on Sensor (TPS) angl e and RPM,
i t wi l l update barometri c pressure i n the MAP mem-
ory cel l . Wi th peri odi c updates, the PCM can make
i ts cal cul ati ons more effecti vel y.
The PCM uses the MAP sensor i nput to ai d i n cal -
cul ati ng the fol l owi ng:
Mani fol d pressure
Barometri c pressure
Engi ne l oad
Spark-advance programs
Shi ft-poi nt strategi es (certai n automati c trans-
mi ssi ons onl y)
I dl e speed
Decel fuel shutoff
The MAP sensor si gnal i s provi ded from a si ngl e
pi ezoresi sti ve el ement l ocated i n the center of a di a-
phragm. The el ement and di aphragm are both made
of si l i cone. As mani fol d pressure changes, the di a-
phragm moves causi ng the el ement to defl ect, whi ch
stresses the si l i cone. When si l i cone i s exposed to
stress, i ts resi stance changes. As mani fol d vacuum
i ncreases, the MAP sensor i nput vol tage decreases
proporti onal l y. The sensor al so contai ns el ectroni cs
that condi ti on the si gnal and provi de temperature
compensati on.
The PCM recogni zes a decrease i n mani fol d pres-
sure by moni tori ng a decrease i n vol tage from the
readi ng stored i n the barometri c pressure memory
cel l . The MAP sensor i s a l i near sensor; meani ng as
pressure changes, vol tage changes proporti onatel y.
The range of vol tage output from the sensor i s usu-
al l y between 4.6 vol ts at sea l evel to as l ow as 0.3
vol ts at 26 i n. of Hg. Barometri c pressure i s the pres-
sure exerted by the atmosphere upon an object. At
sea l evel on a standard day, no storm, barometri c
pressure i s approxi matel y 29.92 i n Hg. For every 100
feet of al ti tude, barometri c pressure drops .10 i n. Hg.
I f a storm goes through i t can change barometri c
pressure from what shoul d be present for that al ti -
tude. You shoul d know what the average pressure
and correspondi ng barometri c pressure i s for your
area.
REMOVAL
REMOVAL - 4. 0L
The MAP sensor i s mounted to the si de of the
throttl e body (Fi g. 40). An L-shaped rubber fi tti ng i s
used to connect the MAP sensor to throttl e body (Fi g.
31).
(1) Remove ai r cl eaner duct and ai r resonator box
at throttl e body.
(2) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 31).
(3) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 31) from the throttl e body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
REMOVAL - 4. 7L
i ntake mani fol d (Fi g. 32). An o-ri ng seal s the sensor
to the i ntake mani fol d.
(1) Di sconnect el ectri cal connector at sensor.
(2) Cl ean area around MAP sensor.
(3) Remove 2 sensor mounti ng bol ts (Fi g. 32).
(4) Remove MAP sensor from i ntake mani fol d.
INSTALLATION
The MAP sensor i s mounted to the si de of the
throttl e body (Fi g. 40). An L-shaped rubber fi tti ng i s
used to connect the MAP sensor to throttl e body (Fi g.
31).
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
(4) I nstal l ai r cl eanerduct/ai r box.
i ntake mani fol d (Fi g. 32). An o-ri ng seal s the sensor
to the i ntake mani fol d.
(1) Cl ean MAP sensor mounti ng hol e at i ntake
mani fol d.
(2) Check MAP sensor o-ri ng seal for cuts or tears.
(3) Posi ti on sensor i nto mani fol d.
(4) I nstal l MAP sensor mounti ng bol ts (screws).
(5) Connect el ectri cal connector.
O2S HEATER RELAY
DESCRIPTION
The 2 oxygen (O2) sensor heater rel ays (upstream
and downstream) are l ocated i n the Powertrai n Di s-
OPERATION
Engi nes equi pped wi th the Cal i forni a (NAE) Emi s-
si ons Package use four O2 sensors.
Two of the four sensor heater el ements (upstream
sensors 1/1 and 2/1) are control l ed by the upstream
heater rel ay through output si gnal s from the Power-
Fig. 31 Rubber L-Shaped FittingMAP Sensor-to-
Throttle Body4.0L Engine
1 - THROTTLE BODY
2 - MAP SENSOR
3 - RUBBER FITTING
4 - MOUNTING SCREWS (2)
Fig. 32 MAP and ECT Sensor Locations4.7L V8
Engine
1 - ECT SENSOR
3 - MAP SENSOR
4 - INTAKE MANIFOLD
MAP SENSOR (Continued)
The other two heater el ements (downstream sen-
sors 1/2 and 2/2) are control l ed by the downstream
heater rel ay through output si gnal s from the PCM.
To avoi d a l arge si mul taneous current surge, power
i s del ayed to the 2 downstream heater el ements by
the PCM for approxi matel y 2 seconds.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
O2S SENSOR
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and
protrude i nto the vehi cl e exhaust system. Dependi ng
on the emi ssi on package, the vehi cl e may use a total
of ei ther 2 or 4 sensors.
Federal Emissions Package: Two sensors are
used: upstream (referred to as 1/1) and downstream
(referred to as 1/2). Wi th thi s emi ssi on package, the
upstream sensor (1/1) i s l ocated just before the mai n
catal yti c convertor. The downstream sensor (1/2) i s
l ocated just after the mai n catal yti c convertor.
4.7L V-8 With California Emissions Package:
On thi s emi ssi ons package, 4 sensors are used: 2
upstream (referred to as 1/1 and 2/1) and 2 down-
stream (referred to as 1/2 and 2/2). Wi th thi s emi s-
si on package, the ri ght upstream sensor (2/1) i s
l ocated i n the ri ght exhaust downpi pe just before the
mi ni -catal yti c convertor. The l eft upstream sensor
(1/1) i s l ocated i n the l eft exhaust downpi pe just
before the mi ni -catal yti c convertor. The ri ght down-
stream sensor (2/2) i s l ocated i n the ri ght exhaust
downpi pe just after the mi ni -catal yti c convertor, and
before the mai n catal yti c convertor. The l eft down-
stream sensor (1/2) i s l ocated i n the l eft exhaust
downpi pe just after the mi ni -catal yti c convertor, and
before the mai n catal yti c convertor.
4.0L 6Cylinder With California Emissions
Package: On thi s emi ssi ons package, 4 sensors are
used: 2 upstream (referred to as 1/1 and 2/1) and 2
downstream (referred to as 1/2 and 2/2). Wi th thi s
emi ssi on package, the rear/upper upstream sensor
(2/1) i s l ocated i n the exhaust downpi pe just before
the rear mi ni -catal yti c convertor. The front/upper
upstream sensor (1/1) i s l ocated i n the exhaust down-
pi pe just before the front mi ni -catal yti c convertor.
The rear/l ower downstream sensor (2/2) i s l ocated i n
the exhaust downpi pe just after the rear mi ni -cata-
l yti c convertor, and before the mai n catal yti c conver-
tor. The front/l ower downstream sensor (1/2) i s
l ocated i n the exhaust downpi pe just after the front
mi ni -catal yti c convertor, and before the mai n cata-
l yti c convertor.
OPERATION
An O2 sensor i s a gal vani c battery that provi des
the PCM wi th a vol tage si gnal (0-1 vol t) i nversel y
proporti onal to the amount of oxygen i n the exhaust.
I n other words, i f the oxygen content i s l ow, the vol t-
age output i s hi gh; i f the oxygen content i s hi gh the
output vol tage i s l ow. The PCM uses thi s i nformati on
to adjust i njector pul se-wi dth to achi eve the
14.7to1 ai r/fuel rati o necessary for proper engi ne
operati on and to control emi ssi ons.
The O2 sensor must have a source of oxygen from
outsi de of the exhaust stream for compari son. Cur-
rent O2 sensors recei ve thei r fresh oxygen (outsi de
ai r) suppl y through the O2 sensor case housi ng.
Four wi res (ci rcui ts) are used on each O2 sensor: a
12vol t feed ci rcui t for the sensor heati ng el ement; a
ground ci rcui t for the heater el ement; a l ow-noi se
sensor return ci rcui t to the PCM, and an i nput ci r-
cui t from the sensor back to the PCM to detect sen-
sor operati on.
Oxygen Sensor Heaters/Heater Relays:
Dependi ng on the emi ssi ons package, the heati ng el e-
ments wi thi n the sensors wi l l be suppl i ed vol tage
from ei ther the ASD rel ay, or 2 separate oxygen sen-
sor rel ays. Refer to Wi ri ng Di agrams to determi ne
whi ch rel ays are used.
The O2 sensor uses a Posi ti ve Thermal Co-effi ci ent
(PTC) heater el ement. As temperature i ncreases,
resi stance i ncreases. At ambi ent temperatures
around 70F, the resi stance of the heati ng el ement i s
approxi matel y 4.5 ohms on 4.0L engi nes. I t i s
approxi matel y 13.5 ohms on the 4.7L engi ne. As the
sensors temperature i ncreases, resi stance i n the
heater el ement i ncreases. Thi s al l ows the heater to
mai ntai n the opti mum operati ng temperature of
approxi matel y 930-1100F (500-600 C). Al though
the sensors operate the same, there are physi cal di f-
ferences, due to the envi ronment that they operate
i n, that keep them from bei ng i nterchangeabl e.
Mai ntai ni ng correct sensor temperature at al l
ti mes al l ows the system to enter i nto cl osed l oop
operati on sooner. Al so, i t al l ows the system to remai n
i n cl osed l oop operati on duri ng peri ods of extended
i dl e.
O2S HEATER RELAY (Continued)
I n Cl osed Loop operati on, the PCM moni tors cer-
tai n O2 sensor i nput(s) al ong wi th other i nputs, and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2 sensor
i nput. The PCM adjusts i njector pul se wi dth based
on preprogrammed (fi xed) val ues and i nputs from
other sensors.
Upstream Sensor (Non-California Emissions):
The upstream sensor (1/1) provi des an i nput vol tage
to the PCM. The i nput tel l s the PCM the oxygen con-
tent of the exhaust gas. The PCM uses thi s i nforma-
ti on to fi ne tune fuel del i very to mai ntai n the correct
oxygen content at the downstream oxygen sensor.
The PCM wi l l change the ai r/fuel rati o unti l the
upstream sensor i nputs a vol tage that the PCM has
determi ned wi l l make the downstream sensor output
(oxygen content) correct.
The upstream oxygen sensor al so provi des an i nput
to determi ne catal yti c convertor effi ci ency.
Downstream Sensor (Non-California Emis-
sions): The downstream oxygen sensor (1/2) i s al so
used to determi ne the correct ai r-fuel rati o. As the
oxygen content changes at the downstream sensor,
the PCM cal cul ates how much ai r-fuel rati o change i s
requi red. The PCM then l ooks at the upstream oxy-
gen sensor vol tage and changes fuel del i very unti l
the upstream sensor vol tage changes enough to cor-
rect the downstream sensor vol tage (oxygen content).
The downstream oxygen sensor al so provi des an
i nput to determi ne catal yti c convertor effi ci ency.
Upstream Sensors (California Engines): Two
upstream sensors are used (1/1 and 2/1). The 1/1 sen-
sor i s the fi rst sensor to recei ve exhaust gases from
the #1 cyl i nder. They provi de an i nput vol tage to the
PCM. The i nput tel l s the PCM the oxygen content of
the exhaust gas. The PCM uses thi s i nformati on to
fi ne tune fuel del i very to mai ntai n the correct oxygen
content at the downstream oxygen sensors. The PCM
wi l l change the ai r/fuel rati o unti l the upstream sen-
sors i nput a vol tage that the PCM has determi ned
wi l l make the downstream sensors output (oxygen
content) correct.
The upstream oxygen sensors al so provi de an i nput
to determi ne mi ni -catal yst effi ci ency. Mai n catal yti c
convertor effi ci ency i s not cal cul ated wi th thi s pack-
age.
Downstream Sensors (California Engines):
Two downstream sensors are used (1/2 and 2/2). The
downstream sensors are used to determi ne the cor-
rect ai r-fuel rati o. As the oxygen content changes at
the downstream sensor, the PCM cal cul ates how
much ai r-fuel rati o change i s requi red. The PCM
then l ooks at the upstream oxygen sensor vol tage,
and changes fuel del i very unti l the upstream sensor
vol tage changes enough to correct the downstream
sensor vol tage (oxygen content).
The downstream oxygen sensors al so provi de an
i nput to determi ne mi ni -catal yst effi ci ency. Mai n cat-
al yti c convertor effi ci ency i s not cal cul ated wi th thi s
package.
Engi nes equi pped wi th ei ther a downstream sen-
sor(s), or a post-catal yti c sensor, wi l l moni tor cata-
l yti c convertor effi ci ency. I f effi ci ency i s bel ow
emi ssi on standards, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated and a Di agnosti c Troubl e
Code (DTC) wi l l be set. Refer to Moni tored Systems
i n Emi ssi on Control Systems for addi ti onal i nforma-
ti on.
REMOVAL
Never apply any type of grease to the oxygen
sensor electrical connector, or attempt any sol-
dering of the sensor wiring harness.
Oxygen sensor (O2S) l ocati ons are shown i n (Fi g.
33) and (Fi g. 34).
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER(S) BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(2) Di sconnect O2S pi gtai l harness from mai n wi r-
i ng harness.
(3) I f equi pped, di sconnect sensor wi re harness
mounti ng cl i ps from engi ne or body.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(4) Remove O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
threads of a new oxygen sensor.
(1) I nstal l O2S sensor. Ti ghten to 30 Nm (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector to mai n
wi ri ng harness.
(3) I f equi pped, connect sensor wi re harness
mounti ng cl i ps to engi ne or body. When Equipped:
The O2S pigtail harness must be clipped and/or
bolted back to their original positions on
engine or body to prevent mechanical damage
to wiring..
O2S SENSOR (Continued)
THROTTLE BODY
DESCRIPTION
The throttl e body i s l ocated on the i ntake mani fol d.
Fuel does not enter the i ntake mani fol d through the
throttl e body. Fuel i s sprayed i nto the mani fol d by
the fuel i njectors.
OPERATION
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body. The throttl e body
contai ns an ai r control passage control l ed by an I dl e
Ai r Control (I AC) motor. The ai r control passage i s
used to suppl y ai r for i dl e condi ti ons. A throttl e val ve
(pl ate) i s used to suppl y ai r for above i dl e condi ti ons.
Certai n sensors are attached to the throttl e body.
The accel erator pedal cabl e, speed control cabl e and
transmi ssi on control cabl e (when equi pped) are con-
nected to the throttl e body l i nkage arm.
control l ed by the PCM.
REMOVAL
REMOVAL - 4. 0L
control l ed by the Powertrai n Control Modul e (PCM).
(1) Remove ai r cl eaner duct and ai r resonator box
at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 35).
Fig. 33 Oxygen Sensor Locations4.0L Engine
O2S SENSOR (Continued)
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to Accel erator Pedal and Throttl e
Cabl e.
(4) Remove four throttl e body mounti ng bol ts.
(5) Remove throttl e body from i ntake mani fol d.
(6) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
REMOVAL - 4. 7L
(1) Remove the ai r duct and ai r resonator box at
throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at I AC motor and TPS (Fi g. 36).
(3) Remove vacuum l i ne at throttl e body.
(4) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to Accel erator Pedal and Throttl e
Cabl e.
(5) Remove three throttl e body mounti ng bol ts
(Fi g. 36).
(6) Remove throttl e body from i ntake mani fol d.
INSTALLATION
control l ed by the Powertrai n Control Modul e (PCM).
(1) Cl ean the mati ng surfaces of the throttl e body
and the i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 11
Nm (100 i n. l bs.) torque.
(5) I nstal l control cabl es.
(6) I nstal l el ectri cal connectors.
(7) I nstal l ai r duct and ai r box at throttl e body.
Fig. 34 Oxygen Sensor Locations4.7L V-8 Engine
THROTTLE BODY (Continued)
(1) Cl ean throttl e body-to-i ntake mani fol d o-ri ng.
(2) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(3) I nstal l throttl e body to i ntake mani fol d by posi -
ti oni ng throttl e body to mani fol d al i gnment pi ns.
(4) I nstal l three mounti ng bol ts. Ti ghten bol ts to
(5) I nstal l control cabl es.
(6) I nstal l vacuum l i ne to throttl e body.
(7) I nstal l el ectri cal connectors.
(8) I nstal l ai r duct/ai r box at throttl e body.
THROTTLE CONTROL CABLE
REMOVAL
REMOVAL - 4. 0L
core wi re from upper end of pedal arm (Fi g. 16).
Pl asti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, remove cl i p hol di ng cabl e
to dashpanel (Fi g. 16).
(4) Remove cabl e housi ng from dash panel and
pul l i nto engi ne compartment.
(5) Remove (unsnap) cabl e from routi ng cl i ps on
engi ne val ve cover.
(6) Remove cabl e connector at throttl e body
bel l crank bal l by unsnappi ng rearward (Fi g. 37).
(7) Remove throttl e cabl e from bracket by com-
pressi ng rel ease tabs (Fi g. 37) and pushi ng cabl e
through hol e i n bracket.
(8) Remove throttl e cabl e from vehi cl e.
Fig. 35 Throttle Body and Sensor Locations4.0L
Engine
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.
Fig. 36 Throttle Body, Sensors and Electrical
Connectors4.7L V-8 Engine
2 - THROTTLE BODY
3 - IAT SENSOR CONNECTOR
4 - IAC MOTOR CONNECTOR
5 - TPS CONNECTOR
THROTTLE BODY (Continued)
REMOVAL - 4. 7L
core wi re from upper end of pedal arm (Fi g. 16).
Pl asti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, remove cl i p hol di ng cabl e
(4) Remove ai r box at throttl e body.
(5) Unsnap cabl e from pl enum routi ng cl i p.
(6) Remove cabl e housi ng from dash panel and
pul l i nto engi ne compartment.
(7) Usi ng fi nger pressure onl y, di sconnect accel era-
tor cabl e connector at throttl e body bel l crank pi n by
pushi ng connector off bel l crank pi n towards front of
vehi cl e (Fi g. 38). DO NOT try to pull connector
off perpendicular to the bellcrank pin. Connec-
tor will be broken.
(8) Li ft accel erator cabl e from top of cabl e cam
(Fi g. 38).
(9) Press tab (Fi g. 39) to rel ease pl asti c cabl e
mount from bracket. Press on tab only enough to
release cable from bracket. If tab is pressed too
much, it will be broken. Sl i de pl asti c mount (Fi g.
39) towards passenger si de of vehi cl e to remove cabl e
from bracket.
(10) Remove throttl e cabl e from vehi cl e.
INSTALLATION
INSTALLATION 4. 0L
(1) Sl i de throttl e cabl e through hol e i n bracket
unti l rel ease tabs l ock i nto bracket.
(2) Connect cabl e bal l end to throttl e body
bel l crank bal l (snaps on).
(3) Snap cabl e i nto routi ng cl i ps on engi ne val ve
cover.
(4) Sl i de rubber grommet away from pl asti c cabl e
housi ng.
(5) I nstal l rubber grommet i nto dash panel unti l
seated.
(6) Push cabl e housi ng i nto rubber grommet and
through openi ng i n dash panel .
Fig. 37 Throttle (Accelerator) Cable at Throttle
Body4.0L Engine
2 - OFF
3 - OFF
4 - THROTTLE BODY BELLCRANK
6 - RELEASE TABS
7 - BRACKET
Fig. 38 Accelerator Cable at Bell Crank4.7L V-8
Engine
1 - THROTTLE BODY
2 - SPEED CONTROL CABLE CONNECTOR
3 - OFF
4 - OFF
5 - ACCELERATOR CABLE CONNECTOR
6 - CABLE CAM
7 - BELLCRANK
THROTTLE CONTROL CABLE (Continued)
(7) From i nsi de vehi cl e, i nstal l cl i p hol di ng cabl e
(8) From i nsi de vehi cl e, sl i de throttl e cabl e core
wi re i nto openi ng i n top of pedal arm.
(9) Push cabl e retai ner (cl i p) i nto pedal arm open-
i ng unti l i t snaps i n pl ace.
(1) Sl i de accel erator cabl e pl asti c mount i nto
bracket. Conti nue sl i di ng unti l tab (Fi g. 39) i s
al i gned to hol e i n mounti ng bracket.
(2) Route accel erator cabl e over top of cabl e cam.
(3) Connect cabl e end to throttl e body bel l crank
pi n (snaps on rearward).
(4) Sl i de rubber grommet away from pl asti c cabl e
housi ng.
(5) I nstal l rubber grommet i nto dash panel unti l
seated.
(6) Push cabl e housi ng i nto rubber grommet and
through openi ng i n dash panel .
(7) From i nsi de vehi cl e, i nstal l cl i p hol di ng cabl e
(8) From i nsi de vehi cl e, sl i de throttl e cabl e core
wi re i nto openi ng i n top of pedal arm.
(9) Push cabl e retai ner (cl i p) i nto pedal arm open-
i ng unti l i t snaps i n pl ace.
(10) Snap cabl e i nto pl enum routi ng cl i p.
(11) I nstal l ai r box to throttl e body.
THROTTLE POSITION SENSOR
DESCRIPTION
The 3wi re Throttl e Posi ti on Sensor (TPS) i s
mounted on the throttl e body and i s connected to the
throttl e bl ade.
OPERATION
The TPS i s a 3wi re vari abl e resi stor that provi des
the Powertrai n Control Modul e (PCM) wi th an i nput
si gnal (vol tage) that represents the throttl e bl ade
posi ti on of the throttl e body. The sensor i s connected
to the throttl e bl ade shaft. As the posi ti on of the
throttl e bl ade changes, the resi stance (output vol t-
age) of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .26
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.49 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
The PCM needs to i denti fy the acti ons and posi ti on
of the throttl e bl ade at al l ti mes. Thi s i nformati on i s
needed to assi st i n performi ng the fol l owi ng cal cul a-
ti ons:
I gni ti on ti mi ng advance
Fuel i njecti on pul se-wi dth
I dl e (l earned val ue or mi ni mum TPS)
Off-i dl e (0.06 vol t)
Wi de Open Throttl e (WOT) open l oop (2.608
vol ts above l earned i dl e vol tage)
Decel erati on fuel l ean out
Fuel cutoff duri ng cranki ng at WOT (2.608 vol ts
above l earned i dl e vol tage)
A/C WOT cutoff (certai n automati c transmi s-
si ons onl y)
Fig. 39 Accelerator Cable Release Tab4.7L V-8
Engine
3 - PRESS TAB FOR REMOVAL
4 - CABLE BRACKET
THROTTLE CONTROL CABLE (Continued)
REMOVAL
REMOVAL - 4. 0L
The TPS i s mounted to the throttl e body.
(1) Di sconnect TPS el ectri cal connector (Fi g. 40).
(2) Remove TPS mounti ng screws (Fi g. 41).
(3) Remove TPS.
REMOVAL - 4. 7L
The TPS i s l ocated on the throttl e body.
tl e body.
(2) Di sconnect TPS el ectri cal connector (Fi g. 36).
(3) Remove two TPS mounti ng bol ts (screws) (Fi g.
42).
(4) Remove TPS from throttl e body.
Fig. 40 TPS Electrical Connector4.0L Engine
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.
Fig. 41 TPS Mounting Screws4.0L Engine
1 - MOUNTING SCREWS
2 - TPS
Fig. 42 TPS Mounting Bolts4.7L V8
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
5 - MOUNTING SCREWS
THROTTLE POSITION SENSOR (Continued)
INSTALLATION
The TPS i s mounted to the throttl e body.
The throttl e shaft end of throttl e body sl i des i nto a
socket i n the TPS (Fi g. 43). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
sensor wi l l not rotate, i nstal l sensor wi th throttl e
shaft on other si de of socket tangs). The TPS wi l l be
under sl i ght tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
The throttl e shaft end of throttl e body sl i des i nto a
socket i n TPS (Fi g. 44). The TPS must be i nstal l ed so
that i t can be rotated a few degrees. I f sensor wi l l
not rotate, i nstal l sensor wi th throttl e shaft on other
si de of socket tangs. The TPS wi l l be under sl i ght
tensi on when rotated.
(1) I nstal l TPS and two retai ni ng bol ts.
(2) Ti ghten bol ts to 7 Nm (60 i n. l bs.) torque.
(3) Manual l y operate throttl e control l ever by hand
to check for any bi ndi ng of TPS.
(4) Connect TPS el ectri cal connector to TPS.
(5) I nstal l ai r duct/ai r box to throttl e body.
Fig. 43 Throttle Position Sensor Installation4.0L
Engine
1 - TANGS
2 - THROTTLE SHAFT
3 - THROTTLE BODY
4 - TPS
Fig. 44 TPS Installation4.7L
1 - THROTTLE BODY
2 - LOCATING TANGS
3 - THROTTLE POSITION SENSOR
4 - SOCKET
5 - THROTTLE SHAFT
THROTTLE POSITION SENSOR (Continued)
STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION - POWER STEERING SYSTEM . . 1
OPERATION - POWER STEERING SYSTEM . . . 1
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - STEERING
FLOW AND PRESSURE . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - 4.7L -
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
STEERING
DESCRIPTION - POWER STEERING SYSTEM
The power steeri ng pump (Fi g. 1) i s a constant
fl ow rate and di spl acement vane type pump. The
pump reservoi r i s attached to the pump body. The
pump i s connected to the steeri ng by the pressure
and return hoses. The steeri ng gear (Fi g. 1) used i s a
reci rcul ati ng bal l type gear. A ti l t and non-ti l t col umn
provi de steeri ng i nput.
The power steeri ng system consi sts of:
OPERATION - POWER STEERING SYSTEM
The rack pi ston bal l s act as a rol l i ng thread
between the worm shaft and rack pi ston. The worm
shaft i s supported by a thrust beari ng at the l ower
end and a beari ng assembl y at the upper end. When
the worm shaft i s turned from i nput from the steer-
i ng col umn the rack pi ston moves. The rack pi ston
teeth mesh wi th the pi tman shaft. Turni ng the worm
shaft turns the pi tman shaft, whi ch moves the steer-
i ng l i nkage.
Fig. 1 POWER STEERING GEAR & PUMP 4.0L
1 - STEERING GEAR
2 - PRESSURE HOSE
3 - PUMP
4 - RETURN HOSE
5 - RESERVOIR
WJ STEERING 19 - 1
DIAGNOSIS AND TESTING - POWER STEERING SYSTEM
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i ts travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash panel
seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components/track bar.
2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other
components.
5. Reposition hose.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
2. Belt routing. 2. Verify belt routing is correct.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
4. Air in the system. 4. Perform pump initial operation.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
19 - 2 STEERING WJ
STEERING (Continued)
BINDING AND STICKING
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
3. Steering component. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of
adjustment.
7. Repair or replace gear.
8. Ball joints binding. 8. Inspect and repair as necessary.
4.7L Hydraulic fan motor steering output
low
Pressure / Flow test fans steering
output flow
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure or flow. 5. Pressure and flow test and repair
as necessary.
6. Internal gear leak. 6. Pressure and flow test, and repair
as necessary.
4.7L
8. Low flow / pressure from fan
motor
8. Pressure and flow test and repair
as necessary.
STEERING WHEEL
DOES NOT WANT TO RETURN TO
CENTER POSITION
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust as necessary.
5. Ball joints binding. 5. Inspect and repair as necessary.
NOTE:
Some roads will cause a vehicle to drift, due to the crown in the road.
WJ STEERING 19 - 3
LOOSE STEERING AND VEHICLE LEADS/DRIFTS
EXCESSIVE PLAY IN STEERING
WHEEL
1. Worn or loose suspension or
steering components.
2. Worn or loose wheel bearings. 2. Repair as necessary.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.
VEHICLE PULLS TO ONE SIDE
DURING BRAKING
1. Tire Pressure. 1. Adjust tire pressure.
2. Air in brake hydrauliics system. 2. Bleed brake system.
3. Worn brake components. 3. Repair as necessary.
VEHICLE LEADS OR DRIFTS
FROM STRAIGHT AHEAD
DIRECTION ON UNCROWNED
ROAD.
2. Radial tire lead. 2. Cross front tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align vehicle.
6. Loose or worn steering/
7. Cross caster out of spec. 7. Adjust or replace axle as
necessary.
DIAGNOSIS AND TESTING - STEERING FLOW
AND PRESSURE
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the gal l ons per mi nute (GPM) or
fl ow rate of the power steeri ng pump al ong wi th the
maxi mum rel i ef pressure. Perform test any ti me a
power steeri ng system probl em i s present. Thi s test
wi l l determi ne i f the power steeri ng pump or power
steeri ng gear i s not functi oni ng properl y. The fol l ow-
i ng pressure and fl ow test i s performed usi ng Power
Steeri ng Anal yzer Tool ki t 6815 (Fi g. 2) and Adapter
Ki t 6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to Tube 6865.
(3) Connect Adapter 6826 to Power Steeri ng Ana-
l yzer test val ve end.
(4) Di sconnect the hi gh pressure hose from the
power steeri ng pump.
(5) Connect Tube 6865 to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to Adapter 6826.
(7) Open the test val ve compl etel y.
Fig. 2 Power Steering Analyzer
1 - TUBE
2 - ADAPTER FITTINGS
3 - ANALYZER
4 - GAUGE HOSE
19 - 4 STEERING WJ
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge.
(9) Shut off the engi ne and check the fl ui d l evel ,
add fl ui d as necessary. Start engi ne agai n and l et
i dl e.
(10) The i ni ti al pressure readi ng shoul d be
345-552 kPa (50-80 psi ). I f pressure i s hi gher i nspect
the hoses for restri cti ons and repai r as necessary.
(11) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. The readi ng shoul d be 2.4 - 2.8
GPM, i f the readi ng i s bel ow thi s speci fi cati on the
pump shoul d be repl aced.
CAUTION: This next step involves testing maximum
pump pressure output and flow control valve oper-
ation. Do not leave valve closed for more than three
seconds as the pump could be damaged.
(12) Cl ose val ve ful l y three ti mes for three seconds
and record hi ghest pressure i ndi cated each ti me. All
three readings must be at pump relief pressure
specifications and within 345 kPa (50 psi) of
each other.
Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 4 seconds at a time
because, pump damage will result.
(13) Open the test val ve and turn the steeri ng
wheel to the extreme l eft and ri ght posi ti ons agai nst
the stops. Record the hi ghest pressure readi ng at
each posi ti on. Compare readi ngs to the pump speci fi -
cati ons chart. I f pressures readi ngs are not wi thi n 50
psi . of each other, the gear i s l eaki ng i nternal l y and
must be repai red.
GEAR INLET SPECIFICATIONS 4.0L & 4.7L
ENGINE
RELIEF
PRESSURE 50
FLOW RATE
(GPM)
4.0L 9653 kPa (1400 psi)
1500 RPM 2.4 - 2.8
GPM
4.7L 9653 kPa (1450 psi)
PUMP MOTOR SPECIFICATIONS 4.7L
ENGINE
RELIEF
PRESSURE 50
FLOW RATE
(GPM)
4.7L 9653 kPa (1900 psi)
1100 RPM 2.4-2.8
GPM Minium
@ 200 psi
DIAGNOSIS AND TESTING - 4. 7L -
HYDRAULIC
The fol l owi ng procedures are used to test the oper-
ati on of the power steeri ng and hydraul i c fan sys-
tems on the vehi cl e. Thi s test wi l l provi de the gal l ons
per mi nute (GPM) or fl ow rate of the power steeri ng
pump al ong wi th any maxi mum rel i ef pressure. Per-
form test anyti me a power steeri ng system probl em
i s present. Thi s test wi l l determi ne i f the power
steeri ng pump, hydraul i c fan, and power steeri ng
gear are not functi oni ng properl y. I t wi l l al so deter-
mi ne i f the fl ow comi ng out of the hydraul i c fan
motor i s suffi ci ent for the power steeri ng gear. The
fol l owi ng pressure and fl ow test i s performed usi ng
the Power Steeri ng Anal yzer Tool ki t 6815 (Fi g. 2)
and Adapter ki t 8630 (Fi g. 3).
FLOW TEST - FLOW FROM POWER STEERING
PUMP
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect the pressure gauge hose from the
Power Steeri ng Anal yzer to Tube 8630-2.
(3) Connect Adapter 8630-3 to Power Steeri ng
Anal yzer test val ve end.
power steeri ng pump.
(5) Connect Tube 8630-2 to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the fan
motor to Adapter 8630-3.
l ate power steeri ng fl ui d through the fl ow/pressure
test gauge.
add fl ui d ass necessary. Start engi ne agai n and l et
i dl e.
(10) The i ni ti al pressure readi ng shoul d be 483 -
690 kPa (70 - 100 psi ). I f pressure i s hi gher i nspect
the hoses for restri cti ons and repai r as necessary.
Fig. 3 4.7L HYDRAULIC POWER STEERING TEST
ADAPTERS
WJ STEERING 19 - 5
(11) I ncrease the engi ne speed to 1100 rpm and
read the fl ow meter. The readi ng shoul d be 2.6 GPM
mi ni mum, i f the readi ng i s bel ow thi s speci fi cati on,
the pump shoul d be repl aced.
FLOW AND PRESSURE TEST - FLOW FROM
HYDRAULIC FAN MOTOR TO STEERING GEAR
(should be done if necessary after the Pump flow
test)
(1) Connect the pressure gauge hose from the
Power Steeri ng Anal yzer to Fi tti ng 8630-1.
(2) Connect Adapter 8630-4 to Power Steeri ng
Anal yzer test val ve end.
power steeri ng gear.
(4) Connect Fi tti ng 8630-1 to the hi gh pressure
hose.
(5) Connect Adapter 8630-4 to the power steeri ng
gear.
l ate power steeri ng fl ui d through the fl ow/pressure
test gauge.
add fl ui d ass necessary. Start engi ne agai n and l et
i dl e.
(9) The i ni ti al pressure readi ng shoul d be 345-552
kPa (50-80 psi ). I f pressure i s hi gher i nspect the
hoses for restri cti ons and repai r as necessary.
(10) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. The readi ng shoul d be 2.4 - 2.8
GPM i f the readi ng i s bel ow thi s speci fi cati on the fan
CAUTION: This next step involves testing maximum
fan motor steering relief pressure. Do not leave the
valve closed for more than three seconds.
(11) Cl ose the val ve ful l y three ti mes for three sec-
onds and record hi ghest pressures i ndi cated each
ti me. Al l three readi ngs must be at fan motor steer-
i ng rel i ef pressures.
(12) Open the test val ve and turn the steeri ng
wheel to the extreme l eft and ri ght posi ti ons agai nst
the stops. Record the hi ghest pressure readi ngs at
each posi ti on. I f pressure readi ngs are not wi thi n 50
psi from each other, the gear i s l eaki ng i nternal l y
and must be repai red.
PUMP MOTOR SPECIFICATIONS 4.7L
ENGINE
RELIEF
PRESSURE 50
FLOW RATE
(GPM)
4.7L 9653 kPa (1900 psi)
1100 RPM 2.4-2.8
GPM Minium
@ 200 psi
19 - 6 STEERING WJ
COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION
SERVICE WARNINGS AND CAUTIONS . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS
STEERING COLUMN . . . . . . . . . . . . . . . . . . . 12
IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - IGNITION
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL
IGNITION SWITCH REMOVAL . . . . . . . . . . . . 13
INSTALLATION
IGNITION SWITCH INSTALLATION . . . . . . . . 13
KEY-IN IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . 14
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
STEERING WHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
COLUMN
DESCRIPTION
SERVICE WARNINGS AND CAUTIONS
DESCRIPTION
The ti l t col umn (Fi g. 1) has been desi gned to be
servi ced as an assembl y, l ess the wi ri ng, swi tches,
shrouds, steeri ng wheel , etc. Most steeri ng col umn
components can be servi ced wi thout removi ng the
steeri ng col umn from the vehi cl e.
To servi ce the steeri ng wheel , swi tches or ai r-
bag,(Refer to 8 - ELECTRI CAL/RESTRAI NTS -
WARNI NG).
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Safety goggles should be worn at all
times when working on steering columns.
Fig. 1 Steering Column
WJ COLUMN 19 - 7
REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. FAILURE TO DO SO MAY RESULT IN ACCI-
DENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY.(Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(1) Posi ti on front wheel s strai ght ahead.
(2) Di sconnect and i sol ate the negati ve (ground)
cabl e from the battery.
(3) Remove the ai rbag,(Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - REMOVAL).
(4) Remove the steeri ng wheel nut and remove
wheel wi th Pul l er C-3894-A (Fi g. 2).
NOTE: Ensure the puller jaws are seated in the
pockets (Fig. 3) of the steering wheel armature.
(5) Remove the cl uster bezel by pul l i ng i t from the
i nstrument panel (Fi g. 4).
Fig. 2 Steering Wheel Puller
1 - PULLER
2 - STEERING WHEEL
Fig. 3 Steering Wheel Pockets
1 - STEERING WHEEL POCKETS
Fig. 4 Cluster Bezel
1 - CLUSTER
2 - CLUSTER BEZEL
3 - STEERING COLUMN
4 - KNEE BLOCKER COVER
19 - 8 COLUMN WJ
COLUMN (Continued)
(6) Remove the knee bl ocker cover (Fi g. 5),(Refer
to 23 - BODY/I NSTRUMENT PANEL - REMOVAL).
(7) Remove the l ower steeri ng col umn shroud
mounti ng screw (Fi g. 6).
(8) Unsnap the two hal ves of the col umn shrouds
by pressi ng on the si des of the upper shroud and ti l t-
i ng the rear of the upper shroud up. Remove the
shrouds from the steeri ng col umn (Fi g. 7).
(9) Remove the upper fi xed shroud mounti ng
screws and remove the shroud (Fi g. 8).
Fig. 5 Knee Blocker Cover
1 - STEERING COLUMN
2 - KNEE BLOCKER COVER
Fig. 6 Column Shroud Mounting Screw
1 - LOWER SHROUD
2 - ACCESS HOLE
Fig. 7 Column Shrouds
1 - UPPER SHROUD
2 - LOWER SHROUD
Fig. 8 Upper Fixed Shroud
1 - UPPER FIXED SHROUD
2 - COLUMN
WJ COLUMN 19 - 9
COLUMN (Continued)
(10) Di sconnect the mul ti fucti on swi tch (Fi g. 9)
and i gni ti on swi tch harness.
(11) Remove the mul ti fucti on swi tch screw from
underneath the swi tch (Fi g. 10). Sl i de the mul ti fuc-
ti on swi tch and cl ock spri ng off the col umn as an
assembl y (Fi g. 11).
(12) Turn the i gni ti on key to the on posi ti on then
rel ease and remove the shi fter i nterl ock cabl e (Fi g.
12) from the i gni ti on l ock cyl i nder housi ng.
Fig. 9 Multifuction Switch Harness
1 - MULTIFUNCTION SWITCH
2 - MULTIFUNCTION SWITCH HARNESS
Fig. 10 Multifuction
1 - CLOCK SPRING
2 - SCREW
Fig. 11 Multifuction Switch And Clock Spring
1 - MULTI-FUNCTION SWITCH ASSEMBLY
2 - CLOCKSPRING
Fig. 12 Shifter Interlock Cable
1 - LOCK CYLINDER HOUSING
2 - INTERLOCK CABLE
19 - 10 COLUMN WJ
COLUMN (Continued)
(13) Remove the col umn coupl er bol t (Fi g. 13) and
sl i de the coupl er off the col umn shaft.
(14) Remove the col umn mounti ng nuts (Fi g. 13)
and l ower col umn off mounti ng studs. Remove the
col umn from the vehi cl e.
(15) Remove the i gni ti on swi tch, cyl i nder and
SKI M, (Refer to 19 - STEERI NG/COLUMN/LOCK
CYLI NDER HOUSI NG - REMOVAL). (Fi g. 14).
INSTALLATION
WARNING: BEFORE SERVICING THE STEERING COL-
UMN THE AIRBAG SYSTEM MUST BE DISARMED.
FAILURE TO DO SO MAY RESULT IN ACCIDENTAL
DEPLOYMENT OF THE AIRBAG AND POSSIBLE PER-
SONAL INJURY. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - INSTALLATION).
(1) I nstal l the i gni ti on swi tch, cyl i nder and SKI M-
,(Refer to 19 - STEERI NG/COLUMN/I GNI TI ON
SWI TCH - I NSTALLATI ON).
(2) I nstal l the col umn i nto the vehi cl e and l i ft the
col umn up onto the mounti ng studs. I nstal l the
mounti ng nuts and ti ghten to 12 Nm (105 i n. l bs.).
(3) Sl i d the coupl er onto the col umn shaft and
i nstal l the coupl er bol t. Ti ghten the coupl er bol t to 49
Nm (36 ft. l bs.).
(4) Turn the i gni ti on key to the on posi ti on then
rel ease and i nstal l the shi fter i nterl ock cabl e (Fi g.
12) i nto i gni ti on l ock cyl i nder housi ng.
(5) Veri fy i gni ti on swi tch and shi fter i nterl ock
operati on.,(Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C - 42RE/GEAR SHI FT CABLE -
ADJUSTMENTS).
(6) Sl i de the mul ti fucti on swi tch and cl ock spri ng
onto the col umn as an assembl y (Fi g. 11).
(7) I nstal l the mul ti fucti on swi tch mounti ng screw
(Fi g. 10).
(8) Connect the mul ti fucti on swi tch (Fi g. 9) and
i gni ti on swi tch harness.
(9) I nstal l the upper fi xed shroud and mounti ng
screws (Fi g. 8).
(10) I nstal l the l ower steeri ng col umn shroud to
the steeri ng col umn. I nstal l and ti ghten the mount-
i ng screw.
(11) I nstal l the upper col umn shroud. Al i gn the
upper shroud to the l ower shroud and snap the two
shroud hal ves together.
(12) I nstal l the knee bl ocker cover (Fi g. 5),(Refer
to 23 - BODY/I NSTRUMENT PANEL - I NSTALLA-
TI ON).
(13) I nstal l the cl uster bezel by i nserti ng i t i nto
the i nstrument panel (Fi g. 4).
(14) Al i gn the steeri ng wheel wi th the col umn
i ndex spl i ne and i nstal l the wheel on the col umn
shaft. Pul l the cl ockspri ng wi re harness through the
steeri ng wheel armature spokes.
(15) I nstal l and ti ghten the steeri ng wheel mount-
i ng nut to 61 Nm (45 ft. l bs.).
(16) Connect the steeri ng wheel wi re harness con-
nector to the cl ock spri ng connector.
(17) I nstal l the ai rbag,(Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - I NSTALLATI ON).
(18) Connect the negati ve (ground) cabl e to the
battery.
Fig. 13 Column Coupler Bolt And Mounting Nuts
1 - COLUMN MOUNTING NUTS
2 - COUPLER BOLT
Fig. 14 Ignition Switch And SKIM
1 - SKIM
2 - IGNITION SWITCH
WJ COLUMN 19 - 11
COLUMN (Continued)
SPECIFICATIONS
TORQUE CHART
Steering Column
Steering Wheel Nut
61 45
Steering Column
Column Bracket Nuts
12 105
Steering Column
Shaft Coupler Bolts
49 36
SPECIAL TOOLS
STEERING COLUMN
IGNITION SWITCH
DESCRIPTION
The el ectri cal i gni ti on swi tch i s l ocated on the
steeri ng col umn. I t i s used as the mai n on/off swi tch-
i ng devi ce for most el ectri cal components. The
mechani cal key l ock cyl i nder i s used to engage/di sen-
gage the el ectri cal i gni ti on swi tch.
DIAGNOSIS AND TESTING - IGNITION SWITCH
ELECTRICAL DIAGNOSIS
For i gni ti on swi tch el ectri cal schemati cs, refer to
I gni ti on Swi tch i n Wi ri ng Di agrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
Vehicles equipped with an automatic trans-
mission and a floor mounted shifter: a cabl e i s
used to connect the i nterl ock devi ce i n the steeri ng
col umn assembl y, to the transmi ssi on fl oor shi ft
l ever. Thi s i nterl ock devi ce i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s rotated to the LOCKED or ACCES-
SORY posi ti on. The i nterl ock devi ce wi thi n the steer-
i ng col umn i s not servi ceabl e. I f repai r i s necessary,
the steeri ng col umn assembl y must be repl aced,(Re-
fer to 19 - STEERI NG/COLUMN - REMOVAL).
I f the i gni ti on key i s di ffi cul t to rotate to or from
the LOCK or ACCESSORY posi ti on, i t may not be
the faul t of the key cyl i nder or the steeri ng col umn
components. The brake transmi ssi on shi ft i nterl ock
cabl e may be out of adjustment,(Refer to 21 -
TRANSMI SSI ON/TRANSAXLE/AUTOMATI C -
44RE/SHI FT I NTERLOCK MECHANI SM - ADJUST-
MENTS) .
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an i nterl ock devi ce i s l ocated wi thi n the steeri ng col -
umn. Thi s i nterl ock devi ce i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s i n the LOCKED or ACCESSORY
posi ti on. I f i t i s di ffi cul t to rotate the key to or from
the LOCK or ACCESSORY posi ti on, the i nterl ock
devi ce wi thi n the steeri ng col umn may be defecti ve.
Thi s devi ce i s not servi ceabl e. I f repai r i s necessary,
the steeri ng col umn assembl y must be repl aced,(Re-
fer to 19 - STEERI NG/COLUMN - REMOVAL).
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter: on certai n mod-
el s, a l ever i s l ocated on the steeri ng col umn behi nd
the i gni ti on key l ock cyl i nder. The l ever must be
manual l y operated to al l ow rotati on of the i gni ti on
key l ock cyl i nder to the LOCK or ACCESSORY posi -
ti on. I f i t i s di ffi cul t to rotate the key to the LOCK or
ACCESSORY posi ti on, the l ever mechani sm may be
defecti ve. Thi s mechani sm i s not servi ceabl e. I f
repai r i s necessary, the steeri ng col umn assembl y
must be repl aced,(Refer to 19 - STEERI NG/COL-
UMN - REMOVAL).
On other model s, the i gni ti on key cyl i nder must be
depressed to al l ow i t to be rotated i nto the LOCK or
ACCESSORY posi ti on. I f i t i s di ffi cul t to rotate the
key to the LOCK or ACCESSORY posi ti on, the l ock
mechani sm wi thi n the steeri ng col umn may be defec-
ti ve. Thi s mechani sm i s not servi ceabl e. I f repai r i s
Puller C-3894-A
19 - 12 COLUMN WJ
COLUMN (Continued)
necessary, the steeri ng col umn assembl y must be
repl aced,(Refer to 19 - STEERI NG/COLUMN -
REMOVAL).
REMOVAL
IGNITION SWITCH REMOVAL
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
(1) Remove key cyl i nder. Refer to previ ous steps.
(2) Remove l ower steeri ng col umn cover screws
and remove cover (Fi g. 19).
(3) Remove i gni ti on swi tch mounti ng screw (Fi g.
17). Use tamper proof torx bi t to remove the screw.
(4) Usi ng a smal l screwdri ver, push on l ocki ng tab
(Fi g. 15) and remove swi tch from steeri ng col umn.
(5) Di sconnect two el ectri cal connectors at rear of
i gni ti on swi tch (Fi g. 17).
INSTALLATION
IGNITION SWITCH INSTALLATION
(1) Before i nstal l i ng i gni ti on swi tch, rotate the sl ot
i n the swi tch to the ON posi ti on (Fi g. 16).
(2) Connect two el ectri cal connectors to rear of
i gni ti on swi tch. Make sure that l ocki ng tabs are ful l y
seated i nto wi ri ng connectors.
(3) Posi ti on swi tch to col umn and i nstal l tamper
proof screw. Ti ghten screw to 3 Nm (26 i n. l bs.).
(4) I nstal l steeri ng col umn l ower cover.
Fig. 15 Ignition Switch Lock Tab
1 - LOCK TAB
2 - IGNITION SWITCH
3 - SCREWDRIVER
Fig. 16 Switch In ON Position
1 - IGNITION SWITCH
2 - ROTATE TO ON POSITION
Fig. 17 Ignition Switch Removal/Installation
1 - TAMPER PROOF SCREW
2 - IGNITION SWITCH
3 - ELECTRICAL CONNECTORS
WJ COLUMN 19 - 13
IGNITION SWITCH (Continued)
DESCRIPTION
The key-i n i gni ti on swi tch i s conceal ed wi thi n and
i ntegral to the i gni ti on swi tch, whi ch i s mounted on
the steeri ng col umn. The key-i n i gni ti on swi tch i s
actuated by the i gni ti on l ock cyl i nder mechani sm,
and i s hard wi red between a body ground and the
Body Control Modul e (BCM) through the i nstrument
panel wi re harness.
The key-i n i gni ti on swi tch cannot be adjusted or
repai red and, i f faul ty or damaged, the enti re i gni -
ti on swi tch uni t must be repl aced,(Refer to 19 -
STEERI NG/COLUMN/LOCK CYLI NDER HOUSI NG
- REMOVAL). For compl ete ci rcui t di agrams, refer to
Body Control Module i n the Contents of Wi ri ng
Di agrams.
OPERATION
The key-i n i gni ti on swi tch cl oses a path to ground
for the BCM when the i gni ti on key i s i nserted i n the
i gni ti on l ock cyl i nder, and opens the ground path
when the key i s removed from the i gni ti on l ock cyl -
i nder. The BCM moni tors the key-i n i gni ti on swi tch
status through an i nternal pul l -up, then sends the
proper swi tch status messages to other el ectroni c
I nterface (PCI ) data bus network. The key-i n i gni ti on
swi tch status i s al so used by the BCM as an i nput
for chi me warni ng system operati on.
For compl ete ci rcui t di agrams, refer to Body Con-
trol Module i n the Contents of Wi ri ng Di agrams.
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
INJURY.
connector from the key-i n i gni ti on swi tch connector
receptacl e on the i gni ti on swi tch. Check for conti nu-
i ty between the key-i n i gni ti on swi tch sense and
ground termi nal s of the key-i n i gni ti on swi tch con-
nector receptacl e. There shoul d be conti nui ty wi th
the key i nserted i n the i gni ti on l ock cyl i nder, and no
conti nui ty wi th the key removed from the i gni ti on
l ock cyl i nder. I f OK, go to Step 2. I f not OK, repl ace
the faul ty i gni ti on swi tch uni t.
nector for the key-i n i gni ti on swi tch and a good
as requi red.
(3) Di sconnect the gray 26-way i nstrument panel
wi re harness connector from the Body Control Mod-
ul e (BCM) connector receptacl e. Check for conti nui ty
between the key-i n i gni ti on swi tch sense ci rcui t cav-
i ty of the i nstrument panel wi re harness connector
for the key-i n i gni ti on swi tch and a good ground.
There shoul d be no conti nui ty. I f OK, go to Step 4. I f
not OK, repai r the shorted key-i n i gni ti on swi tch
sense ci rcui t as requi red.
(4) Check for conti nui ty between the key-i n i gni -
ti on swi tch sense ci rcui t cavi ti es of the i nstrument
panel wi re harness connector for the key-i n i gni ti on
swi tch and the gray 26-way i nstrument panel wi re
not OK, repai r the open key-i n i gni ti on swi tch sense
LOCK CYLINDER
REMOVAL
(2) I f equi pped wi th an automati c transmi ssi on,
pl ace shi fter i n PARK posi ti on.
(3) Rotate key to ON posi ti on.
19 - 14 COLUMN WJ
(4) A rel ease tang i s l ocated on bottom of key cyl -
i nder (Fi g. 18).
(5) Posi ti on a smal l screwdri ver or pi n punch i nto
tang access hol e on bottom of steeri ng col umn l ower
cover (Fi g. 19).
(6) Push the pi n punch up whi l e pul l i ng key cyl i n-
der from steeri ng col umn.
INSTALLATION
(1) I f equi pped wi th an automati c transmi ssi on,
pl ace shi fter i n PARK posi ti on.
(2) Posi ti on key cyl i nder i nto steeri ng col umn as i t
woul d normal l y be i n the ON posi ti on.
(3) Press key cyl i nder i nto col umn unti l i t snaps
i nto posi ti on.
(4) Check mechani cal operati on of swi tch. Auto-
matic Transmission: Be sure transmi ssi on l ever i s
l ocked i n PARK posi ti on after key removal . I f key i s
di ffi cul t to rotate or i s di ffi cul t to remove, the shi ft
l ever-to-steeri ng col umn cabl e may be out of adjust-
ment or defecti ve. Refer to Transmi ssi on for proce-
dures. Manual Transmission: Be sure key cannot
be removed unti l rel ease l ever i s operated. I f key can
be removed, rel ease l ever mechani sm may be defec-
ti ve. Rel ease l ever mechani sm i s not servi ced sepa-
ratel y. I f repai r i s necessary, the steeri ng col umn
must be repl aced,(Refer to 19 - STEERI NG/COL-
UMN - REMOVAL).
(6) Check el ectri cal operati on of swi tch.
STEERING WHEEL
REMOVAL
For steeri ng wheel removal procedure,(Refer to 8 -
REMOVAL).
INSTALLATION
For steeri ng wheel i nstal l ati on procedure,(Refer to
8 - ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
I NSTALLATI ON).
Fig. 18 Key Cylinder Release Tang
1 - KEY CYLINDER
2 - RELEASE TANG
Fig. 19 Key Cylinder and Cover Removal
1 - LOWER COVER
2 - ACCESS HOLE
3 - PIN PUNCH
4 - COVER SCREWS (3)
WJ COLUMN 19 - 15
LOCK CYLINDER (Continued)
GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
ADJUSTMENTS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
POWER STEERING GEAR . . . . . . . . . . . . . . 18
SPECIAL TOOLS
POWER STEERING GEAR . . . . . . . . . . . . . . 19
PITMAN SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
PITMAN SHAFT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
PITMAN SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
RACK PISTON/VALVE ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
STUB SHAFT HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
GEAR
DESCRIPTION
The power steeri ng gear i s a reci rcul ati ng bal l type
gear (Fi g. 1) .
The fol l owi ng gear components can be servi ced:
Pi tman Shaft and Cover
Pi tman Shaft Beari ngs
Pi tman Shaft Oi l Seal /Dust Seal
Stud Shaft Housi ng wi th Seal
O-Ri ngs and Tefl on Ri ngs
NOTE: If rack piston assembly is damaged the gear
must be replaced.
OPERATION
The gear acts as a rol l i ng thread between the
worm shaft and rack pi ston. The worm shaft i s sup-
ported by a thrust beari ng at the l ower end and a
beari ng assembl y at the upper end. When the worm
shaft i s turned the rack pi ston moves. The rack pi s-
ton teeth mesh wi th the pi tman shaft. Turni ng the
worm shaft turns the pi tman shaft, whi ch turns the
steeri ng l i nkage.
REMOVAL
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on wi th the steeri ng wheel centered and l ocked.
(2) Remove the ai r cl eaner housi ng,(Refer to 9 -
(3) Drai n or si phon the power steeri ng system.
(4) Remove the pressure and return l i nes (Fi g.
2)from the steeri ng gear. Refer to hose removal i n
thi s secti on.
(5) Remove the col umn coupl er shaft bol t (Fi g.
2)and remove the shaft from the gear.
(7) Remove the l eft front wheel and ti re assembl y.
(8) Remove the pi tman arm from gear wi th Pul l er
C-4150A.
(9) Remove the wi ndshi el d washer reservoi r,(Refer
to 8 - ELECTRI CAL/WI PERS/WASHERS/WASHER
RESERVOI R - REMOVAL).
(10) Remove the steeri ng gear mounti ng bol ts.
Remove the steeri ng gear out of the engi ne compart-
ment (Fi g. 3).
INSTALLATION
(1) Posi ti on the steeri ng gear on the frame rai l and
i nstal l the bol ts. Ti ghten the bol ts to 108 Nm (80 ft.
l bs.) torque.
(2) I nstal l the pi tman arm and ti ghten nut to 251
Nm (185 ft. l bs.).
(3) I nstal l wi ndshi el d washer reservoi r,(Refer to 8 -
ELECTRI CAL/WI PERS/WASHERS/WASHER RES-
ERVOI R - I NSTALLATI ON).
(4) I nstal l the wheel and ti re assembl y.
(6) I nstal l the pressure and return hoses to the
steeri ng gear and ti ghten to 20-38 Nm (14-28 ft.
l bs.).
(7) I nstal l the col umn coupl er shaft.
(8) I nstal l the ai r cl eaner housi ng,(Refer to 9 -
19 - 16 GEAR WJ
(9) Fi l l the power steeri ng pump (Refer to 19 -
STEERI NG/PUMP - STANDARD PROCEDURE).
Fig. 1 Recirculating Ball Type Gear
1 - ADJUSTER NUT
2 - COVER
3 - PITMAN SHAFT
4 - O-RING
5 - BEARING
6 - GEAR HOUSING
7 - RACK PISTON
8 - RETAINING RING
9 - O-RING
10 - BEARING
11 - STUB SHAFT HOUSING
12 - PITMAN SHAFT SEAL
13 - PLASTIC BACKUP WASHER
14 - METAL BACKUP WASHER
15 - RETAINING RING
16 - DUST SEAL
Fig. 2 Pressure And Return Lines
1 - PRESSURE LINE
2 - RETURN LINE
3 - COUPLER BOLT
4 - STEERING GEAR
Fig. 3 Steering Gear Mounting
1 - MOUNTING BOLTS
2 - PITMAN SHAFT
3 - STABILIZER BAR
WJ GEAR 19 - 17
GEAR (Continued)
ADJ USTMENTS
STEERING GEAR
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
OVER-CENTER
(1) Rotate the stub shaft wi th Socket 8343 from
stop to stop and count the number of turns.
(2) Center the stub shaft by rotati ng i t from the
stop 1/2 of the total amount of turns.
(3) Pl ace torque wrench and Socket 8343 i n a ver-
ti cal posi ti on on the stub shaft. Rotate the wrench 45
degrees each si de of the center and record the hi gh-
est rotati onal torque i n thi s range (Fi g. 4) . Thi s i s
the Over-Center Rotati ng Torque.
NOTE: The stub shaft must rotate smoothly without
sticking or binding.
(4) Rotate the stub shaft between 90 and 180 to
the l eft of center and record the l eft off-center pre-
l oad. Repeat thi s to the ri ght of center and record the
ri ght off-center prel oad. The average of these two
recorded readi ngs i s the Prel oad Rotati ng Torque.
(5) The Over-Center Rotati ng Torque shoul d be
0.45-0.80 Nm (4-7 i n. l bs.) higher than the Prel oad
Rotati ng Torque.
(6) I f an adjustment to the Over-Center Rotati ng
Torque i s necessary, fi rst l oosen the adjuster l ock
nut. Then turn the pi tman shaft adjuster screw back
(COUNTERCLOCKWI SE) unti l ful l y extended, then
turn back i n (CLOCKWI SE) one ful l turn.
(7) Remeasure Over-Center Rotati ng Torque. I f
necessary turn the adjuster screw and repeat mea-
surement unti l correct Over-Center Rotati ng Torque
i s reached.
NOTE: To increase the Over-Center Rotating Torque
turn the screw CLOCKWISE.
(8) Prevent the adjuster screw from turni ng whi l e
ti ghteni ng adjuster l ock nut. Ti ghten the adjuster
l ock nut to 37-52 Nm (27-38 ft. l bs.).
SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
Steering Gear
Type
Recirculating Ball
Steering Gear
Overall Ratio
12.7:1
Pitman Shaft Overcenter Drag
New Gear (under 400 miles)
0.45-0.80
+ Worm Shaft Preload
4-7
Pitman Shaft Overcenter Drag
Used Gear (over 400 miles)
0.5-0.6
4-5
Fig. 4 Checking Over-center Rotation Torque
1 - CENTER
19 - 18 GEAR WJ
GEAR (Continued)
SPECIAL TOOLS
POWER STEERING GEAR
Puller Seal 7794-A
Slide Hammer C-637
Remover, Pitman Arm C-4150A
Handle C-4171
Driver 8277
Driver 8294
Scoket 8343
WJ GEAR 19 - 19
GEAR (Continued)
PITMAN SHAFT
REMOVAL
(1) Cl ean exposed end of pi tman shaft and housi ng
wi th a wi re brush.
(2) Rotate the stub shaft wi th a wrench (Fi g.
5)from stop to stop and count the number of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pi tman shaft cover bol ts and remove
the shaft assembl y (Fi g. 6).
(5) Remove pi tman shaft cover o-ri ng.
(6) Remove pi tman shaft dust seal from the hous-
i ng wi th a Pul l er 7794-A and Sl i de Hammer C-637
(Fi g. 7).
(7) Remove the pi tman shaft oi l seal retai ni ng ri ng
wi th snap ri ng pl i ers (Fi g. 8).
(8) Remove oi l seal metal backup washer then
pl asti c backup washer from the housi ng.
(9) Remove pi tman shaft oi l seal from the housi ng
wi th a Pul l er 7794-A and Sl i de Hammer C-637 (Fi g.
7).
(10) Drop Dri ver 8277 through the top beari ng and
al i gn the dri ver up wi th the l ower beari ng. (Fi g. 9).
I nstal l Handl e C-4171 i nto the dri ver and remove the
l ower beari ng.
(11) Turn the gear over and remover the upper
beari ng wi th Dri ver 8277 and Handl e C-4171.
INSTALLATION
(1) I nstal l upper pi tman shaft beari ng, wi th Dri ver
8294 and Handl e C-4171 (Fi g. 10). Dri ve beari ng i nto
housi ng unti l the dri ver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
Fig. 5 Center Stub
1 - WRENCH
2 - STUB SHAFT
Fig. 6 Cover and Pitman Shaft
1 - ADJUSTER NUT
2 - PITMAN SHAFT COVER
3 - O-RING
4 - GEAR HOUSING
5 - PITMAN SHAFT
Fig. 7 Oil Seal Removal
1 - PULLER
2 - STEERING GEAR
19 - 20 GEAR WJ
(2) I nstal l l ower pi tman shaft beari ng wi th the
other si de Dri ver 8294 and Handl e C-4171 (Fi g. 11).
Dri ve beari ng i nto housi ng unti l the beari ng shoul der
i s seated agai nst the housi ng.
(3) Coat the oi l seal and backup washers wi th spe-
cial greasesuppl i ed wi th the new seal .
(4) I nstal l the oi l seal wi th Dri ver 8294 and Han-
dl e C-4171.
(5) I nstal l pl asti c backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) I nstal l metal backup washer.
(7) I nstal l the retai ner ri ng wi th snap ri ng pl i ers.
(8) Coat the dust seal wi th special grease sup-
pl i ed wi th the new seal .
(9) I nstal l dust seal wi th Dri ver 8294 and Handl e
C-4171.
(10) I nstal l new pi tman shaft cover o-ri ng.
(11) I nstal l pi tman shaft assembl y i nto the hous-
i ng.
(12) I nstal l cover bol ts and ti ghten to 62 Nm (46
ft. l bs.).
(13) Perform over-center rotati on torque adjust-
ment.
Fig. 8 Oil Seal Retaining Ring
1 - SNAP RING PLIERS
2 - RETAINING RING
Fig. 9 Bearing Driver
1 - UPPER BEARING
2 - LOWER BEARING
3 - DRIVER
Fig. 10 Upper Pitman Shaft Bearing
1 - DRIVER
2 - UPPER BEARING
Fig. 11 Lower Pitman Shaft Bearing
1 - STEERING GEAR
2 - BEARING SHOULDER
3 - DRIVER
4 - LOWER BEARING
WJ GEAR 19 - 21
PITMAN SHAFT (Continued)
PITMAN SHAFT BEARING
REMOVAL
it is not centered.
(Fi g. 7).
pl asti c backup washer from the housi ng (Fi g. 12).
wi th a Pul l er 7794-A and Sl i de Hammer C-637 (Fi g. 7).
l ower beari ng.
INSTALLATION
dl e C-4171.
seal.
C-4171.
i ng.
ft. l bs.).
ment.
PITMAN SHAFT SEAL
REMOVAL
it is not centered.
(Fi g. 7).
pl asti c backup washer from the housi ng (Fi g. 12).
Fig. 12 Backup Washers
1 - METAL BACK UP WASHER
2 - PLASTIC BACK UP WASHER
19 - 22 GEAR WJ
wi th a Pul l er 7794-A and Sl i de Hammer C-637 (Fi g.
7).
l ower beari ng.
INSTALLATION
dl e C-4171.
seal.
C-4171.
i ng.
ft. l bs.).
ment.
RACK PISTON/VALVE
ASSEMBLY
REMOVAL
(1) Remove the steeri ng gear (Refer to 19 -
STEERI NG/GEAR - REMOVAL).
it is not centered.
(6) Remove the pi tman shaft cover o-ri ng.
(7) Remove stub shaft housi ng bol ts (Fi g. 13).
(8) Remove the housi ng from the stub shaft (Fi g.
14).
Fig. 13 Stub Shaft Housing
2 - BOLTS
3 - STUB SHAFT
Fig. 14 Housing Removal
1 - STEERING GEAR
WJ GEAR 19 - 23
PITMAN SHAFT SEAL (Continued)
(9) Remove stub shaft housi ng o-ri ngs (Fi g. 15).
(10) Remove the rack pi ston/val ve assembl y retai n-
i ng ri ng wi th snap ri ng pl i ers (Fi g. 16).
(11) Pul l the rack pi ston/val ve assembl y out of the
gear housi ng (Fi g. 17).
NOTE: If the rack piston is damage the gear assem-
bly must be replaced.
(12) Remove tefl on ri ngs and o-ri ng (Fi g. 18) from
the rack pi ston/val ve assembl y.
CAUTION: The rack piston teflon ring and o-ring
must be replaced whenever the assembly is
removed from the housing.
Fig. 15 O-Rings
1 - LARGE O-RING
2 - SMALL O-RING
Fig. 16 Retaining Ring
1 - SNAP RING
3 - STUB SHAFT
Fig. 17 Rack Piston/Valve Assembly
1 - STEERING GEAR
2 - RACK PISTON/VALVE ASSEMBLY
Fig. 18 Teflon Rings And O-Ring
1 - RACK PISTON
2 - VALVE
3 - TEFLON RINGS
4 - TEFLON AND O-RING
19 - 24 GEAR WJ
RACK PISTON/VALVE ASSEMBLY (Continued)
INSTALLATION
(1) Lubri cate new o-ri ng and tefl on ri ngs wi th
power steeri ng fl ui d and i nstal l on the rack pi ston/
val ve assembl y.
(2) Lubri cate the rack pi ston/val ve assembl y wi th
power steeri ng fl ui d.
(3) Sl i de the assembl y i nto the gear housi ng.
(4) I nstal l new stub shaft housi ng o-ri ngs and
i nstal l the housi ng. Ti ghten the housi ng bol ts to 62
Nm (46 ft. l bs.).
(5) I nstal l new o-ri ng on the pi tman shaft cover.
(6) I nstal l the pi tman shaft i nto the gear housi ng.
(7) I nstal l the pi tman shaft cover bol ts and ti ghten
to 62 Nm (46 ft. l bs.).
(8) Perform over-center rotati on torque adjustment
(Refer to 19 - STEERI NG/GEAR - ADJUSTMENTS)..
(9) I nstal l the steeri ng gear (Refer to 19 - STEER-
I NG/GEAR - I NSTALLATI ON).
STUB SHAFT HOUSING
REMOVAL
NOTE: If stub shaft housing, seal or bearing is dam-
aged the housing must be replaced.
(1) Remove the steeri ng gear (Refer to 19 -
STEERI NG/GEAR - REMOVAL).
(2) Remove stub shaft housi ng bol ts (Fi g. 19).
(3) Remove housi ng from the steeri ng gear (Fi g.
20).
(4) Remove stub shaft housi ng o-ri ngs (Fi g. 15).
INSTALLATION
NOTE: If stub shaft housing, seal or bearing is dam-
aged the housing must be replaced.
(1) Grease stub shaft seal wi th special grease-
suppl i ed wi th new stub shaft housi ng.
(2) I nstal l new stub shaft housi ng o-ri ngs.
(3) I nstal l housi ng on the steeri ng gear.
(4) I nstal l the housi ng bol ts and ti ghten to 62 Nm
( 46 ft. l bs.).
(5) I nstal l the steeri ng gear (Refer to 19 - STEER-
I NG/GEAR - I NSTALLATI ON).
Fig. 19 Stub Shaft Housing
2 - BOLTS
3 - STUB SHAFT
Fig. 20 Housing Removal
1 - STEERING GEAR
2 - HOUSING
WJ GEAR 19 - 25
RACK PISTON/VALVE ASSEMBLY (Continued)
LINKAGE
TABLE OF CONTENTS
page page
LINKAGE
DESCRIPTION
STEERING LINKAGE RIGHT HAND DRIVE
(RHD) VEHICLES. . . . . . . . . . . . . . . . . . . . . . 26
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 28
SPECIAL TOOLS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . 28
DAMPER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
DRAG LINK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
PITMAN ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
TIE ROD END
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
LINKAGE
DESCRIPTION
STEERING LINKAGE RIGHT HAND DRIVE
(RHD) VEHICLES
Vehi cl es equi pped wi th ri ght hand dri ve (RHD)
steeri ng uti l i ze the same components of l eft hand
dri ve vehi cl es. The RHD Steeri ng l i nkage i s desi gned
as a mi rror i mage of l eft hand dri ve l i nkage wi th the
excepti on of the steeri ng damper (Fi g. 1), whi ch i s
mounted on the same si de of the vehi cl e weather
RHD or LHD. See fi gure bel ow for reference. Al l
speci fi cati ons are the same as LHD. Refer to Group
19, Steeri ng of the gasol i ne engi ne servi ce manual for
addi ti onal i nformati on.
DESCRIPTION
The steeri ng l i nkage consi sts of a pi tman arm,
drag l i nk, ti e rod, and steeri ng dampener (Fi g. 2) .
An adjustment sl eeve on the ti e rod i s used to set
wheel toe posi ti on. The sl eeve on the drag l i nk i s
used for steeri ng wheel centeri ng.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
19 - 26 LINKAGE WJ
Fig. 1 Right Hand Drive Steering Linkage
1 - PITMAN ARM
2 - STEERING DAMPENER
Fig. 2 Steering Linkage
1 - DRAG LINK
2 - PITMAN ARM
3 - TIE ROD END
4 - TIE ROD
5 - DAMPER
6 - TIE ROD END
WJ LINKAGE 19 - 27
LINKAGE (Continued)
SPECIFICATIONS
TORQUE CHART
Pitman Arm
Shaft Nut
251 185
Drag Link
Pitman Arm Nut
88 65
Drag Link
Knuckle Nut
47 35
Drag Link
Clamp Nuts
41 30
Tie Rod
Knuckle Nut
47 35
Tie Rod
Clamp Nuts
41 30
Steering Damper
Axle Bolt
88 65
Steering Damper
Tie Rod Nut
41 30
SPECIAL TOOLS
STEERING LINKAGE
DAMPER
DESCRIPTION
The damper i s mounted to the axl e housi ng and
the ti e rod end. The damper consi sts of steel tube
shock absorber wi th a permanent bushed end.
OPERATION
The steeri ng damper provi des steeri ng system
dampi ng.
REMOVAL
(1) Remove the nut from the bal l stud at the ti e
rod.
(2) Remove the steeri ng damper from the ti e rod.
(3) Remove the steeri ng damper nut and bol t from
the axl e bracket (Fi g. 3) .
Puller C-3894A
Remover Pitman C-4150A
19 - 28 LINKAGE WJ
LINKAGE (Continued)
INSTALLATION
(1) I nstal l the steeri ng damper to the axl e bracket
and ti e rod.
(2) I nstal l the steeri ng damper bol t i n the axl e
bracket and ti ghten bol t to 88 Nm (65 ft. l bs.).
(3) I nstal l the nut at the ti e rod and ti ghten to 41
Nm (30 ft. l bs.).
DRAG LINK
DESCRIPTION
The drag l i nk and ends are compri sed of two forged
ends connected by a steel adjusti ng tube. The drag
l i nk connects the steeri ng gear pi tman arm to the
steeri ng knuckl e. The l arger offset end i s attached to
the pi tman arm.
OPERATION
The sl eeve i s used for steeri ng wheel centeri ng.
REMOVAL
(2) Remove ri ght wheel and ti re assembl y.
(3) Remove the cotter pi ns and nuts at the ri ght
steeri ng knuckl e and pi tman arm (Fi g. 4) .
(4) Remove the drag l i nk from the steeri ng
knuckl e and pi tman arm Pul l er C-3894-A.
(5) Loosen adjustment sl eeve cl amp bol ts and
unscrew the ti e rod ends from the adjustment sl eeve.
INSTALLATION
(1) Screw the ti e rod ends i nto the adjustment
sl eeve.
(2) I nstal l the drag l i nk onto the ri ght steeri ng
knuckl e and pi tman arm.
(3) Ti ghten the nut at the steeri ng knuckl e to 47
Nm (35 ft. l bs.). Ti ghten the pi tman nut to 88 Nm
(65 ft. l bs.). I nstal l new cotter pi ns.
(4) Posi ti on cl amp bol ts to thei r ori gi nal posi ti on
and ti ghten to 41 Nm (30 ft. l bs.).
(5) I nstal l ri ght wheel and ti re assembl y.
(7) Center the steeri ng wheel .
PITMAN ARM
DESCRIPTION
The pi tman arm i s attached at one end of the
steeri ng gears sector shaft. The other end i s con-
nected to the drag l i nk.
OPERATION
The pi tman arm transfers rotary moti on i nto si de
to si de moti on.
REMOVAL
(1) Remove the cotter pi n and nut from the drag
l i nk at the pi tman arm (Fi g. 5) .
(2) Remove the drag l i nk bal l stud from the pi t-
man arm wi th a pul l er.
(3) Remove the nut and washer from the steeri ng
gear shaft. Mark the pi tman shaft and pi tman arm
for i nstal l ati on reference. Remove the pi tman arm
from steeri ng gear wi th Pul l er C-4150A.
Fig. 3 Steering Damper
1 - DAMPER
2 - TIE ROD
Fig. 4 Drag Link
1 - STEERING GEAR
2 - PITMAN ARM
3 - CLAMP
4 - DRAG LINK
5 - CLAMP
WJ LINKAGE 19 - 29
DAMPER (Continued)
INSTALLATION
(1) Al i gn and i nstal l the pi tman arm on steeri ng
gear shaft.
(2) I nstal l the washer and nut on the shaft and
ti ghten the nut to 251 Nm (185 ft. l bs.).
(3) I nstal l drag l i nk bal l stud to pi tman arm.
I nstal l nut and ti ghten to 88 Nm (65 ft. l bs.). I nstal l
a new cotter pi n.
TIE ROD END
DESCRIPTION
The ends are forged, wi th a l ubed for l i fe bal l
socket.
OPERATION
The ti e rod ends connect the drag l i nk to the wheel
assembl y. The ti e rod provi des toe al i gnment and
transfers steeri ng i nput from the drag l i nk to the
wheel s.
REMOVAL
(3) Remove the damper nut from the ti e rod cl amp
(Fi g. 6).
(4) Remove the damper from the ti e rod.
(5) Remove the cotter pi ns and nuts from the ti e
rod ends at the steeri ng knuckl es (Fi g. 6).
(6) Remove the ti e rod ends from the steeri ng
knuckl es wi th Pul l er C-3894-A..
(7) Loosen the adjustment sl eeve cl amp bol ts and
unscrew the ti e rod ends from the sl eeve.
INSTALLATION
(1) Screw the ti e rod ends i nto the adjustment
sl eeve.
(2) I nstal l the ti e rod on the steeri ng knuckl es and
i nstal l the nuts.
(3) Ti ghten the nuts to 47 Nm (35 ft. l bs.). I nstal l
new cotter pi ns and bend end 60.
(4) Posi ti on the adjustment sl eeve cl amp bol ts to
thei r ori gi nal l ocati on and ti ghten to 41 Nm (30 ft.
l bs.).
(5) I nstal l the damper on the ti e rod and i nstal l
the nut.
(6) Ti ghten the nut to 41 Nm (30 ft. l bs.). I nstal l
new cotter pi ns and bend end 60.
(9) Perform toe posi ti on adjustment.
Fig. 5 Pitman Arm
1 - STEERING GEAR
2 - PITMAN ARM
Fig. 6 Tie Rod Assembly
1 - TIE ROD END
2 - CLAMP
3 - DAMPER
4 - TIE ROD
5 - CLAMP
6 - TIE ROD END
19 - 30 LINKAGE WJ
PITMAN ARM (Continued)
PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION - 4.0L, 4.7L . . . . . . . . . . . . . . . . 32
OPERATION
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . 32
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 33
STANDARD PROCEDURE
STANDARD PROCEDURE - INITIAL
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . 33
STANDARD PROCEDURE - INITIAL
OPERATION - 4.7L . . . . . . . . . . . . . . . . . . . . 33
REMOVAL
REMOVAL - 4.0L ENGINE . . . . . . . . . . . . . . . 34
REMOVAL - 4.7L ENGINE . . . . . . . . . . . . . . . 34
INSTALLATION
INSTALLATION - 4.0L ENGINE . . . . . . . . . . . 34
INSTALLATION - 4.7L ENGINE . . . . . . . . . . . 34
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 35
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . 36
FLUID COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
HOSES - 4.0L
DESCRIPTION
DESCRIPTION - PRESSURE LINE . . . . . . . . 37
DESCRIPTION - RETURN LINE . . . . . . . . . . . 37
OPERATION
OPERATION - PRESSURE LINE . . . . . . . . . . 37
OPERATION - RETURN LINE . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
HOSES - 4.7L
DESCRIPTION
DESCRIPTION - 1/2 PRESSURE HOSE . . . . 38
DESCRIPTION - 1/2 RETURN HOSE . . . . . . 38
DESCRIPTION - 3/8 PRESSURE HOSE . . . . 38
DESCRIPTION - 3/8 GEAR OUTLET HOSE . 38
DESCRIPTION - 3/8 RETURN HOSE . . . . . . 38
OPERATION
OPERATION - 1/2 PRESSURE HOSE . . . . . . 38
OPERATION - 1/2 RETURN HOSE . . . . . . . . 38
OPERATION - 3/8 PRESSURE HOSE . . . . . . 39
OPERATION - 3/8 GEAR OUTLET HOSE . . . 39
OPERATION - 3/8RETURN HOSE . . . . . . . . 39
REMOVAL
REMOVAL - 1/2 PRESSURE HOSE . . . . . . . 39
REMOVAL - 1/2 RETURN HOSE . . . . . . . . . . 39
REMOVAL - 3/8 PRESSURE HOSE . . . . . . . 39
REMOVAL - 3/8 RETURN HOSE . . . . . . . . . . 39
REMOVAL - 3/8 GEAR OUTLET HOSE . . . . . 40
REMOVAL - INLET COOLER HOSE . . . . . . . . 40
REMOVAL - OUTLET COOLER HOSE . . . . . . 40
INSTALLATION
INSTALLATION - 1/2 PRESSURE HOSE . . . . 40
INSTALLATION - 1/2 RETURN HOSE . . . . . . 40
INSTALLATION - 3/8 PRESSURE HOSE . . . . 41
INSTALLATION - 3/8 RETURN HOSE . . . . . . 41
INSTALLATION - 3/8 GEAR OUTLET HOSE . 41
INSTALLATION - INLET COOLER HOSE . . . . 41
INSTALLATION - OUTLET COOLER HOSE . . 41
PULLEY
DESCRIPTION
POWER STEERING PUMP PULLEY - 3.1L
DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
WJ PUMP 19 - 31
PUMP
DESCRIPTION - 4. 0L, 4. 7L
Hydraul i c pressure for the power steeri ng system
i s provi ded by a bel t dri ven power steeri ng pump
(Fi g. 1) and (Fi g. 2). The pump shaft has a
pressed-on dri ve pul l ey that i s bel t dri ven by the
crankshaft pul l ey.
OPERATION
OPERATION - 4. 7L
The power steeri ng pump i s a constant fl ow rate
and di spl acement, vane-type pump. The pump has
i nternal parts that operate submerged i n fl ui d. The
fl ow control ori fi ce and the pressure rel i ef val ve,
whi ch l i mi ts the pump pressure, are i nternal to the
pump. The reservoi r i s attached to the pump body
wi th spri ng cl i ps. The power steeri ng pump i s used
to dri ve the hydraul i c engi ne cool i ng fan, whi ch sep-
arates the fl ow to the fan gerotors and the power
steeri ng gear. The power steeri ng pump i s connected
to the engi ne cool i ng fan by pressure and return
hoses and the pump i s connected to the steeri ng gear
vi a a return hose from the steeri ng cool er (Fi g. 2).
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
OPERATION - 4. 0L
The power steeri ng pump i s a constant fl ow rate
and di spl acement, vane-type pump. The pump i nter-
nal parts operate submerged i n fl ui d. The fl ow con-
trol ori fi ce i s part of the hi gh pressure l i ne fi tti ng.
The pressure rel i ef val ve i nsi de the fl ow control val ve
l i mi ts the pump pressure. The reservoi r i s attached
to the pump body wi th spri ng cl i ps. The power steer-
i ng pump i s connected to the steeri ng gear by the
pressure and return hoses (Fi g. 1).
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
Fig. 1 Pump With Integral Reservoir
1 - CAP
2 - FLUID RESERVOIR (TYPICAL)
3 - HIGH-PRESSURE FITTING
4 - DRIVE PULLEY
5 - PUMP BODY
6 - RESERVOIR CLIP
Fig. 2 4.7L POWER STEERING PUMP
1 - PRESSURE HOSE QUICK CONNECT NUT
2 - CAP
3 - FLUID RESERVOIR
4 - LOW-PRESSURE RETURN FROM THE COOLER
5 - LOW-PRESSURE RETURN FROM THE HYDRAULIC FAN
DRIVE
6 - PUMP BODY
7 - HIGH PRESSURE FITTING
19 - 32 PUMP WJ
DIAGNOSIS AND TESTING - PUMP LEAKAGE
(1) Possi bl e areas of pump l eakage (Fi g. 3).
STANDARD PROCEDURE
STANDARD PROCEDURE - INITIAL OPERATION
- 4. 0L
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal ambi ent temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - INITIAL OPERATION
- 4. 7L
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
NOTE: Remove as much of the old fluid out of the
system as possible with a suction tool or by remov-
ing a hose, When a component has failed. Then
refill it with fresh fluid until it is clean. This may
have to be done more than once.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal ambi ent temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(7) Lower the vehi cl e, start the engi ne, and use
the DRB I I I to acti vate the hydraul i c fan on ful l fan
operati on.
(8) Turn the steeri ng wheel sl owl y from l ock to l ock.
(9) Stop the engi ne, check the fl ui d l evel and refi l l
as requi red and repeat the process
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
(10) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
Fig. 3 4.0L Power Steering Pump
WJ PUMP 19 - 33
PUMP (Continued)
(11) Whi l e the vehi cl e i s i n park, use the DRB I I I
to acti vate the hydraul i c fan to ful l fan operati on and
bri efl y rev the engi ne up to 3000 rpm to ful l y engage
the hydraul i c fan.
REMOVAL
(1) Remove serpenti ne dri ve bel t,(Refer to 7 -
REMOVAL).
(2) Remove pressure and return hoses from pump
and drai n the pump.
(3) Loosen the pump bracket bol t at the engi ne bl ock.
(4) Remove 3 pump mounti ng bol ts (Fi g. 4)
through pul l ey access hol es.
(5) Ti l t pump downward and remove from engi ne.
(6) Remove pul l ey from pump.
(1) Remove the serpenti ne dri ve bel t,(Refer to 7 -
REMOVAL).
(2) Remove the pressure and return hoses from
pump and drai n pump.
(3) Remove 3 pump mounti ng bol ts through pul l ey
access hol es (Fi g. 5).
(4) Remove the pump from the vehi cl e.
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) I nstal l pump on the engi ne mounti ng bracket.
(3) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 Nm (20 ft. l bs.).
(4) Ti ghten pump bracket bol t to 57 Nm (42 ft.
l bs.).
(5) I nstal l the pressure l i ne on the pump and
(6) I nstal l the return hoses on pump.
(7) I nstal l the dri ve bel t,(Refer to 7 - COOLI NG/
ACCESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(8) Add power steeri ng fl ui d,(Refer to 19 - STEER-
I NG/PUMP - STANDARD PROCEDURE).
(1) Posi ti on the pump on the l eft cyl i nder head
and i nstal l bol ts through pul l ey access hol es. Ti ghten
(2) I nstal l the pressure and return hoses to pump.
(3) I nstal l serpenti ne dri ve bel t,(Refer to 7 -
I NSTALLATI ON).
Fig. 4 PUMP MOUNTING 4.0L
1 - PUMP ASSEMBLY
2 - PUMP BRACKET
Fig. 5 Pump Mounting
2 - PUMP
19 - 34 PUMP WJ
PUMP (Continued)
SPECIFICATIONS
TORQUE CHART
Power Steering Pump
Bracket Bolt-4.0L
57 42
Power Steering Pump
Pump Bolts-4.0L
28 21 250
Power Steering Pump
Pump Bolts-4.7L
28 21 250
Power Steering Pump
Flow Control Valve
75 55
Power Steering Pump
Pressure Line
4.0L
20-38 14-28
Power Steering Pump
Pressure Line
4.7L
47 35 416
Power Steering Pump
Return Line
4.0L & 4.7L
20-38 14-28
High Pressure Inlet Hose
to Hydraulic Fan
Drive1/2 inch Fitting
49 36
High Pressure Outlet
Hose to Steering
Gear3/8 inch Fitting
29 21.5
Power Steering Cooler
Lines
at the Cooler
22.5 17 200
WJ PUMP 19 - 35
PUMP (Continued)
SPECIAL TOOLS
POWER STEERING PUMP
FLUID COOLER
DESCRIPTION
4.7L model s of thi s vehi cl e are equi pped wi th a
cool er for the power steeri ng system fl ui d. The power
steeri ng fl ui d cool er i s l ocated at the front of the
vehi cl e. I t i s mounted to the radi ator support just
forward of the ai r-condi ti oni ng condenser and just
rearward of the front fasci a (Fi g. 6). The cool er i s
posi ti oned so i t i s i n the ai r fl ow through the front
fasci a of the vehi cl e.
REMOVAL
(2) Drai n the power steeri ng fl ui d out of the reser-
voi r.
(3) Remove the front fasci a gri l l e assembl y,(Refer
to 13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCI A - REMOVAL).
(4) Remove the gri l l e openi ng rei nforcement panel
(5) Pl ace a drai n pan under the cool er.
(6) Di sconnect the l ower hose at cool er (Fi g. 6).
(7) Di sconnect the upper hose at cool er (Fi g. 6).
(8) Remove the three cool er mounti ng bol ts (Fi g.
6).
(9) Remove the cool er from the vehi cl e.
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
4.7L HYDRAULIC POWER STEERING TEST
ADAPTER KIT - 8630
Puller C-4333
Installer, Power Steering Pulley C-4063B
Fig. 6 POWER STEERING FLUID COOLER
1 - POWER STEERING COOLER
2 - POWER STEERING COOLER LINES CLIP
19 - 36 PUMP WJ
PUMP (Continued)
INSTALLATION
(1) Posi ti on and i nstal l the power steeri ng cool er
to the vehi cl e.
(2) I nstal l the three mounti ng bracket bol ts (Fi g.
6).
(3) Reconnect the upper hose at cool er (Fi g. 6).
(4) Reconnect the l ower hose at cool er (Fi g. 6).
(6) Refi l l the power steeri ng fl ui d and bl eed the
system,(Refer to 19 - STEERI NG/PUMP - STAN-
DARD PROCEDURE).
(8) I nstal l the gri l l e openi ng rei nforcement panel
(9) I nstal l the front fasci a gri l l e,(Refer to 13 -
- I NSTALLATI ON).
HOSES - 4.0L
DESCRIPTION
DESCRIPTION - PRESSURE LINE
The hose consi sts of two metal ends and rubber
center secti on that contai ns a tuni ng cabl e. The
pump end uses a qui ck connect fi tti ng. Lubi rcati on
must be used on the qui ck connect nut and o-ri ng
when i nstal l i ng.
DESCRIPTION - RETURN LINE
Power steeri ng return l i ne i s a hose whi ch i s
cl amped at the pump and the gear.
OPERATION
OPERATION - PRESSURE LINE
Power steeri ng pressure l i ne, i s used to transfer
hi gh pressure power steeri ng fl ui d, from the power
steeri ng pump to the power steeri ng gear on the
4.0L. The 4.7L power steeri ng pressure l i ne, i s used
to transfer hi gh pressure power steeri ng fl ui d, from
the power steeri ng pump to the engi ne cool i ng fan
and the steeri ng gear.
OPERATION - RETURN LINE
Power steeri ng return l i ne, i s used to transfer l ow
pressure power steeri ng fl ui d, from the power steer-
i ng gear to the power steeri ng pump.
REMOVAL
(1) Drai n the power steeri ng fl ui d from the reser-
voi r.
(2) Remove the ai r box,(Refer to 9 - ENGI NE/AI R
I NTAKE SYSTEM/AI R CLEANER HOUSI NG -
REMOVAL).
(3) Di sconnect the power steeri ng pressure hose
from the power steeri ng pump and then the power
steeri ng gear (Fi g. 7).
(4) Di sconnect the power steeri ng return hose from
the power steeri ng cool er and the reservoi r.
(5) Remove the hoses from the vehi cl e.
INSTALLATION
(1) I nstal l the hoses to the vehi cl e.
(2) Reconnect the power steeri ng return hose to
the power steeri ng cool er and the reservoi r.
(3) Reconnect the power steeri ng pressure hose to
the power steeri ng pump and then the power steer-
i ng gear.
(4) I nstal l the ai r box,(Refer to 9 - ENGI NE/AI R
I NSTALLATI ON).
DARD PROCEDURE).
Fig. 7 POWER STEERING HOSES
1 - RETURN HOSE
2 - HIGH PRESSURE HOSE
3 - STEERING GEAR
WJ PUMP 19 - 37
FLUID COOLER (Continued)
HOSES - 4.7L
DESCRIPTION
DESCRIPTION - 1/2 PRESSURE HOSE
The hose consi sts of two metal ends and a rubber
center wi th qui ck connect nuts at both ends. The
hose connects the power steeri ng pump to the
hydraul i c fan motor and i s cl i pped to the fan shroud
(Fi g. 8). Lubri cati on must be used on the qui ck con-
nect nuts and o-ri ngs when i nstal l i ng.
DESCRIPTION - 1/2 RETURN HOSE
The fan motor return l i ne i s a mol ded rubber hose
that i s cl amped at the hydraul i c motor and the power
steeri ng reservoi r (Fi g. 9).
DESCRIPTION - 3/8 PRESSURE HOSE
The hose consi sts of two metal ends and two rub-
ber secti ons one of whi ch contai ns a tuni ng cabl e
(Fi g. 10). The hose i s cl i pped i n two pl aces to the fan
shroud. Lubri cati on must be used on the o-ri ngs
when i nstal l i ng.
DESCRIPTION - 3/8 GEAR OUTLET HOSE
The gear outl et l i ne consi sts of a metal secti on that
connects to the gear and a rubber secti on that cl amps
to the steeri ng cool er i nl et tube (Fi g. 11).
DESCRIPTION - 3/8 RETURN HOSE
The return hose i s a formed rubber hose that con-
nects the steeri ng cool er outl et tube to the power
steeri ng reservoi r (Fi g. 12). I t i s cl amped at both
ends.
OPERATION
OPERATION - 1/2 PRESSURE HOSE
The 1/2 pressure hose i s used to transfer hi gh
pressure power steeri ng fl ui d from the power steer-
i ng pump to the engi ne cool i ng fan motor (Fi g. 8).
OPERATION - 1/2 RETURN HOSE
The power steeri ng return l i ne returns l ow pres-
sure excess fl ow from the hydraul i c fan motor back to
the power steeri ng pump (Fi g. 9).
Fig. 8 1/2 PRESSURE HOSE
1 - 1/2 PRESSURE HOSE
3 - STEERING GEAR
Fig. 9 1/2 RETURN HOSE
1 - 1/2 RETURN HOSE
2 - HOSE CLAMP
Fig. 10 3/8 PRESSURE HOSE
1 - 3/8 PRESSURE HOSE
2 - STEERING GEAR
19 - 38 PUMP WJ
OPERATION - 3/8 PRESSURE HOSE
Hi gh pressure power steeri ng fl ui d i s transmi tted
from the hydraul i c fan motor to the steeri ng gear by
the 3/8 steeri ng l i ne.
OPERATION - 3/8 GEAR OUTLET HOSE
The gear outl et hose transmi ts power steeri ng fl ui d
under moderate l ow pressure to the power steeri ng
cool er i nl et tube.
OPERATION - 3/8RETURN HOSE
Low pressure power steeri ng fl ui d i s transmi tted
from the steeri ng cool er back to the power steeri ng
pump by the 3/8 return hose.
REMOVAL
REMOVAL - 1/2 PRESSURE HOSE
(1) Drai n the power steeri ng fl ui d from the reservoi r.
REMOVAL).
(4) Remove the metal ski d pl ate.
hydraul i c fan motor (Fi g. 8).
power steeri ng pump (Fi g. 8).
(7) Remove the hose from the cl i pped posi ti on on
the fan shroud.
(8) Remove the hose from the vehi cl e.
REMOVAL - 1/2 RETURN HOSE
voi r.
REMOVAL).
(5) Di sconnect the rubber return hose from the
(6) Di sconnect the rubber return hose from the
power steeri ng reservoi r .
REMOVAL - 3/8 PRESSURE HOSE
voi r.
REMOVAL).
power steeri ng gear (Fi g. 10).
(7) Remove the hose from the cl i pped posi ti on on
the fan shroud.
REMOVAL - 3/8 RETURN HOSE
voi r.
REMOVAL).
(4) Di sconnect the rubber hose from the steeri ng
cool er outl et tube (Fi g. 12).
Fig. 11 3/8 GEAR OUTLET HOSE
1 - HOSE CLAMP
2 - 3/8 GEARR OUTLET HOSE
Fig. 12 3/8 RETURN HOSE
1 - HOSE CLAMP
2 - 3/8 RETURN HOSE
3 - HYDRAULIC COOLING FAN MOTOR
WJ PUMP 19 - 39
HOSES - 4.7L (Continued)
(5) Di sconnect the rubber hose from the power
steeri ng reservoi r (Fi g. 12).
REMOVAL - 3/8 GEAR OUTLET HOSE
voi r.
REMOVAL).
(4) Di sconnect the rubber hose from the steeri ng
cool er i nl et tube (Fi g. 11).
(5) Di sconnect the metal tube from the power
steeri ng gear (Fi g. 11).
REMOVAL - INLET COOLER HOSE
voi r.
REMOVAL).
FASCI A - REMOVAL).
(7) Di sconnect the l ower hose at cool er (Fi g. 6).
(8) Di sconnect the cool er hose at the gear.
(9) Remove the bracket hol di ng the cool er hoses
(Fi g. 13).
(10) Remove the cool er hose from the vehi cl e.
REMOVAL - OUTLET COOLER HOSE
voi r.
REMOVAL).
FASCI A - REMOVAL).
(7) Di sconnect the upper hose at cool er (Fi g. 6).
(8) Di sconnect the cool er hose at the reservoi r.
(9) Remove the bracket hol di ng the cool er hoses
(Fi g. 13).
(10) Remove the cool er hose from the vehi cl e.
INSTALLATION
INSTALLATION - 1/2 PRESSURE HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(2) Reconnect the hi gh pressure hose to the power
steeri ng pump (Fi g. 8) Ti ghten the hose to 22.5 Nm
(17 ft.l bs.).
(3) Reconnect the hi gh pressure hose to the
hydraul i c fan motor (Fi g. 8) Ti ghten the hose to 22.5
Nm (17 ft.l bs.).
(4) I nstal l the hose to the cl i pped posi ti on on the
fan shroud.
(5) I nstal l the metal ski d pl ate.
I NSTALLATI ON).
DARD PROCEDURE).
INSTALLATION - 1/2 RETURN HOSE
(2) Reconnect the rubber return hose to the power
steeri ng reservoi r (Fi g. 9) Ti ghten the hose cl amp.
(3) Reconnect the rubber return hose to the
hydraul i c fan motor (Fi g. 9) Ti ghten the hose.
I NSTALLATI ON).
DARD PROCEDURE).
Fig. 13 COOLER HOSES MOUNTING BRACKET
1 - RADIATOR
2 - COOLER HOSES MOUNTING BRACKET
2 - COOLER HOSE
19 - 40 PUMP WJ
INSTALLATION - 3/8 PRESSURE HOSE
when reinstalling.
(2) Reconnect the hi gh pressure hose to the
hydraul i c fan motor (Fi g. 10) Ti ghten the hose to
22.5 Nm (17 ft.l bs.).
(3) Reconnect the hi gh pressure hose to the power
steeri ng gear (Fi g. 10) Ti ghten the hose to 22.5 Nm
(17 ft.l bs.).
(4) I nstal l the hose to the cl i pped posi ti on on the
fan shroud.
I NSTALLATI ON).
DARD PROCEDURE).
INSTALLATION - 3/8 RETURN HOSE
(2) Reconnect the rubber hose to the steeri ng
cool er outl et tube (Fi g. 12) Ti ghten the hose cl amp.
(3) Reconnect the rubber hose to the power steer-
i ng reservoi r (Fi g. 12) Ti ghten the hose cl amp.
I NSTALLATI ON).
DARD PROCEDURE).
INSTALLATION - 3/8 GEAR OUTLET HOSE
when reinstalling.
(2) Reconnect the rubber hose to the steeri ng
cool er i nl et tube (Fi g. 11) Ti ghten the hose cl amp.
(3) Reconnect the metal tube to the power steeri ng
gear (Fi g. 11) Ti ghten the hose to 22.5 Nm (17 ft.l bs.).
I NSTALLATI ON).
DARD PROCEDURE).
INSTALLATION - INLET COOLER HOSE
(1) I nstal l the cool er hose to the vehi cl e.
(2) Reconnect the cool er hose at the gear.
(3) Reconnect the l ower hose at cool er (Fi g. 6).
Ti ghten the hose to 22.5 Nm (17 ft.l bs.)
(4) I nstal l the bracket hol di ng the cool er hoses
(Fi g. 13).
I NSTALLATI ON).
(7) I nstal l the front fasci a gri l l e assembl y, (Refer to
13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCI A - I NSTALLATI ON).
(8) Reconnect negati ve battery cabl e at battery.
DARD PROCEDURE).
INSTALLATION - OUTLET COOLER HOSE
(1) I nstal l the cool er hose to the vehi cl e.
(2) Reconnect the cool er hose at the reservoi r.
(3) Reconnect the upper hose at the cool er (Fi g. 6).
Ti ghten the hose to 22.5 Nm (17 ft. l bs.)
(4) I nstal l the bracket hol di ng the cool er hoses
(Fi g. 13). Ti ghten the bracket to 22.5 Nm (17 ft. l bs.)
I NSTALLATI ON).
(7) I nstal l the front fasci a gri l l e assembl y, (Refer to
13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCI A - I NSTALLATI ON).
(8) Reconnect negati ve battery cabl e at battery.
DARD PROCEDURE).
PULLEY
DESCRIPTION
POWER STEERING PUMP PULLEY - 3. 1L
DIESEL
To servi ce the power steeri ng pump pul l ey on the
3.1L turbo di esel engi ne. Refer to the power steeri ng
pump removal and i nstal l ati on procedure i n thi s
group. The pul l ey must be removed to servi ce the
pump assembl y. Detai l ed i nstructi ons are provi ded i n
the pump procedure.
REMOVAL
CAUTION: On vehicles equipped with the 4.0L or
4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new pulley
must be installed if removed.
(1) Remove pump assembl y.
(2) Remove pul l ey from pump wi th Pul l er C-4333
or equi val ent pul l er (Fi g. 14).
WJ PUMP 19 - 41
INSTALLATION
NOTE: The pulley is marked front for installation.
CAUTION: On vehicles equipped with the 4.0L or
4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new pulley
must be installed if removed.
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
or equi val ent i nstal l er (Fi g. 15). The front edge of the
pul l ey hub must be fl ush wi th the end of the shaft.
Ensure the tool and pul l ey are al i gned wi th the
pump shaft.
(3) I nstal l pump assembl y.
(4) Wi th Serpenti ne Bel t, run engi ne unti l warm (5
mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
RESERVOIR
REMOVAL
(1) Remove power steeri ng pump.
(2) Cl ean exteri or of pump.
(3) Cl amp the pump body i n a soft jaw vi ce.
NOTE: Use new retaining clips for installation.
(4) Pry up tab and sl i de the retai ni ng cl i ps off (Fi g.
16).
(5) Remove fl ui d reservoi r from pump body.
Remove and di scard O-ri ng seal .
INSTALLATION
(1) Lubri cate new O-ri ng Seal wi th Mopar Power
Steeri ng Fl ui d or equi val ent.
(2) I nstal l O-ri ng seal i n housi ng.
(3) I nstal l reservoi r onto housi ng.
(4) Sl i de and tap i n new reservoi r retai ner cl i ps
unti l tab l ocks to housi ng.
(5) I nstal l power steeri ng pump.
Fig. 14 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
Fig. 15 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4063B
Fig. 16 Pump Reservoir Clips
1 - RESERVOIR
2 - RETAINING CLIPS
19 - 42 PUMP WJ
PULLEY (Continued)
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 42RE . . . . . . . . . . 1
AUTOMATIC TRANSMISSION - 545RFE . . . . . . 177
TRANSFER CASE - NV242 . . . . . . . . . . . . . . . . 280
TRANSFER CASE - NV247 . . . . . . . . . . . . . . . . 315
AUTOMATIC TRANSMISSION - 42RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 42RE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - PRELIMINARY . 11
DIAGNOSIS AND TESTING - ROAD
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH AND BAND
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 29
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . 43
SPECIFICATIONS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 55
SPECIAL TOOLS
RE TRANSMISSIONS . . . . . . . . . . . . . . . . . . 57
ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 60
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 60
BANDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ADJUSTMENTS
ADJUSTMENT - BANDS . . . . . . . . . . . . . . . . 62
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 63
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
TRANSMISSION SHIFT INTERLOCK . . . . . . . 63
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK . . . . . . . . . . . . . . . . . . . . 64
ELECTRONIC GOVERNOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
EXTENSION HOUSING BUSHING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
EXTENSION HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
FLUID AND FILTER
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL . . . . . . . . . . . . . . 69
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . . 69
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 70
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
WJ TRANSMISSION AND TRANSFER CASE 21 - 1
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT . . . . . . . . . . . . . . . . 71
STANDARD PROCEDURE - TRANSMISSION
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FRONT CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 73
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FRONT SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 77
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
ADJUSTMENTS - GEARSHIFT CABLE . . . . . . . 79
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 80
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK . . . . . . . . . . . . . . . . . . . . . . 81
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 81
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 83
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
OUTPUT SHAFT FRONT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
OUTPUT SHAFT REAR BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
OVERDRIVE CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
OVERDRIVE OFF SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS . . . . . . . . . . . . . . . 87
OVERDRIVE UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 88
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 104
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 105
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 105
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 106
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 106
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PARK LOCK CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 108
PARK/NEUTRAL POSITION SWITCH
DIAGNOSIS AND TESTING - PARK/NEUTRAL
POSITION SWITCH . . . . . . . . . . . . . . . . . . . 109
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 110
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 110
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 112
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 112
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 112
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
REAR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 118
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 118
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 119
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 120
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
REAR SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 122
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 122
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 123
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 123
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 125
SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 125
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 126
SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 126
THROTTLE VALVE CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
ADJUSTMENTS - TRANSMISSION THROTTLE
VALVE CABLE . . . . . . . . . . . . . . . . . . . . . . . 126
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 128
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 132
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 133
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 134
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 134
21 - 2 AUTOMATIC TRANSMISSION - 42RE WJ
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE . . . . . . . . 134
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 134
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 134
VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 135
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 139
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 155
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 166
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 175
ADJUSTMENTS - VALVE BODY . . . . . . . . . . . 175
AUTOMATIC TRANSMISSION -
42RE
DESCRIPTION
The 42RE i s a four speed ful l y automati c transmi s-
si on (Fi g. 1) wi th an el ectroni c governor. The 42RE i s
equi pped wi th a l ock-up cl utch i n the torque con-
verter. Fi rst through thi rd gear ranges are provi ded
by the cl utches, bands, overrunni ng cl utch, and pl an-
etary gear sets i n the transmi ssi on. Fourth gear
range i s provi ded by the overdri ve uni t that contai ns
an overdri ve cl utch, di rect cl utch, pl anetary gear set,
and overrunni ng cl utch.
The transmi ssi on contai ns a front, rear, and di rect
cl utch whi ch functi on as the i nput dri vi ng compo-
nents. I t al so contai ns the ki ckdown (front) and the
l ow/reverse (rear) bands whi ch, al ong wi th the over-
runni ng cl utch and overdri ve cl utch, serve as the
hol di ng components. The dri vi ng and hol di ng compo-
nents combi ne to sel ect the necessary pl anetary gear
components, i n the front, rear, or overdri ve pl anetary
gear set, transfer the engi ne power from the i nput
shaft through to the output shaft.
The val ve body i s mounted to the l ower si de of the
transmi ssi on and contai ns the val ves to control pres-
sure regul ati on, fl ui d fl ow control , and cl utch/band
appl i cati on. The oi l pump i s mounted at the front of
the transmi ssi on and i s dri ven by the torque con-
verter hub. The pump suppl i es the oi l pressure nec-
essary for cl utch/band actuati on and transmi ssi on
l ubri cati on.
WJ AUTOMATIC TRANSMISSION - 42RE 21 - 3
F
i
g
.
1
4
2
R
E
T
r
a
n
s
m
i
s
s
i
o
n
AUTOMATIC TRANSMISSION - 42RE (Continued)
IDENTIFICATION
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan gas-
ket surface (Fi g. 2). Refer to thi s i nformati on when
orderi ng repl acement parts.
GEAR RATIOS The 42RE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.74:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69:1
Rev. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21:1
OPERATION
The appl i cati on of each dri vi ng or hol di ng compo-
nent i s control l ed by the val ve body based upon the
manual l ever posi ti on, throttl e pressure, and gover-
nor pressure. The governor pressure i s a vari abl e
pressure i nput to the val ve body and i s one of the
si gnal s that a shi ft i s necessary. Fi rst through fourth
gear are obtai ned by sel ecti vel y appl yi ng and rel eas-
i ng the di fferent cl utches and bands. Engi ne power i s
thereby routed to the vari ous pl anetary gear assem-
bl i es whi ch combi ne wi th the overrunni ng cl utch
assembl i es to generate the di fferent gear rati os. The
torque converter cl utch i s hydraul i cal l y appl i ed and
i s rel eased when fl ui d i s vented from the hydraul i c
ci rcui t by the torque converter control (TCC) sol enoi d
on the val ve body. The torque converter cl utch i s con-
trol l ed by the Powertrai n Control Modul e (PCM). The
torque converter cl utch engages i n fourth gear, and
i n thi rd gear under vari ous condi ti ons, such as when
the O/D swi tch i s OFF, when the vehi cl e i s crui si ng
on a l evel surface after the vehi cl e has warmed up.
The torque converter cl utch wi l l di sengage momen-
tari l y when an i ncrease i n engi ne l oad i s sensed by
the PCM, such as when the vehi cl e begi ns to go
uphi l l or the throttl e pressure i s i ncreased. The
torque converter cl utch feature i ncreases fuel econ-
omy and reduces the transmi ssi on fl ui d temperature.
Si nce the overdri ve cl utch i s appl i ed i n fourth gear
onl y and the di rect cl utch i s appl i ed i n al l ranges
except fourth gear, the transmi ssi on operati on for
park, neutral , and fi rst through thi rd gear wi l l be
descri bed fi rst. Once these powerfl ows are descri bed,
the thi rd to fourth shi ft sequence wi l l be descri bed.
1 - CONVERTER CLUTCH 15 - HOUSING
2 - TORQUE CONVERTER 16 - REAR BEARING
3 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 17 - OUTPUT SHAFT
4 - FRONT BAND 18 - SEAL
5 - FRONT CLUTCH 19 - OVERDRIVE OVERRUNNING CLUTCH
6 - DRIVING SHELL 20 - OVERDRIVE PLANETARY GEAR
7 - REAR BAND 21 - DIRECT CLUTCH SPRING
8 - TRANSMISSION OVERRUNNING CLUTCH 22 - OVERDRIVE CLUTCH PISTON
9 - OVERDRIVE UNIT 23 - VALVE BODY ASSEMBLY
10 - PISTON RETAINER 24 - FILTER
11 - OVERDRIVE CLUTCH 25 - FRONT PLANETARY GEAR
12 - DIRECT CLUTCH 26 - REAR CLUTCH
13 - INTERMEDIATE SHAFT 27 - TRANSMISSION
14 - FRONT BEARING 28 - REAR PLANETARY GEAR
Fig. 2 Transmission Part And Serial Number
Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
PARK POWERFLOW
As the engi ne i s runni ng and the crankshaft i s
rotati ng, the fl expl ate and torque converter, whi ch
are al so bol ted to i t, are al l rotati ng i n a cl ockwi se
di recti on as vi ewed from the front of the engi ne. The
notched hub of the torque converter i s connected to
the oi l pumps i nternal gear, suppl yi ng the transmi s-
si on wi th oi l pressure. As the converter turns, i t
turns the i nput shaft i n a cl ockwi se di recti on. As the
i nput shaft i s rotati ng, the front cl utch hub-rear
cl utch retai ner and al l thei r associ ated parts are al so
rotati ng, al l bei ng di rectl y connected to the i nput
shaft. The power fl ow from the engi ne through the
front cl utch hub and rear cl utch retai ner stops at the
rear cl utch retai ner. Therefore, no power fl ow to the
output shaft occurs because no cl utches are appl i ed.
The onl y mechani sm i n use at thi s ti me i s the park-
i ng sprag (Fi g. 3), whi ch l ocks the parki ng gear on
the output shaft to the transmi ssi on case.
NEUTRAL POWERFLOW
Wi th the gear sel ector i n the NEUTRAL posi ti on
(Fi g. 4), the power fl ow of the transmi ssi on i s essen-
ti al l y the same as i n the park posi ti on. The onl y
operati onal di fference i s that the parki ng sprag has
been di sengaged, unl ocki ng the output shaft from the
transmi ssi on case and al l owi ng i t to move freel y.
Fig. 3 Park Powerflow
1 - LEVER ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5 - PAWL
REVERSE POWERFLOW
When the gear sel ector i s moved i nto the
REVERSE posi ti on (Fi g. 5), the front cl utch and the
rear band are appl i ed. Wi th the appl i cati on of the
front cl utch, engi ne torque i s appl i ed to the sun gear,
turni ng i t i n a cl ockwi se di recti on. The cl ockwi se
rotati on of the sun gear causes the rear pl anet pi n-
i ons to rotate agai nst engi ne rotati on i n a counter-
cl ockwi se di recti on. The rear band i s hol di ng the l ow
reverse drum, whi ch i s spl i ned to the rear carri er.
Si nce the rear carri er i s bei ng hel d, the torque from
the pl anet pi ni ons i s transferred to the rear annul us
gear, whi ch i s spl i ned to the output shaft. The output
shaft i n turn rotates wi th the annul us gear i n a
countercl ockwi se di recti on gi vi ng a reverse gear out-
put. The enti re transmi ssi on of torque i s appl i ed to
the rear pl anetary gearset onl y. Al though there i s
torque i nput to the front gearset through the sun
gear, no other member of the gearset i s bei ng hel d.
Duri ng the enti re reverse stage of operati on, the
front pl anetary gears are i n an i dl i ng condi ti on.
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
2 - OUTPUT SHAFT 6 - INPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED
FIRST GEAR POWERFLOW
When the gearshi ft l ever i s moved i nto the DRI VE
posi ti on the transmi ssi on goes i nto fi rst gear (Fi g. 6).
As soon as the transmi ssi on i s shi fted from PARK or
NEUTRAL to DRI VE, the rear cl utch appl i es, appl y-
i ng the rear cl utch pack to the front annul us gear.
Engi ne torque i s now appl i ed to the front annul us
gear turni ng i t i n a cl ockwi se di recti on. Wi th the
front annul us gear turni ng i n a cl ockwi se di recti on, i t
causes the front pl anets to turn i n a cl ockwi se di rec-
ti on. The rotati on of the front pl anets cause the sun
to revol ve i n a countercl ockwi se di recti on. The sun
gear now transfers i ts countercl ockwi se rotati on to
the rear pl anets whi ch rotate back i n a cl ockwi se
di recti on. Wi th the rear annul us gear stati onary, the
rear pl anet rotati on on the annul us gear causes the
rear pl anet carri er to revol ve i n a countercl ockwi se
di recti on. The rear pl anet carri er i s spl i ned i nto the
l ow-reverse drum, and the l ow reverse drum i s
spl i ned to the i nner race of the over-runni ng cl utch.
Wi th the over-runni ng cl utch l ocked, the pl anet car-
ri er i s hel d, and the resul ti ng torque provi ded by the
pl anet pi ni ons i s transferred to the rear annul us
gear. The rear annul us gear i s spl i ned to the output
shaft and rotated al ong wi th i t (cl ockwi se) i n an
underdri ve gear reducti on mode.
Fig. 6 First Gear Powerflow
1 - OUTPUT SHAFT 5 - OVER-RUNNING CLUTCH HOLDING
2 - OVER-RUNNING CLUTCH HOLDING 6 - INPUT SHAFT
3 - REAR CLUTCH APPLIED 7 - REAR CLUTCH APPLIED
SECOND GEAR POWERFLOW
I n DRI VE-SECOND (Fi g. 7), the same el ements
are appl i ed as i n MANUAL-SECOND. Therefore, the
power fl ow wi l l be the same, and both gears wi l l be
di scussed as one i n the same. I n DRI VE-SECOND,
the transmi ssi on has proceeded from fi rst gear to i ts
shi ft poi nt, and i s shi fti ng from fi rst gear to second.
The second gear shi ft i s obtai ned by keepi ng the rear
cl utch appl i ed and appl yi ng the front (ki ckdown)
band. The front band hol ds the front cl utch retai ner
that i s l ocked to the sun gear dri vi ng shel l . Wi th the
rear cl utch sti l l appl i ed, the i nput i s sti l l on the front
annul us gear turni ng i t cl ockwi se at engi ne speed.
Now that the front band i s hol di ng the sun gear sta-
ti onary, the annul us rotati on causes the front pl anets
to rotate i n a cl ockwi se di recti on. The front carri er i s
then al so made to rotate i n a cl ockwi se di recti on but
at a reduced speed. Thi s wi l l transmi t the torque to
the output shaft, whi ch i s di rectl y connected to the
front pl anet carri er. The rear pl anetary annul us gear
wi l l al so be turni ng because i t i s di rectl y spl i ned to
the output shaft. Al l power fl ow has occurred i n the
front pl anetary gear set duri ng the dri ve-second
stage of operati on, and now the over-runni ng cl utch,
i n the rear of the transmi ssi on, i s di sengaged and
freewheel i ng on i ts hub.
Fig. 7 Second Gear Powerflow
1 - KICKDOWN BAND APPLIED 6 - INPUT SHAFT
2 - OUTPUT SHAFT 7 - REAR CLUTCH APPLIED
3 - REAR CLUTCH ENGAGED 8 - KICKDOWN BAND APPLIED
5 - OVER-RUNNING CLUTCH FREE-WHEELING
DIRECT DRIVE POWERFLOW
The vehi cl e has accel erated and reached the shi ft
poi nt for the 2-3 upshi ft i nto di rect dri ve (Fi g. 8).
When the shi ft takes pl ace, the front band i s
rel eased, and the front cl utch i s appl i ed. The rear
cl utch stays appl i ed as i t has been i n al l the forward
gears. Wi th the front cl utch now appl i ed, engi ne
torque i s now on the front cl utch retai ner, whi ch i s
l ocked to the sun gear dri vi ng shel l . Thi s means that
the sun gear i s now turni ng i n engi ne rotati on (cl ock-
wi se) and at engi ne speed. The rear cl utch i s sti l l
appl i ed so engi ne torque i s al so sti l l on the front
annul us gear. I f two members of the same pl anetary
set are dri ven, di rect dri ve resul ts. Therefore, when
two members are rotati ng at the same speed and i n
the same di recti on, i t i s the same as bei ng l ocked up.
The rear pl anetary set i s al so l ocked up, gi ven the
sun gear i s sti l l the i nput, and the rear annul us gear
must turn wi th the output shaft. Both gears are
turni ng i n the same di recti on and at the same speed.
The front and rear pl anet pi ni ons do not turn at al l
i n di rect dri ve. The onl y rotati on i s the i nput from
the engi ne to the connected parts, whi ch are acti ng
as one common uni t, to the output shaft.
Fig. 8 Direct Drive Powerflow
1 - FRONT CLUTCH APPLIED 6 - INPUT SHAFT
2 - OVER-RUNNING CLUTCH FREE-WHEELING 7 - OVER-RUNNING CLUTCH FREE-WHEELING
3 - OUTPUT SHAFT 8 - REAR CLUTCH APPLIED
4 - REAR CLUTCH APPLIED 9 - FRONT CLUTCH APPLIED
FOURTH GEAR POWERFLOW
Fourth gear overdri ve range i s el ectroni cal l y con-
trol l ed and hydraul i cal l y acti vated. Vari ous sensor
i nputs are suppl i ed to the powertrai n control modul e
to operate the overdri ve sol enoi d on the val ve body.
The sol enoi d contai ns a check bal l that opens and
cl oses a vent port i n the 3-4 shi ft val ve feed passage.
The overdri ve sol enoi d (and check bal l ) are not ener-
gi zed i n fi rst, second, thi rd, or reverse gear. The vent
port remai ns open, di verti ng l i ne pressure from the
2-3 shi ft val ve away from the 3-4 shi ft val ve. The
overdri ve control swi tch must be i n the ON posi ti on
to transmi t overdri ve status to the PCM. A 3-4
upshi ft occurs onl y when the overdri ve sol enoi d i s
energi zed by the PCM. The PCM energi zes the over-
dri ve sol enoi d duri ng the 3-4 upshi ft. Thi s causes the
sol enoi d check bal l to cl ose the vent port al l owi ng
l i ne pressure from the 2-3 shi ft val ve to act di rectl y
on the 3-4 upshi ft val ve. Li ne pressure on the 3-4
shi ft val ve overcomes val ve spri ng pressure movi ng
the val ve to the upshi ft posi ti on. Thi s acti on exposes
the feed passages to the 3-4 ti mi ng val ve, 3-4 qui ck
fi l l val ve, 3-4 accumul ator, and ul ti matel y to the
overdri ve pi ston. Li ne pressure through the ti mi ng
val ve moves the overdri ve pi ston i nto contact wi th
the overdri ve cl utch. The di rect cl utch i s di sengaged
before the overdri ve cl utch i s engaged. The boost
val ve provi des i ncreased fl ui d appl y pressure to the
overdri ve cl utch duri ng 3-4 upshi fts, and when accel -
erati ng i n fourth gear. The 3-4 accumul ator cushi ons
overdri ve cl utch engagement to smooth 3-4 upshi fts.
The accumul ator i s charged at the same ti me as
appl y pressure acts agai nst the overdri ve pi ston.
TRANSMISSION
Automati c transmi ssi on probl ems can be a resul t of
poor engi ne performance, i ncorrect fl ui d l evel , i ncor-
rect l i nkage or cabl e adjustment, band or hydraul i c
control pressure adjustments, hydraul i c system mal -
functi ons or el ectri cal /mechani cal component mal -
functi ons. Begi n di agnosi s by checki ng the easi l y
accessi bl e i tems such as: fl ui d l evel and condi ti on,
l i nkage adjustments and el ectri cal connecti ons. A
road test wi l l determi ne i f further di agnosi s i s neces-
sary.
DIAGNOSIS AND TESTING - PRELIMINARY
Two basi c procedures are requi red. One procedure
for vehi cl es that are dri vabl e and an al ternate proce-
dure for di sabl ed vehi cl es (wi l l not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(2) Check fl ui d l evel and condi ti on.
(3) Adjust throttl e and gearshi ft l i nkage i f com-
pl ai nt was based on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(6) Perform ai r-pressure test to check cl utch-band
operati on.
VEHICLE IS DISABLED
(2) Check for broken or di sconnected gearshi ft or
throttl e l i nkage.
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri ve pl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that di agnosti c troubl e
codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, band or overrunni ng cl utch probl ems. I f the
condi ti on i s advanced, an overhaul wi l l be necessary
to restore normal operati on.
A sl i ppi ng cl utch or band can often be determi ned
by compari ng whi ch i nternal uni ts are appl i ed i n the
vari ous gear ranges. The Cl utch and Band Appl i ca-
ti on chart provi des a basi s for anal yzi ng road test
resul ts.
CLUTCH AND BAND APPLICATION CHART
SHIFT
LEVER
POSI-
TION
TRANSMISSION CLUTCHES AND BANDS OVERDRIVE CLUTCHES
FRONT
CLUTCH
FRONT
BAND
REAR
CLUTCH
REAR
BAND
OVER-
RUNNING
CLUTCH
OVER-
DRIVE
CLUTCH
DIRECT
CLUTCH
OVER-
RUNNING
CLUTCH
Reverse X X X
Drive -
First
X X X X
Drive -
Second
X X X X
Drive -
Third
X X X X
Drive -
Fourth
X X X
Manual
Second
X X X X X
Manual
First
X X X X X
Note that the rear cl utch i s appl i ed i n al l forward
ranges (D, 2, 1). The transmi ssi on overrunni ng cl utch
i s appl i ed i n fi rst gear (D, 2 and 1 ranges) onl y. The
rear band i s appl i ed i n 1 and R range onl y.
Note that the overdri ve cl utch i s appl i ed onl y i n
fourth gear and the overdri ve di rect cl utch and over-
runni ng cl utch are appl i ed i n al l ranges except fourth
gear.
For exampl e: I f sl i ppage occurs i n fi rst gear i n D
and 2 range but not i n 1 range, the transmi ssi on
overrunni ng cl utch i s faul ty. Si mi l arl y, i f sl i ppage
occurs i n any two forward gears, the rear cl utch i s
sl i ppi ng.
Appl yi ng the same method of anal ysi s, note that
the front and rear cl utches are appl i ed si mul ta-
neousl y onl y i n D range thi rd and fourth gear. I f the
transmi ssi on sl i ps i n thi rd gear, ei ther the front
cl utch or the rear cl utch i s sl i ppi ng.
I f the transmi ssi on sl i ps i n fourth gear but not i n
thi rd gear, the overdri ve cl utch i s sl i ppi ng. By sel ect-
i ng another gear whi ch does not use these cl utches,
the sl i ppi ng uni t can be determi ned. For exampl e, i f
the transmi ssi on al so sl i ps i n Reverse, the front
cl utch i s sl i ppi ng. I f the transmi ssi on does not sl i p i n
Reverse, the rear cl utch i s sl i ppi ng.
I f sl i ppage occurs duri ng the 3-4 shi ft or onl y i n
fourth gear, the overdri ve cl utch i s sl i ppi ng. Si mi -
l arl y, i f the di rect cl utch were to fai l , the transmi s-
si on woul d l ose both reverse gear and overrun
braki ng i n 2 posi ti on (manual second gear).
I f the transmi ssi on wi l l not shi ft to fourth gear, the
control swi tch, overdri ve sol enoi d or rel ated wi ri ng
may al so be the probl em cause.
Thi s process of el i mi nati on can be used to i denti fy
a sl i ppi ng uni t and check operati on. Proper use of
the Cl utch and Band Appl i cati on Chart i s the key.
Al though road test anal ysi s wi l l hel p determi ne the
sl i ppi ng uni t, the actual cause of a mal functi on usu-
al l y cannot be determi ned unti l hydraul i c and ai r
pressure tests are performed. Practi cal l y any condi -
ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Unl ess a mal functi on i s obvi ous, such as no dri ve
i n D range fi rst gear, do not di sassembl e the trans-
mi ssi on. Perform the hydraul i c and ai r pressure tests
to hel p determi ne the probabl e cause.
PRESSURE TEST
Hydraul i c test pressures range from a l ow of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port i n reverse.
An accurate tachometer and pressure test gauges
are requi red. Test Gauge C-3292 has a 100 psi range
and i s used at the accumul ator, governor, and front
servo ports. Test Gauge C-3293-SP has a 300 psi
range and i s used at the rear servo and overdri ve
ports where pressures exceed 100 psi .
Pressure Test Port Locations
Test ports are l ocated at both si des of the transmi s-
si on case (Fi g. 9).
Li ne pressure i s checked at the accumul ator port
on the ri ght si de of the case. The front servo pressure
port i s at the ri ght si de of the case just behi nd the
fi l l er tube openi ng.
The rear servo and governor pressure ports are at
the ri ght rear of the transmi ssi on case. The overdri ve
cl utch pressure port i s at the l eft rear of the case.
Test One - Transmission In Manual Low
NOTE: This test checks pump output, pressure reg-
ulation, and condition of the rear clutch and servo
circuit. Both test gauges are required for this test.
(1) Connect tachometer to engi ne. Posi ti on tachom-
eter so i t can be observed from dri ver seat i f hel per
wi l l be operati ng engi ne. Rai se vehi cl e on hoi st that
wi l l al l ow rear wheel s to rotate freel y.
(2) Connect 100 psi Gauge C-3292 to accumul ator
port. Then connect 300 psi Gauge C-3293-SP to rear
servo port.
(3) Di sconnect throttl e and gearshi ft cabl es from
l evers on transmi ssi on val ve body manual shaft.
(4) Have hel per start and run engi ne at 1000 rpm.
(5) Move transmi ssi on shi ft l ever ful l y forward
i nto 1 range.
(6) Gradual l y move transmi ssi on throttl e l ever
from ful l forward to ful l rearward posi ti on and note
pressures on both gauges:
Li ne pressure at accumul ator port shoul d be
54-60 psi (372-414 kPa) wi th throttl e l ever forward
and gradual l y i ncrease to 90-96 psi (621-662 kPa) as
throttl e l ever i s moved rearward.
Rear servo pressure shoul d be same as l i ne pres-
sure wi thi n 3 psi (20.68 kPa).
Test Two - Transmission In 2 Range
NOTE: This test checks pump output, line pressure
and pressure regulation. Use 100 psi Test Gauge
C-3292 for this test.
(1) Leave vehi cl e i n pl ace on hoi st and l eave Test
Gauge C-3292 connected to accumul ator port.
(2) Have hel per start and run engi ne at 1000 rpm.
(3) Move transmi ssi on shi ft l ever one detent rear-
ward from ful l forward posi ti on. Thi s i s 2 range.
(4) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and read pressure on
gauge.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease to 90-96 psi (621-662 kPa) as l ever i s moved
rearward.
Test Three - Transmission In D Range Third Gear
NOTE: This test checks pressure regulation and
condition of the clutch circuits. Both test gauges
are required for this test.
(1) Turn OD swi tch off.
(2) Leave vehi cl e on hoi st and l eave Gauge C-3292
i n pl ace at accumul ator port.
(3) Move Gauge C-3293-SP over to front servo port
for thi s test.
(4) Have hel per start and run engi ne at 1600 rpm
for thi s test.
(5) Move transmi ssi on shi ft l ever two detents rear-
ward from ful l forward posi ti on. Thi s i s D range.
(6) Read pressures on both gauges as transmi ssi on
throttl e l ever i s gradual l y moved from ful l forward to
ful l rearward posi ti on:
Li ne pressure at accumul ator i n D range thi rd
gear, shoul d be 54-60 psi (372-414 kPa) wi th throttl e
l ever forward and i ncrease as l ever i s moved rear-
ward.
Front servo pressure i n D range thi rd gear,
shoul d be wi thi n 3 psi (21 kPa) of l i ne pressure up to
ki ckdown poi nt.
Fig. 9 Pressure Test Port Locations
1 - OVERDRIVE CLUTCH TEST PORT
2 - GOVERNOR TEST PORT
3 - ACCUMULATOR TEST PORT
4 - FRONT SERVO TEST PORT
5 - REAR SERVO TEST PORT
Test Four - Transmission In Reverse
NOTE: This test checks pump output, pressure reg-
ulation and the front clutch and rear servo circuits.
Use 300 psi Test Gauge C-3293-SP for this test.
(1) Leave vehi cl e on hoi st and l eave gauge C-3292
i n pl ace at accumul ator port.
(2) Move 300 psi Gauge C-3293-SP back to rear
servo port.
(3) Have hel per start and run engi ne at 1600 rpm
for test.
(4) Move transmi ssi on shi ft l ever four detents
rearward from ful l forward posi ti on. Thi s i s Reverse
range.
(5) Move transmi ssi on throttl e l ever ful l y forward
then ful l y rearward and note readi ng at Gauge
C-3293-SP.
(6) Pressure shoul d be 145 - 175 psi (1000-1207
kPa) wi th throttl e l ever forward and i ncrease to 230 -
280 psi (1586-1931 kPa) as l ever i s gradual l y moved
rearward.
Test Five - Governor Pressure
NOTE: This test checks governor operation by mea-
suring governor pressure response to changes in
vehicle speed. It is usually not necessary to check
governor operation unless shift speeds are incor-
rect or if the transmission will not downshift. The
test should be performed on the road or on a hoist
that will allow the rear wheels to rotate freely.
(1) Move 100 psi Test Gauge C-3292 to governor
pressure port.
(2) Move transmi ssi on shi ft l ever two detents rear-
ward from ful l forward posi ti on. Thi s i s D range.
(3) Have hel per start and run engi ne at curb i dl e
speed. Then fi rml y appl y servi ce brakes so wheel s
wi l l not rotate.
(4) Note governor pressure:
Governor pressure shoul d be no more than 20.6
kPa (3 psi ) at curb i dl e speed and wheel s not rotat-
i ng.
I f pressure exceeds 20.6 kPa (3 psi ), a faul t
exi sts i n governor pressure control system.
(5) Rel ease brakes, sl owl y i ncrease engi ne speed,
and observe speedometer and pressure test gauge (do
not exceed 30 mph on speedometer). Governor pres-
sure shoul d i ncrease i n proporti on to vehi cl e speed.
Or approxi matel y 6.89 kPa (1 psi ) for every 1 mph.
(6) Governor pressure ri se shoul d be smooth and
drop back to no more than 20.6 kPa (3 psi ), after
engi ne returns to curb i dl e and brakes are appl i ed to
prevent wheel s from rotati ng.
(7) Compare resul ts of pressure test wi th anal ysi s
chart.
Test Six - Transmission In Overdrive Fourth Gear
NOTE: This test checks line pressure at the over-
drive clutch in fourth gear range. Use 300 psi Test
Gauge C-3293-SP for this test. The test should be
performed on the road or on a chassis dyno.
(1) Remove tachometer; i t i s not needed for thi s
test.
(2) Move 300 psi Gauge to overdri ve cl utch pres-
sure test port. Then remove other gauge and rei nstal l
test port pl ug.
(4) Turn OD swi tch on.
(5) Secure test gauge so i t can be vi ewed from
dri vers seat.
(6) Start engi ne and shi ft i nto D range.
(7) I ncrease vehi cl e speed gradual l y unti l 3-4 shi ft
occurs and note gauge pressure.
(8) Pressure shoul d be 469-496 kPa (68-72 psi )
wi th cl osed throttl e and i ncrease to 620-827 kPa (90-
120 psi ) at 1/2 to 3/4 throttl e. Note that pressure can
i ncrease to around 896 kPa (130 psi ) at ful l throttl e.
(9) Return to shop or move vehi cl e off chassi s
dyno.
PRESSURE TEST ANALYSIS CHART
TEST CONDITION INDICATION
Line pressure OK during
any one test
Pump and regulator
valve OK
Line pressure OK in R
but low in D, 2, 1
Leakage in rear clutch
area (seal rings, clutch
seals)
Pressure low in D Fourth
Gear Range
Overdrive clutch piston
seal, or check ball
problem
Pressure OK in 1, 2 but
low in D3 and R
Leakage in front clutch
area
Pressure OK in 2 but low
in R and 1
Leakage in rear servo
Front servo pressure in 2 Leakage in servo; broken
servo ring or cracked
servo piston
Pressure low in all
positions
Clogged filter, stuck
regulator valve, worn or
faulty pump, low oil level
Governor pressure too
high at idle speed
Governor pressure
solenoid valve system
fault. Refer to diagnostic
book.
TEST CONDITION INDICATION
Governor pressure low at
all mph figures
Faulty governor pressure
solenoid, transmission
control module, or
governor pressure
sensor
Lubrication pressure low
at all throttle positions
Clogged fluid cooler or
lines, seal rings leaking,
worn pump bushings,
pump, clutch retainer, or
clogged filter.
Line pressure high Output shaft plugged,
sticky regulator valve
Line pressure low Sticky regulator valve,
clogged filter, worn pump
TRANSMISSION CLUTCH AND BAND
OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on front/rear cl utch and band operati on. The test
can be conducted wi th the transmi ssi on ei ther i n the
vehi cl e or on the work bench, as a fi nal check, after
overhaul .
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
servo and cl utch appl y passages are shown (Fi g. 10).
Front Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through front cl utch appl y pas-
sage. Pi ston movement can be fel t and a soft thump
heard as the cl utch appl i es.
Rear Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through rear cl utch appl y passage.
Pi ston movement can be fel t and a soft thump heard
as the cl utch appl i es.
Front Servo Apply Air Test
Appl y ai r pressure to the front servo appl y pas-
sage. The servo rod shoul d extend and cause the
band to ti ghten around the drum. Spri ng pressure
shoul d rel ease the servo when ai r pressure i s
removed.
Rear Servo Air Test
Appl y ai r pressure to the rear servo appl y passage.
The servo rod shoul d extend and cause the band to
ti ghten around the drum. Spri ng pressure shoul d
rel ease the servo when ai r pressure i s removed.
HOUSING FLUID LEAK
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Pump seal l eaks tend to move al ong the
dri ve hub and onto the rear of the converter. Pump
body l eaks fol l ow the same path as a seal l eak (Fi g.
11). Pump vent or pump attachi ng bol t l eaks are gen-
eral l y deposi ted on the i nsi de of the converter hous-
i ng and not on the converter i tsel f (Fi g. 11). Pump
o-ri ng or gasket l eaks usual l y travel down the i nsi de
of the converter housi ng. Front band l ever pi n pl ug
Fig. 10 Air Pressure Test Passages
1 - REAR SERVO APPLY
2 - FRONT SERVO APPLY
3 - PUMP SUCTION
4 - FRONT CLUTCH APPLY
5 - FRONT SERVO RELEASE
6 - LINE PRESSURE TO ACCUMULATOR
7 - PUMP PRESSURE
8 - TO CONVERTER
9 - REAR CLUTCH APPLY
10 - FROM CONVERTER
11 - TO COOLER
l eaks are general l y deposi ted on the housi ng and not
on the converter.
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
(1) Leaks at the wel d joi nt around the outsi de
di ameter wel d (Fi g. 12).
(2) Leaks at the converter hub wel d (Fi g. 12).
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Ti ghten front band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
front/rear cl utches from comi ng out when oi l pump i s
removed.
(3) Remove oi l pump and remove pump seal .
I nspect pump housi ng drai nback and vent hol es for
obstructi ons. Cl ear hol es wi th sol vent and wi re.
(4) I nspect pump bushi ng and converter hub. I f
bushi ng i s scored, repl ace i t. I f converter hub i s
scored, ei ther pol i sh i t wi th crocus cl oth or repl ace
converter.
(5) I nstal l new pump seal , O-ri ng, and gasket.
Repl ace oi l pump i f cracked, porous or damaged i n
any way. Be sure to l oosen the front band before
i nstal l i ng the oi l pump, damage to the oi l pump seal
may occur i f the band i s sti l l ti ghtened to the front
cl utch retai ner.
(6) Loosen ki ckdown l ever pi n access pl ug three
turns. Appl y Locti te 592, or Permatex No. 2 to
pl ug threads and ti ghten pl ug to 17 Nm (150 i n. l bs.)
torque.
(7) Adjust front band.
(8) Lubri cate pump seal and converter hub wi th
transmi ssi on fl ui d or petrol eum jel l y and i nstal l con-
verter.
(9) I nstal l transmi ssi on and converter housi ng
dust shi el d.
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS
The di agnosi s charts provi de addi ti onal reference
when di agnosi ng a transmi ssi on faul t. The charts
provi de general i nformati on on a vari ety of transmi s-
si on, overdri ve uni t and converter cl utch faul t condi -
ti ons.
The hydraul i c fl ow charts i n the Schemati cs and
Di agrams secti on of thi s group, outl i ne fl ui d fl ow and
hydraul i c ci rcui try. Ci rcui t operati on i s provi ded for
PARK, NEUTRAL, FI RST, SECOND, THI RD,
FOURTH, MANUAL FI RST, MANUAL SECOND,
and REVERSE gear ranges. Normal worki ng pres-
sures are al so suppl i ed for each of the gear ranges.
Fig. 11 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Fig. 12 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
DIAGNOSIS CHARTS
HARSH
ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
1. Fluid Level Low. 1. Add Fluid
2. Throttle Linkage Mis-adjusted. 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts
Loose.
3. Check engine mount, transmission mount,
propeller shaft, rear spring to body bolts, rear
control arms, crossmember and axle bolt torque.
Tighten loose bolts and replace missing bolts.
4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace U-Joint.
5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as needed.
6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or adjust
valve body as needed.
7. Band Mis-adjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads before
installing new nut. Replace pinion gear if threads
are damaged.
10. Clutch, band or planetary
component damaged.
10. Remove, disassemble and repair transmission
as necessary.
11. Converter Clutch Faulty. 11. Replace converter and flush cooler and line
before installing new converter.
DELAYED
ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Mis-adjusted. 3. Adjust linkage and repair linkage if worn or
damaged.
4. Torque Converter Drain Back
(Oil drains from torque converter
into transmission sump).
4. If vehicle moves normally after 5 seconds after
shifting into gear, no repair is necessary. If longer,
inspect pump bushing for wear. Replace pump
house.
5. Rear Band Mis-adjusted. 5. Adjust band.
6. Valve Body Filter Plugged. 6. Replace fluid and filter. If oil pan and old fluid
were full of clutch disc material and/or metal
particles, overhaul will be necessary.
7. Oil Pump Gears Worn/Damaged. 7. Remove transmission and replace oil pump.
8. Governor Circuit and Solenoid
Valve Electrical Fault.
8. Test with DRB scan tool and repair as
required.
9. Hydraulic Pressure Incorrect. 9. Perform pressure test, remove transmission
and repair as needed.
10. Reaction Shaft Seal Rings
Worn/Broken.
10. Remove transmission, remove oil pump and
replace seal rings.
11. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
11. Remove and disassemble transmission and
12. Regulator Valve Stuck. 12. Clean.
13. Cooler Plugged. 13. Transfer case failure can plug cooler.
NO DRIVE RANGE
(REVERSE OK)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission and
rear clutch and seals. Repair/replace worn or
damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body. Replace
assembly if any valves or bores are damaged.
5. Transmission Overrunning
Clutch Broken.
5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings
Worn/Damaged.
6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR
REVERSE (VEHICLE
WILL NOT MOVE)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
Loose/Misadjusted.
2. Inspect, adjust and reassemble linkage as
needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.
3. Perform preliminary inspection procedure for
vehicle that will not move. Refer to procedure in
diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission. Repair
or replace failed components as needed. Replace
filter. If filter and fluid contained clutch material or
metal particles, an overhaul may be necessary.
Perform lube flow test. Flush oil. Replace cooler
as necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low pressure.
Replace pump body assembly if necessary.
6. Valve Body Malfunctioned. 6. Check and inspect valve body. Replace valve
body (as assembly) if any valve or bore is
damaged. Clean and reassemble correctly if all
parts are in good condition.
7. Transmission Internal
Component Damaged.
7. Remove and disassemble transmission. Repair
or replace failed components as needed.
8. Park Sprag not Releasing -
Check Stall Speed, Worn/
Damaged/Stuck.
8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Inspect and replace as required.
SHIFTS DELAYED OR
ERRATIC (SHIFTS
ALSO HARSH AT
TIMES)
1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if low.
2. Fluid Filter Clogged. 2. Replace filter. If filter and fluid contained clutch
material or metal particles, an overhaul may be
necessary. Perform lube flow test.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage as described in service section.
4. Throttle Linkage Binding. 4. Check cable for binding. Check for return to
closed throttle at transmission.
Mis-adjusted.
5. Adjust linkage/cable as described in service
section.
6. Clutch or Servo Failure. 6. Remove valve body and air test clutch, and
band servo operation. Disassemble and repair
transmission as needed.
7. Governor Circuit Electrical Fault. 7. Test using DRB scan tool and repair as
required.
8. Front Band Mis-adjusted. 8. Adjust band.
9. Pump Suction Passage Leak. 9. Check for excessive foam on dipstick after
normal driving. Check for loose pump bolts,
defective gasket. Replace pump assembly if
needed.
NO REVERSE (D
RANGES OK)
Mis-adjusted/Damaged.
1. Repair or replace linkage parts as needed.
2. Park Sprag Sticking. 2. Replace overdrive annulus gear.
3. Rear Band Mis-adjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace valve
body if any valves or valve bores are worn or
damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as necessary.
6. Direct Clutch in Overdrive Worn. 6. Disassemble overdrive. Replace worn or
damaged parts.
7. Front Clutch Burnt. 7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)
1. Governor Circuit Electrical Fault. 1. Test using DRB scan tool and repair as
required.
2. Valve Body Malfunction. 2. Repair stuck 1-2 shift valve or governor plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
MOVES IN 2ND OR
3RD GEAR,
ABRUPTLY
DOWNSHIFTS TO
LOW
1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for stuck 1-2
valve or governor plug.
NO LOW GEAR
(MOVES IN 2ND OR
3RD GEAR ONLY)
1. Governor Circuit Electrical Fault. 1. Test with DRB scan tool and repair as
required.
2. Valve Body Malfunction. 2. Remove, clean and inspect. Look for sticking
1-2 shift valve, 2-3 shift valve, governor plug or
broken springs.
3. Front Servo Piston Cocked in
Bore.
3. Inspect servo and repair as required.
4. Front Band Linkage Malfunction 4. Inspect linkage and look for bind in linkage.
NO KICKDOWN OR
NORMAL
DOWNSHIFT
1. Throttle Linkage Mis-adjusted. 1. Adjust linkage.
2. Accelerator Pedal Travel
Restricted.
2. Verify floor mat is not under pedal, repair worn
accelerator cable or bent brackets.
3. Valve Body Hydraulic Pressures
Too High or Too Low Due to Valve
Body Malfunction or Incorrect
Hydraulic Control Pressure
Adjustments.
3. Perform hydraulic pressure tests to determine
cause and repair as required. Correct valve body
pressure adjustments as required.
4. Governor Circuit Electrical Fault. 4. Test with DRB scan tool and repair as
required.
5. Valve Body Malfunction. 5. Perform hydraulic pressure tests to determine
cause and repair as required. Correct valve body
pressure adjustments as required.
6. TPS Malfunction. 6. Replace sensor, check with DRB scan tool.
7. PCM Malfunction. 7. Check with DRB scan tool and replace if
required.
8. Valve Body Malfunction. 8. Repair sticking 1-2, 2-3 shift valves, governor
plugs, 3-4 solenoid, 3-4 shift valve, 3-4 timing
valve.
STUCK IN LOW
GEAR (WILL NOT
UPSHIFT)
1. Throttle Linkage Mis-adjusted/
Stuck.
1. Adjust linkage and repair linkage if worn or
damaged. Check for binding cable or missing
return spring.
2. Gearshift Linkage Mis-adjusted. 2. Adjust linkage and repair linkage if worn or
damaged.
3. Governor Component Electrical
Fault.
3. Check operating pressures and test with DRB
scan tool, repair faulty component.
4. Front Band Out of Adjustment. 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches and
bands. Repair faulty component.
CREEPS IN
NEUTRAL
1. Gearshift Linkage Mis-adjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped. 2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to determine
cause and repair as required.
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Mis-assembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Mis-assembled. 3. Remove, disassemble, inspect valve body.
Reassemble correctly if necessary. Replace
assembly if valves or springs are damaged.
Check for loose bolts or screws.
4. Pump Passages Leaking. 4. Check pump for porous casting, scores on
mating surfaces and excess rotor clearance.
Repair as required. Loose pump bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE
ONLY
1. Fluid Level Low. 1. Add fluid and check for leaks.
4. Rear Band Worn. 4. Replace as required.
5. Overdrive Direct Clutch Worn. 5. Disassemble overdrive. Repair as needed.
6. Hydraulic Pressure Too Low. 6. Perform hydraulic pressure tests to determine
cause.
7. Rear Servo Leaking. 7. Air pressure check clutch-servo operation and
repair as required.
8. Band Linkage Binding. 8. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES
2. Fluid Foaming. 2. Check for high oil level, bad pump gasket or
seals, dirt between pump halves and loose pump
bolts. Replace pump if necessary.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking,
Leaking Seal Rings, Clutch Seals
Leaking, Servo Leaks, Clogged
Filter or Cooler Lines.
6. Perform hydraulic and air pressure tests to
determine cause.
7. Rear Clutch Malfunction,
Leaking Seals or Worn Plates.
7. Air pressure check clutch-servo operation and
repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR
D ONLY, BUT NOT
IN MANUAL 1
POSITION
Overrunning Clutch Faulty. Replace overrunning clutch.
GROWLING,
GRATING OR
SCRAPING NOISES
1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.
3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/
Broken.
4. Inspect and check for debris in oil pan. Repair
as required.
5. Oil Pump Components
Scored/Binding.
5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.
6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands
Mis-adjusted.
8. Adjust bands.
DRAGS OR LOCKS
UP
1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and repair
as required.
3. Front or Rear Band Mis-
adjusted.
3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in case.
5. Servo Band or Linkage
Malfunction.
5. Air pressure check servo operation and repair
as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required (look
for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow check.
Inspect pump for excessive side clearance.
Replace pump as required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.
1. Test wiring and connectors with test lamp and
volt/ohmmeter. Repair wiring as necessary. Replace
connectors and/or harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRB scan tool.
Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRB scan tool at PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace solenoid if
plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup timing
valve.
NO 4-3 DOWNSHIFT
WHEN CONTROL
SWITCH IS TURNED
OFF
1. Control Switch Open/Shorted. 1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.
2. Test solenoids and replace if seized or shorted.
3. PCM Malfunction. 3. Test with DRB scan tool. Replace PCM if faulty.
4. Valve Body Stuck Valves. 4. Repair stuck 3-4, lockup or lockup timing valve.
CLUNK NOISE FROM
DRIVELINE ON
CLOSED THROTTLE
4-3 DOWNSHIFT
1. Transmission Fluid Low. 1. Add Fluid.
2. Throttle Cable Mis-adjusted. 2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.
3. Replace overdrive piston thrust plate spacer.
3-4 UPSHIFT
OCCURS
IMMEDIATELY AFTER
2-3 SHIFT
1. Overdrive Solenoid Connector or
Wiring Shorted.
1. Test connector and wiring for loose connections,
shorts or ground and repair as needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary. Check with
DRB scan tool.
3. PCM Malfunction. 3. Test PCM with DRB scan tool and replace
controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and inspect valve
body components. Make sure all valves and plugs
slide freely in bores. Polish valves with crocus
cloth if needed.
WHINE/NOISE
RELATED TO ENGINE
SPEED
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing. Should not
touch engine or bell housing.
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed and
repair as necessary (i.e., shorts or grounds in
circuit).
3. O/D Switch Wire Shorted/Open
Cut.
3. Check wires/connections with 12V test lamp
and voltmeter. Repair damaged or loose
wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.
4. Check with DRB scan tool and repair or
replace as necessary.
5. TPS Malfunction. 5. Check with DRB scan tool and replace if
necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.
6. Test switch/sensor as described in service
section and replace if necessary. Engine no start.
7. PCM Malfunction. 7. Check with DRB scan tool and replace if
necessary.
8. Overdrive Solenoid Shorted/
Open.
8. Replace solenoid if shorted or open and repair
loose or damaged wires (DRB scan tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.
9. Remove, disassemble, and clean valve body
thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball bleed
orifice.
SLIPS IN OVERDRIVE
FOURTH GEAR
2. Overdrive Clutch Pack Worn. 2. Remove overdrive unit and rebuild clutch pack.
3. Overdrive Piston Retainer Bleed
Orifice Blown Out.
3. Disassemble transmission, remove retainer and
replace orifice.
4. Overdrive Piston or Seal
Malfunction.
4. Remove overdrive unit. Replace seals if worn.
Replace piston if damaged. If piston retainer is
damaged, remove and disassemble the
transmission.
5. 3-4 Shift Valve, Timing Valve or
Accumulator Malfunction.
5. Remove and overhaul valve body. Replace
accumulator seals. Make sure all valves operate
freely in bores and do not bind or stick. Make sure
valve body screws are correctly tightened and
separator plates are properly positioned.
6. Overdrive Unit Thrust Bearing
Failure.
6. Disassemble overdrive unit and replace thrust
bearing (NO. 1 thrust bearing is between
overdrive piston and clutch hub; NO. 2 thrust
bearing is between the planetary gear and the
direct clutch spring plate; NO. 3 thrust bearing is
between overrunning clutch hub and output shaft).
7. O/D Check Valve/Bleed Orifice
Failure.
7. Check for function/secure orifice insert in O/D
piston retainer.
DELAYED 3-4
UPSHIFT (SLOW TO
ENGAGE)
2. Throttle Valve Cable Mis-
adjusted.
2. Adjust throttle valve cable.
3. Overdrive Clutch Pack
Worn/Burnt.
3. Remove unit and rebuild clutch pack.
4. TPS Faulty. 4. Test with DRB scan tool and replace as
necessary
5. Overdrive Clutch Bleed Orifice
Plugged.
5. Disassemble transmission and replace orifice.
6. Overdrive Solenoid or Wiring
Shorted/Open.
6. Test solenoid and check wiring for loose/
corroded connections or shorts/grounds. Replace
solenoid if faulty and repair wiring if necessary.
7. Overdrive Excess Clearance. 7. Remove unit. Measure end play and select
proper spacer.
8. O/D Check Valve Missing or
Stuck.
8. Check for presence of check valve. Repair or
replace as required.
TORQUE
CONVERTER LOCKS
UP IN SECOND
AND/OR THIRD
GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for continuity,
shorts or grounds. Replace solenoid and relay if
faulty. Repair wiring and connectors as necessary.
HARSH 1-2, 2-3, 3-4
OR 3-2 SHIFTS
Lockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
NO START IN PARK
OR NEUTRAL
Mis-adjusted.
1. Adjust linkage/cable.
2. Neutral Sense Wire Open/Cut. 2. Check continuity with test lamp. Repair as
required.
3. Park/Neutral Switch, or
Transmission Range Sensor Faulty.
3. Refer to service section for test and
replacement procedure.
Transmission Range Sensor
Connection Faulty.
4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
5. Inspect lever assembly and replace if damaged.
NO REVERSE (OR
SLIPS IN REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch pack.
3. Front Clutch Malfunctioned/
Burned.
3. Air-pressure test clutch operation. Remove and
rebuild if necessary.
4. Overdrive Thrust Bearing
Failure.
4. Disassemble geartrain and replace bearings.
5. Direct Clutch Spring Collapsed/
Broken.
5. Remove and disassemble unit. Check clutch
position and replace spring.
OIL LEAKS. 1. Fluid Lines and Fittings
Loose/Leaks/Damaged.
1. Tighten fittings. If leaks persist, replace fittings
and lines if necessary.
2. Fill Tube (where tube enters
case) Leaks/Damaged.
2. Replace tube seal. Inspect tube for cracks in fill
tube.
3. Pressure Port Plug Loose
Loose/Damaged.
3. Tighten to correct torque. Replace plug or
reseal if leak persists.
4. Pan Gasket Leaks. 4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
5. Replace shaft seal.
6. Rear Bearing Access Plate
Leaks.
6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.
7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.
8. Replace gasket.
Transmission Range Sensor
Leaks/Damaged.
9. Replace switch and gasket.
10. Converter Housing Area Leaks. 10. Check for leaks at seal caused by worn seal
or burr on converter hub (cutting seal), worn
bushing, missing oil return, oil in front pump
housing or hole plugged. Check for leaks past
O-ring seal on pump or past pump-to-case bolts;
pump housing porous, oil coming out vent due to
overfill or leak past front band shaft access plug.
11. Pump Seal Leaks/Worn/
Damaged.
11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.
12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
NOISY OPERATION
IN FOURTH GEAR
ONLY
1. Overdrive Clutch Discs, Plates
or Snap Rings Damaged.
1. Remove unit and rebuild clutch pack.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.
2. Remove and disassemble unit. Replace either
thrust bearing if damaged.
3. Output Shaft Bearings
Scored/Damaged.
3. Remove and disassemble unit. Replace either
bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning
Clutch Rollers Worn/Scored.
5. Remove and overhaul overdrive unit.
THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s , or equi val ent. Thi s repai r con-
si sts of dri l l i ng out the worn-out damaged threads.
Then tap the hol e wi th a speci al Hel i -Coi l tap, or
equi val ent, and i nstal l i ng a Hel i -Coi l i nsert, or
equi val ent, i nto the hol e. Thi s bri ngs the hol e back to
i ts ori gi nal thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
REMOVAL
The overdri ve uni t can be removed and servi ced
separatel y. I t i s not necessary to remove the enti re
transmi ssi on assembl y to perform overdri ve uni t
repai rs.
I f onl y the overdri ve uni t requi res servi ce, refer to
Overdri ve Removal for proper procedures.
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, pump bush-
ing, or oil seal can be damaged if the converter is
left attached to the driveplate during removal. Be
sure to remove the transmission and converter as
an assembly.
(2) Di sconnect and l ower or remove necessary
exhaust components.
(3) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(4) Remove starter motor. (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - REMOVAL)
(5) Di sconnect and remove crankshaft posi ti on sen-
sor. (Refer to 14 - FUEL SYSTEM/FUEL I NJEC-
TI ON/CRANKSHAFT POSI TI ON SENSOR -
REMOVAL) Retai n sensor attachi ng bol ts.
CAUTION: The crankshaft position sensor will be
damaged if the transmission is removed, or
installed, while the sensor is still bolted to the
engine block, or transmission (4.0L only). To avoid
damage, be sure to remove the sensor before
removing the transmission.
(6) Remove the bol ts hol di ng the bel l housi ng
brace to the transmi ssi on.
(7) Remove nut hol di ng the bel l housi ng brace to
the engi ne to transmi ssi on bendi ng brace.
(8) Remove the bel l housi ng brace from the trans-
mi ssi on (Fi g. 13).
(9) Remove the bol t hol di ng the torque converter
cover to the transmi ssi on.
(10) Remove the torque converter cover from the
transmi ssi on.
(11) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan.
(12) Remove fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube seal . On 4 x 4
model s, i t wi l l al so be necessary to remove bol t
attachi ng transfer case vent tube to converter hous-
i ng.
(13) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(14) Mark propel l er shaft and axl e yokes for
assembl y al i gnment. Then di sconnect and remove
propel l er shaft. On 4 x 4 model s, remove both propel -
l er shafts.
(15) Di sconnect wi res from park/neutral posi ti on
swi tch and transmi ssi on sol enoi d.
(16) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever (Fi g. 14).
Fig. 13 Bell Housing Brace and Converter Cover
1 - Transmission
2 - Torque Converter Cover
3 - Bellhousing Brace
Fig. 14 Transmission Shift Cable
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
(17) Di sconnect throttl e val ve cabl e from transmi s-
si on bracket and throttl e val ve l ever (Fi g. 15).
(18) Di sconnect transfer case shi ft cabl e from the
transfer case shi ft l ever (Fi g. 16).
(19) Remove the cl i p securi ng the transfer case
shi ft cabl e i nto the cabl e support bracket.
(20) Di sconnect transmi ssi on fl ui d cool er l i nes at
transmi ssi on fi tti ngs and cl i ps.
(21) Support rear of engi ne wi th safety stand or
jack.
(22) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(23) Remove bol ts securi ng rear support and cush-
i on to transmi ssi on and crossmember (Fi g. 17).
(24) Remove bol ts attachi ng crossmember to frame
and remove crossmember.
(25) Remove transfer case (Fi g. 18) and (Fi g. 19).
Fig. 15 Throttle Valve Cable
1 - THROTTLE VALVE CABLE
2 - THROTTLE VALVE LEVER
3 - THROTTLE BODY
Fig. 16 Transfer Case Shift Cable
1 - TRANSFER CASE SHIFT LEVER
2 - TRANSFER CASE SHIFT CABLE
Fig. 17 Rear Transmission Crossmember
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
Fig. 18 Remove NV247 Transfer Case
1 - NV247 TRANSFER CASE
(26) Remove bol ts hol di ng the upper transmi ssi on
bendi ng braces to the torque converter housi ng and
the overdri ve uni t (Fi g. 20).
(27) Remove al l remai ni ng converter housi ng bol ts.
(28) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(29) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(30) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
(31) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
DISASSEMBLY
(1) Cl ean transmi ssi on exteri or wi th steam gun or
wi th sol vent. Wear eye protecti on duri ng cl eani ng
operati ons.
(2) Pl ace transmi ssi on i n a verti cal posi ti on.
(3) Measure i nput shaft end pl ay as fol l ows (Fi g.
21).
(a) Attach Adapter 8266-6 to Handl e 8266-8.
(b) Attach di al i ndi cator C-3339 to Handl e
8266-8.
(c) I nstal l the assembl ed tool onto the i nput
shaft of the transmi ssi on and ti ghten the retai ni ng
screw on Adapter 8266-6 to secure i t to the i nput
shaft.
(d) Posi ti on the di al i ndi cator pl unger agai nst a
fl at spot on the oi l pump and zero the di al i ndi ca-
tor.
(e) Move the i nput shaft i n and out. Record the
maxi mum travel for assembl y reference.
(4) Remove shi ft and throttl e l evers from val ve
body manual l ever shaft.
(5) Pl ace transmi ssi on i n hori zontal posi ti on.
(6) Remove transmi ssi on oi l pan and gasket.
(7) Remove fi l ter from val ve body (Fi g. 22). Keep
fi l ter screws separate from other val ve body screws.
Fi l ter screws are l onger and shoul d be kept wi th fi l -
ter.
(8) Remove park/neutral posi ti on swi tch.
(9) Remove hex head bol ts attachi ng val ve body to
transmi ssi on case (Fi g. 23). A total of 10 bol ts are
used. Note di fferent bol t l engths for assembl y refer-
ence.
Fig. 20 Remove Upper Transmission Bending
Braces
1 - TRANSMISSION BENDING BRACES
Fig. 21 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339
(10) Remove val ve body assembl y. Push val ve body
harness connector out of case. Then work park rod
and val ve body out of case (Fi g. 24).
(11) Remove accumul ator pi ston and i nner and
outer spri ngs (Fi g. 25).
(12) Remove pump oi l seal wi th sui tabl e pry tool
or sl i de-hammer mounted screw.
(13) Loosen front band adjusti ng screw l ocknut 4-5
turns. Then ti ghten band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
front/rear cl utches from comi ng out wi th pump and
possi bl y damagi ng cl utch or pump components.
(14) Remove oi l pump bol ts.
(15) Thread bol ts of Sl i de Hammer Tool s C-3752
i nto threaded hol es i n pump body fl ange (Fi g. 26).
(16) Bump sl i de hammer wei ghts outward to
remove pump and reacti on shaft support assembl y
from case (Fi g. 26).
(17) Loosen front band adjusti ng screw unti l band
i s compl etel y l oose.
Fig. 22 Oil Filter Removal
1 - OIL FILTER
2 - VALVE BODY
3 - FILTER SCREWS (2)
Fig. 23 Valve Body Bolt Locations
1 - VALVE BODY BOLTS
2 - VALVE BODY BOLTS
Fig. 24 Valve Body Removal
1 - GOVERNOR PRESSURE SENSOR
2 - VALVE BODY
3 - PARK ROD
4 - ACCUMULATOR PISTON
5 - GOVERNOR PRESSURE SOLENOID
Fig. 25 Accumulator Piston And Springs
2 - OUTER SPRING
3 - INNER SPRING
(18) Squeeze front band together and remove band
strut (Fi g. 27).
(19) Remove front band l ever (Fi g. 28).
(20) Remove front band l ever shaft pl ug, i f neces-
sary, from converter housi ng.
(21) Remove front band l ever shaft.
(22) Remove front and rear cl utch uni ts as assem-
bl y. Grasp i nput shaft, hol d cl utch uni ts together and
remove them from case (Fi g. 29).
(23) Li ft front cl utch off rear cl utch (Fi g. 30). Set
cl utch uni ts asi de for overhaul .
(24) Remove i ntermedi ate shaft thrust washer
from front end of shaft or from rear cl utch hub (Fi g.
31).
(25) Remove output shaft thrust pl ate from i nter-
medi ate shaft hub (Fi g. 32).
(26) Sl i de front band off dri vi ng shel l (Fi g. 33) and
remove band from case.
Fig. 26 Removing Oil Pump And Reaction Shaft
Support Assembly
1 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY
2 - SLIDE HAMMER TOOLS C-3752
Fig. 27 Removing Front Band Strut
1 - BAND LEVER
2 - BAND STRUT
3 - FRONT BAND
Fig. 28 Removing Front Band Lever
1 - FRONT BAND LEVER
Fig. 29 Removing Front/Rear Clutch Assemblies
1 - INPUT SHAFT
2 - FRONT CLUTCH
3 - REAR CLUTCH
(27) Remove pl anetary geartrai n as assembl y (Fi g.
34). Support geartrai n wi th both hands duri ng
removal . Do not al l ow machi ned surfaces on i nterme-
di ate shaft or overdri ve pi ston retai ner to become
ni cked or scratched.
(28) I f overdri ve uni t i s not to be servi ced, i nstal l
Al i gnment Shaft 6227-2 i nto the overdri ve uni t to
prevent mi sal i gnment of the overdri ve cl utches dur-
i ng servi ce of mai n transmi ssi on components.
Fig. 30 Separating Front/Rear Clutch Assemblies
1 - FRONT CLUTCH
2 - REAR CLUTCH
Fig. 31 Removing Intermediate Shaft Thrust Washer
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
3 - REAR CLUTCH RETAINER HUB
Fig. 32 Removing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT HUB
2 - INTERMEDIATE SHAFT THRUST PLATE
Fig. 33 Front Band Removal
1 - DRIVING SHELL
2 - FRONT BAND
(29) Loosen rear band adjusti ng screw 4-5 turns.
(30) Remove l ow-reverse drum snap-ri ng (Fi g. 35).
(31) Remove l ow-reverse drum and reverse band.
(32) Remove overrunni ng cl utch rol l er and spri ng
assembl y as a uni t (Fi g. 36).
(33) Compress front servo rod gui de about 1/8 i nch
wi th Val ve Spri ng Compressor C-3422-B (Fi g. 37).
(34) Remove front servo rod gui de snap-ri ng. Exer-
ci se cauti on when removi ng snap-ri ng. Servo bore
can be scratched or ni cked i f care i s not exerci sed.
(35) Remove compressor tool s and remove front
servo rod gui de, spri ng and servo pi ston.
Fig. 34 Removing Planetary Geartrain And
Intermediate Shaft Assembly
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
Fig. 35 Removing Low-Reverse Drum Snap-Ring
1 - LOW-REVERSE DRUM
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING
Fig. 36 Overrunning Clutch Assembly Removal
1 - OVERRUNNING CLUTCH CAM
2 - REAR BAND REACTION PIN
3 - OVERRUNNING CLUTCH ASSEMBLY
Fig. 37 Compressing Front Servo Rod Guide
1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP-RING
(36) Compress rear servo spri ng retai ner about
1/16 i nch wi th Val ve Spri ng Compressor C-3422-B
(Fi g. 38).
(37) Remove rear servo spri ng retai ner snap-ri ng.
Then remove compressor tool s and remove rear servo
spri ng and pi ston.
(38) I nspect transmi ssi on components.
NOTE: To Service the overrunning clutch cam or
overdrive piston retainer, refer to the Overrunning
Clutch Cam service procedure in this section.
CLEANING
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
Lubri cate transmi ssi on parts wi th Mopar ATF +4,
type 9602, transmi ssi on fl ui d duri ng overhaul and
assembl y. Use petrol eum jel l y, Mopar Door Ease, or
Ru-Gl yde to prel ubri cate seal s, O-ri ngs, and thrust
washers. Petrol eum jel l y can al so be used to hol d
parts i n pl ace duri ng reassembl y.
INSPECTION
I nspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repai red wi th Hel i coi l thread i nserts. However, the
case wi l l have to be repl aced i f i t exhi bi ts any type of
damage or wear.
Lubri cate the front band adjusti ng screw threads
wi th petrol eum jel l y and thread the screw part-way
i nto the case. Be sure the screw turns freel y.
I nspect the transmi ssi on bushi ngs duri ng overhaul .
Bushi ng condi ti on i s i mportant as worn, scored bush-
i ngs contri bute to l ow pressures, cl utch sl i p and
accel erated wear of other components. However, do
not repl ace bushi ngs as a matter of course. Repl ace
bushi ngs onl y when they are actual l y worn, or
scored.
Use recommended tool s to repl ace bushi ngs. The
tool s are si zed and desi gned to remove, i nstal l , and
seat bushi ngs correctl y. The bushi ng repl acement
tool s are i ncl uded i n Bushi ng Tool Set C-3887-B.
Pre-si zed servi ce bushi ngs are avai l abl e for
repl acement purposes. Onl y the sun gear bushi ngs
are not servi ced.
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on
shafts, or val ves, use extreme care to avoi d roundi ng
off sharp edges. Sharp edges are vi tal as they pre-
vent forei gn matter from getti ng between the val ve
and val ve bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or
O-ri ngs duri ng overhaul . Repl ace these parts as a
matter of course. Al so do not reuse snap ri ngs or
E-cl i ps that are bent or di storted. Repl ace these parts
as wel l .
ASSEMBLY
Do not al l ow di rt, grease, or forei gn materi al to
enter the case or transmi ssi on components duri ng
assembl y. Keep the transmi ssi on case and compo-
nents cl ean. Al so make sure the tool s and workbench
area used for assembl y operati ons are equal l y cl ean.
Shop towel s used for wi pi ng off tool s and hands
must be made from lint free materi al . Li nt wi l l sti ck
to transmi ssi on parts and coul d i nterfere wi th val ve
operati on, or even restri ct fl ui d passages.
Lubri cate the transmi ssi on components wi th
Mopar transmi ssi on fl ui d duri ng reassembl y. Use
Mopar Door Ease, or Ru-Gl yde on seal s and
O-ri ngs to ease i nstal l ati on.
Fig. 38 Compressing Rear Servo Spring
1 - FRONT SERVO SNAP-RING
2 - REAR SERVO SNAP-RING
3 - SPECIAL TOOL
Petrol eum jel l y can al so be used to hol d thrust
washers, thrust pl ates and gaskets i n posi ti on duri ng
assembl y. However, do not use chassi s grease, bear-
i ng grease, whi te grease, or si mi l ar l ubri cants on any
transmi ssi on part. These types of l ubri cants can
eventual l y bl ock or restri ct fl ui d passages and i nter-
fere wi th val ve operati on. Use petrol eum jel l y onl y.
Do not force parts i nto pl ace. The transmi ssi on
components and subassembl i es are easi l y i nstal l ed by
hand when properl y al i gned.
I f a part seems extremel y di ffi cul t to i nstal l , i t i s
ei ther mi sal i gned or i ncorrectl y assembl ed. Al so ver-
i fy that thrust washers, thrust pl ates and seal ri ngs
are correctl y posi ti oned before assembl y. These parts
can i nterfere wi th proper assembl y i f mi s-posi ti oned.
The pl anetary geartrai n, front/rear cl utch assem-
bl i es and oi l pump are al l much easi er to i nstal l
when the transmi ssi on case i s upri ght.
(1) I nstal l rear servo pi ston, spri ng and retai ner
(Fi g. 39). I nstal l spri ng on top of servo pi ston and
i nstal l retai ner on top of spri ng.
(2) I nstal l front servo pi ston assembl y, servo
spri ng and rod gui de (Fi g. 40).
(3) Compress front/rear servo spri ngs wi th Val ve
Spri ng Compressor C-3422-B and i nstal l each servo
snap-ri ng (Fi g. 41).
(4) Lubri cate cl utch cam rol l ers wi th transmi ssi on
fl ui d.
(5) I nstal l rear band i n case (Fi g. 42). Be sure twi n
l ugs on band are seated agai nst reacti on pi n.
(6) I nstal l l ow-reverse drum and check overrun-
ni ng cl utch operati on as fol l ows:
(a) Lubri cate overrunni ng cl utch race (on drum
hub) wi th transmi ssi on fl ui d.
(b) Gui de drum through rear band.
(c) Ti l t drum sl i ghtl y and start race (on drum
hub) i nto overrunni ng cl utch rol l ers.
(d) Press drum rearward and turn i t i n cl ock-
wi se di recti on unti l drum seats i n overrunni ng
cl utch (Fi g. 43).
Fig. 39 Rear Servo Components
1 - SERVO PISTON
2 - PISTON SPRING
3 - SNAP-RING
4 - RETAINER
5 - PISTON SEAL
Fig. 40 Front Servo Components
1 - PISTON SEAL RINGS
2 - SERVO PISTON
3 - SNAP-RING
4 - ROD GUIDE
5 - SPRING
6 - ROD
Fig. 41 Compressing Front/Rear Servo Springs
1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP-RING
(e) Turn drum back and forth. Drum shoul d
rotate freel y i n cl ockwi se di recti on and l ock i n
countercl ockwi se di recti on (as vi ewed from front of
case).
(7) I nstal l snap-ri ng that secures l ow-reverse drum
to hub of overdri ve pi ston retai ner (Fi g. 44).
(8) I nstal l rear band l ever and pi vot pi n (Fi g. 45).
Al i gn l ever wi th pi n bores i n case and push pi vot pi n
i nto pl ace.
(9) I nstal l pl anetary geartrai n assembl y (Fi g. 46).
Fig. 42 Rear Band Installation
1 - REAR BAND
Fig. 43 Installing Low-Reverse Drum
1 - REAR BAND
Fig. 44 Installing Low-Reverse Drum Retaining
Snap-Ring
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING
Fig. 45 Rear Band Lever And Pivot Pin Installation
1 - REAR BAND LEVER
2 - LEVER PIVOT PIN
(10) I nstal l thrust pl ate on i ntermedi ate shaft hub
(Fi g. 47). Use petrol eum jel l y to hol d thrust pl ate i n
pl ace.
(11) Check seal ri ng on rear cl utch retai ner hub
and seal ri ngs on i nput shaft (Fi g. 48). Al so veri fy
that shaft seal ri ngs are i nstal l ed i n sequence shown.
(12) I nstal l rear cl utch thrust washer (Fi g. 49).
Use addi ti onal petrol eum jel l y to hol d washer i n
pl ace i f necessary.
(13) Al i gn cl utch di scs i n front cl utch and i nstal l
front cl utch on rear cl utch (Fi g. 50). Rotate front
cl utch retai ner back and forth unti l compl etel y
seated on rear cl utch retai ner.
(14) Coat i ntermedi ate shaft thrust washer wi th
petrol eum jel l y. Then i nstal l washer i n rear cl utch
hub (Fi g. 51). Use enough petrol eum jel l y to hol d
washer i n pl ace. Be sure grooved si de of washer faces
rearward (toward output shaft) as shown. Al so note
that washer onl y fi ts one way i n cl utch hub. Note
thi ckness of thi s washer. I t i s a sel ect fi t part and i s
used to control transmi ssi on end pl ay.
Fig. 46 Installing Planetary Geartrain
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
Fig. 47 Installing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT HUB
2 - INTERMEDIATE SHAFT THRUST PLATE
Fig. 48 Input Shaft Seal Ring Location
1 - INPUT SHAFT
2 - TEFLON SEAL RING
3 - PLASTIC SEAL RING
4 - REAR CLUTCH RETAINER
Fig. 49 Installing Rear Clutch Thrust Washer
2 - REAR CLUTCH THRUST WASHER (FIBER)
(15) Al i gn dri ve teeth on rear cl utch di scs wi th
smal l screwdri ver (Fi g. 52). Thi s makes i nstal l ati on
on front pl anetary easi er.
(16) Rai se front end of transmi ssi on upward as far
as possi bl e and support case wi th wood bl ocks. Front/
rear cl utch and oi l pump assembl i es are easi er to
i nstal l i f transmi ssi on i s as cl ose to upri ght posi ti on
as possi bl e.
(17) Sl i de front band i nto case.
(18) I nstal l front and rear cl utch uni ts as assembl y
(Fi g. 53). Al i gn rear cl utch wi th front annul us gear
and i nstal l assembl y i n dri vi ng shel l . Be sure output
shaft thrust washer and thrust pl ate are not di s-
pl aced duri ng i nstal l ati on.
(19) Careful l y work assembl ed cl utches back and
forth to engage and seat rear cl utch di scs on front
annul us gear. Al so be sure front cl utch dri ve l ugs are
ful l y engaged i n sl ots of dri vi ng shel l after i nstal l a-
ti on.
(20) Assembl e front band strut.
(21) I nstal l front band adjuster, strut and adjust-
i ng screw (Fi g. 54).
(22) Ti ghten band adjusti ng screw unti l band just
gri ps cl utch retai ner. Veri fy that front/rear cl utches
are sti l l seated before conti nui ng.
Fig. 50 Assembling Front And Rear Clutch Units
1 - TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 - REAR CLUTCH ASSEMBLY
Fig. 51 Installing Intermediate Shaft Thrust Washer
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
3 - REAR CLUTCH RETAINER HUB
Fig. 52 Aligning Rear Clutch Disc Lugs
1 - REAR CLUTCH DISCS
2 - USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC
TEETH
(23) Check seal ri ngs on reacti on shaft support
hub. Veri fy that seal ri ngs are hooked together and
that the thrust washer i s properl y posi ti oned (Fi g.
55). Use petrol eum jel l y to hol d thrust washer i n
pl ace i f necessary.
(24) Lubri cate oi l pump body seal wi th petrol eum
jel l y. Lubri cate pump shaft seal l i p wi th petrol eum
jel l y.
(25) Thread two Pi l ot Stud Tool s C-3288-B i nto
bol t hol es i n oi l pump bore fl ange (Fi g. 56).
(26) Al i gn and i nstal l oi l pump gasket (Fi g. 56).
Fig. 53 Installing Front/Rear Clutch Assemblies
1 - INPUT SHAFT
2 - FRONT CLUTCH
3 - REAR CLUTCH
Fig. 54 Front Band Linkage Installation
1 - BAND LEVER
2 - BAND STRUT
3 - FRONT BAND
Fig. 55 Reaction Shaft Support Seal Rings And
Thrust Washer
1 - REACTION SHAFT SUPPORT HUB
2 - THRUST WASHER
3 - SEAL RINGS
Fig. 56 Installing Pilot Studs And Oil Pump Gasket
1 - OIL PUMP GASKET
2 - PILOT STUD TOOLS C-3288-B
(27) I nstal l oi l pump (Fi g. 57). Al i gn and posi ti on
pump on pi l ot studs. Sl i de pump down studs and
work i t i nto front cl utch hub and case by hand. Then
i nstal l 2 or 3 pump bol ts to hol d pump i n pl ace.
(28) Remove pi l ot stud tool s and i nstal l remai ni ng
oi l pump bol ts. Ti ghten bol ts al ternatel y i n di agonal
(29) Measure i nput shaft end pl ay (Fi g. 58).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or the intermediate shaft
thrust washer is incorrect. The intermediate shaft
thrust washer is selective.
(a) Attach Adapter 8266-6 to Handl e 8266-8.
(b) Attach di al i ndi cator C-3339 to Handl e
8266-8.
(c) I nstal l the assembl ed tool onto the i nput
shaft of the transmi ssi on and ti ghten the retai ni ng
screw on Adapter 8266-6 to secure i t to the i nput
shaft.
(d) Posi ti on the di al i ndi cator pl unger agai nst a
fl at spot on the oi l pump and zero the di al i ndi ca-
tor.
(e) Move i nput shaft i n and out and record read-
i ng. End pl ay shoul d be 0.56-2.31 mm (0.022-0.091
i n.). Adjust as necessary.
(30) I nstal l accumul ator pi ston and i nner and
outer spri ngs (Fi g. 59).
(31) Veri fy that val ve body sol enoi d harness i s
secured i n 3-4 accumul ator housi ng cover pl ate.
Fig. 57 Installing Oil Pump
1 - OIL PUMP
2 - PILOT STUD TOOL
3 - PILOT STUD TOOL
Fig. 58 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339
Fig. 59 Accumulator Piston And Springs
2 - VALVE BODY
3 - PARK ROD
(32) I nstal l val ve body as fol l ows:
(a) Al i gn and careful l y i nsert park rod i nto pawl .
Rod wi l l make cl i ck noi se as i t enters pawl . Move
rod sl i ghtl y to check engagement.
(b) Al i gn and seat val ve body on case. Be sure
manual l ever shaft and overdri ve connector are
ful l y seated i n case. Al so be sure val ve body wi ri ng
i s not pi nched or ki nked.
(c) I nstal l and start al l val ve body attachi ng
bol ts by hand. Then ti ghten bol ts evenl y, i n a di ag-
onal pattern to 12 Nm (105 i n. l bs.) torque. Do not
overti ghten val ve body bol ts. Thi s coul d resul t i n
di storti on and cross l eakage after i nstal l ati on.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity.
(33) I nstal l new fi l ter on val ve body. Ti ghten fi l ter
(34) Adjust front and rear bands.
(35) I nstal l seal on park/neutral posi ti on swi tch.
Then i nstal l and ti ghten swi tch to 34 Nm (25 ft.
l bs.).
(36) I nstal l magnet i n oi l pan. Magnet goes on
smal l protrusi on at corner of pan.
(37) Posi ti on new oi l pan gasket on case and
i nstal l oi l pan. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.).
(38) I nstal l new val ve body manual shaft seal i n
case (Fi g. 60). Lubri cate seal l i p and manual shaft
wi th petrol eum jel l y. Start seal over shaft and i nto
case. Seat seal wi th 15/16 i nch, deep wel l socket.
(39) I nstal l throttl e val ve and shi ft sel ector l evers
on val ve body manual l ever shaft.
INSTALLATION
(1) Check torque converter hub and hub dri ve
notches for sharp edges burrs, scratches, or ni cks.
Pol i sh the hub and notches wi th 320/400 gri t paper
and crocus cl oth i f necessary. The hub must be
smooth to avoi d damagi ng pump seal duri ng i nstal l a-
ti on.
(2) Lubri cate oi l pump seal l i p wi th transmi ssi on
fl ui d.
(3) Al i gn converter and oi l pump.
(4) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(5) Check converter seati ng wi th steel scal e and
strai ghtedge (Fi g. 61). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(6) Temporari l y secure converter wi th C-cl amp.
(7) Posi ti on transmi ssi on on jack and secure i t
wi th chai ns.
(8) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Al so be sure transmi ssi on dowel pi ns are seated i n
engi ne bl ock and protrude far enough to hol d trans-
mi ssi on i n al i gnment.
(9) Appl y a l i ght coati ng of Mopar Hi gh Temp
grease to the torque converter hub pocket i n the rear
of the crankshaft
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
Fig. 60 Installing Manual Lever Shaft Seal
1 - 15/16 SOCKET
2 - SEAL
Fig. 61 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
(11) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
(12) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft.
(13) I nstal l two bol ts to attach converter housi ng
to engi ne.
(14) I nstal l the upper transmi ssi on bendi ng braces
to the torque converter housi ng and the overdri ve
uni t. Ti ghten the bol ts to 41 Nm (30 ft.l bs.).
(15) I nstal l remai ni ng torque converter housi ng to
engi ne bol ts. Ti ghten to 68 Nm (50 ft.l bs.).
(16) I nstal l rear transmi ssi on crossmember.
Ti ghten crossmember to frame bol ts to 68 Nm (50
ft.l bs.).
(17) I nstal l rear support to transmi ssi on. Ti ghten
bol ts to 47 Nm (35 ft.l bs.).
(18) Lower transmi ssi on onto crossmember and
i nstal l bol ts attachi ng transmi ssi on mount to cross-
member. Ti ghten cl evi s bracket to crossmember bol ts
to 47 Nm (35 ft.l bs.). Ti ghten the cl evi s bracket to
rear support bol t to 68 Nm (50 ft.l bs.).
(19) Remove engi ne support fi xture.
(20) I nstal l crankshaft posi ti on sensor. (Refer to 14
- FUEL SYSTEM/FUEL I NJECTI ON/CRANKSHAFT
POSI TI ON SENSOR - I NSTALLATI ON)
(21) I nstal l new pl asti c retai ner grommet on any
shi ft cabl e that was di sconnected. Grommets shoul d
not be reused. Use pry tool to remove rod from grom-
met and cut away ol d grommet. Use pl i ers to snap
new grommet i nto cabl e and to snap grommet onto
l ever.
(22) Connect gearshi ft and throttl e val ve cabl e to
transmi ssi on.
(23) Connect wi res to park/neutral posi ti on swi tch
and transmi ssi on sol enoi d connector. Be sure trans-
mi ssi on harnesses are properl y routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(24) I nstal l al l torque converter-to-dri vepl ate bol ts
by hand.
(25) Veri fy that the torque converter i s pul l ed
fl ush to the dri vepl ate. Ti ghten bol ts to 31 Nm (270
i n. l bs.).
(26) I nstal l converter housi ng access cover. Ti ghten
bol t to 23 Nm (200 i n.l bs.).
(27) I nstal l the bel l housi ng brace to the torque
converter cover and the engi ne to transmi ssi on bend-
i ng brace. Ti ghten the bol ts and nut to 41 Nm (30
ft.l bs.).
(28) I nstal l starter motor (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - I NSTALLA-
TI ON) and cool er l i ne bracket.
(29) Connect cool er l i nes to transmi ssi on.
(30) I nstal l transmi ssi on fi l l tube. I nstal l new seal
on tube before i nstal l ati on.
(31) I nstal l exhaust components.
(32) I nstal l transfer case. Ti ghten transfer case
nuts to 35 Nm (26 ft.l bs.).
(33) I nstal l the transfer case shi ft cabl e to the
cabl e support bracket and the transfer case shi ft
l ever.
(34) Al i gn and connect propel l er shaft(s).
(35) Adjust gearshi ft l i nkage and throttl e val ve
cabl e i f necessary.
(37) Fi l l transmi ssi on wi th Mopar ATF +4, type
9602, fl ui d.
HYDRAULIC SCHEMATICS
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SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Planetary end play 0.127-1.22
mm
0.005-0.048
in.
Input shaft end play 0.56-2.31
mm
0.022-0.091
in.
Clutch pack clearance/
Front.
1.70-
3.40mm
0.067-0.134
in.
Clutch pack clearance/
Rear.
0.559-0.914
mm
0.022-0.036
in.
Front clutch 4 discs
Rear clutch 4 discs
Overdrive clutch 3 discs
Direct clutch 6 discs
42RE Band adjustment
from 72 in. lbs.
Front band Back off 3 turns
Rear band Back off 4 turns
Recommended fluid Mopar ATF +4, type 9602
GEAR RATIOS
1ST GEAR 2.74:1
2ND GEAR 1.54:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.21:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Front clutch thrust washer (reaction shaft
support hub)
1.55 mm 0.061 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) Select fit to set end play
Output shaft thrust washer (rear clutch hub) 1.5-1.6 mm 0.060-0.063 in.
Rear clutch pack snap-ring 1.5 mm 0.060 in.
1.95 mm 0.076 in.
2.45 mm 0.098 in.
Planetary geartrain snap-ring (at front of output shaft) Select fit (three thicknesses avalible)
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
procedures in
Overdrive Unit D&A
procedures
Intermiediate shaft spacer
PRESSURE TEST
Overdrive clutch Fourth gear only Pressure should be 469-496 kPa (68-72 psi) with
closed throttle and increase to 620-896 kPa (90-130
psi) at 1/2 to 3/4 throttle.
Line pressure (at
accumulator)
Closed throttle 372-414 kPa (54-60 psi).
Front servo Third or Fourth gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
Governor D range closed throttle Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.
Fitting, cooler line at trans 18 13 -
Bolt, torque convertor 31 - 270
Bolt, clevis bracket to crossmember 47 35 -
Bolt, clevis bracket to rear support 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Plug, front band reaction 17 13 -
Locknut, front band adj. 34 25 -
Switch, park/neutral 34 25 -
Bolt, fluid pan 17 13 -
Screws, fluid filter 4 - 35
Bolt, oil pump 20 15 -
Bolt, overrunning clutch cam 17 13 -
Bolt, O/D to trans. 34 25 -
Bolt, O/D piston retainer 17 13 -
Plug, pressure test port 14 10 -
Bolt, reaction shaft support 20 15 -
Locknut, rear band 41 30 -
Bolt, speedometer adapter 11 - 100
Screw, vehicle speed sensor 2.5 - 21
Bolt, valve body to case 12 - 100
Sensor, trans speed 27 20 -
Screw, solenoid wiring connector 4 - 35
Screw, solenoid to transfer plate 4 - 35
SPECIAL TOOLS
RE TRANSMISSIONS
Shaft, Spring Compressor and Alignment - 6227
Bar, Gauge - 6311
Pilot, Extension Housing - C-3288-B
Gauge, Oil Pressure - C-3292
Gauge, Oil Pressure - C-3293SP
Dial Indicator - C-3339
Compressor, Spring - C-3422-C
Puller, Slide Hammer - C-3752
Gauge, Throttle Setting - C-3763
Installer, Seal - C-3860-A
Remover, Seal - C-3985-B
Handle, Universal - C-4171
Dial Caliper - C-4962
Kit, Bushing Remover/Installer - C-3887-J
Nut, Bushing Remover - SP-1191, From kit C-3887-J
Cup, Bushing Remover - SP-3633, From kit C-3887-J
Remover, Bushing - SP-3551
Installer, Bushing - SP-5117
Remover, Bushing - SP-5324
Installer, Bushing - SP-5325
Compressor, Spring - C-3575-A
Gauge - 6312
Adapter, Band Adjuster - C-3705
Flusher, Oil Cooler - 6906-B
Installer, Piston - 8114
Remover, Bushing - 6957
Installer, Bushing - 6951
Retainer, Detent Ball and Spring - 6583
ACCUMULATOR
DESCRIPTION
The accumul ator (Fi g. 62) i s a hydraul i c devi ce
that has the sol e purpose of cushi oni ng the appl i ca-
ti on of a band or cl utch. The accumul ator consi sts of
a dual -l and pi ston and a spri ng l ocated i n a bore i n
the transmi ssi on case. The 3-4 accumul ator i s l ocated
i n a housi ng attached to the si de of the val ve body
(Fi g. 63).
OPERATION
Both the accumul ator and the 3-4 accumul ator
functi on the same. Li ne pressure i s di rected to the
smal l end of the pi ston when the transmi ssi on i s
pl aced i nto a DRI VE posi ti on (Fi g. 64), bottomi ng i t
agai nst the accumul ator pl ate. When the 1-2 upshi ft
occurs (Fi g. 65), l i ne pressure i s di rected to the l arge
end of the pi ston and then to the ki ckdown servo. As
the l i ne pressure reaches the accumul ator, the com-
bi nati on of spri ng pressure and l i ne pressure forces
the pi ston away from the accumul ator pl ate. Thi s
causes a bal anced pressure si tuati on, whi ch resul ts
i n a cushi oned band appl i cati on. After the ki ckdown
servo has become i mmovabl e, l i ne pressure wi l l fi n-
i sh pushi ng the accumul ator up i nto i ts bore. When
the l arge end of the accumul ator pi ston i s seated i n
i ts bore, the band or cl utch i s ful l y appl i ed.
NOTE: The accumulator is shown in the inverted
position for illustrative purposes.
INSPECTION
I nspect the accumul ator pi ston and seal ri ngs (Fi g.
66). Repl ace the seal ri ngs i f worn or cut. Repl ace the
pi ston i f chi pped or cracked.
Check condi ti on of the accumul ator i nner and
outer spri ngs (Fi g. 66). Repl ace the spri ngs i f the
coi l s are cracked, di storted or col l apsed.
Fig. 62 Accumulator
2 - PISTON SPRING
Fig. 63 3-4 Accumulator and Housing
2 - 3-4 ACCUMULATOR HOUSING
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
Fig. 64 Accumulator in DRIVE - FIRST Gear Position
1 - LINE PRESSURE
BANDS
DESCRIPTION
KICKDOWN (FRONT) BAND
The ki ckdown, or front, band (Fi g. 67) hol ds the
common sun gear of the pl anetary gear sets. The
front (ki ckdown) band i s made of steel , and faced on
i ts i nner ci rcumference wi th a fri cti on-type l i ni ng.
One end of the band i s anchored to the transmi ssi on
case, and the other i s acted on wi th a pushi ng force
by a servo pi ston. The front band i s a si ngl e-wrap
desi gn (the band does not compl etel y encompass/
wrap the drum that i t hol ds).
LOW/REVERSE (REAR) BAND
The l ow/reverse band, or rear, band (Fi g. 68) i s
si mi l ar i n appearance and operati on to the front
band. The rear band i s sl i ghtl y di fferent i n that i t
does not use a l i nk bar, but i s acted di rectl y on by
the appl y l ever. Thi s i s referred to as a doubl e-wrap
band desi gn (the drum i s compl etel y encompassed/
wrapped by the band). The doubl e-wrap band pro-
vi des a greater hol di ng power i n compari son to the
si ngl e-wrap desi gn.
OPERATION
KICKDOWN (FRONT) BAND
The ki ckdown band hol ds the common sun gear of
the pl anetary gear sets by appl yi ng and hol di ng the
front cl utch retai ner, whi ch i s spl i ned to the sun gear
dri vi ng shel l , and i n turn spl i ned di rectl y to the sun
gear. The appl i cati on of the band by the servo i s typ-
i cal l y done by an appl y l ever and l i nk bar.
LOW/REVERSE (REAR) BAND
The rear band hol ds the rear pl anet carri er sta-
ti onary by bei ng mounted around and appl i ed to the
l ow/reverse drum.
Fig. 65 Accumulator in SECOND Gear Position
1 - BOTTOM OF BORE
2 - LINE PRESSURE
3 - SHUTTLE VALVE
Fig. 66 Accumulator Components
1 - INNER SPRING
3 - OUTER SPRING
4 - SEAL RINGS
Fig. 67 Front Band
1 - FRONT BAND
BANDS (Continued)
ADJ USTMENTS
ADJUSTMENT - BANDS
FRONT BAND
The front (ki ckdown) band adjusti ng screw i s
l ocated on the l eft si de of the transmi ssi on case
above the manual val ve and throttl e val ve l evers.
(2) Loosen band adjusti ng screw l ocknut (Fi g. 69).
Then back l ocknut off 3-5 turns. Be sure adjusti ng
screw turns freel y i n case. Appl y l ubri cant to screw
threads i f necessary.
(3) Ti ghten band adjusti ng screw to 8 Nm (72 i n.
l bs.) torque wi th I nch Pound Torque Wrench
C-3380-A, a 3-i n. extensi on and appropri ate Torx
socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw, tighten the screw to only 5 Nm
(47-50 in. lbs.) torque.
(4) Back off front band adjusti ng screw 3 turns.
(5) Hol d adjuster screw i n posi ti on and ti ghten
l ocknut to 41 Nm (30 ft. l bs.) torque.
REAR BAND
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(2) Remove transmi ssi on oi l pan and drai n fl ui d.
(3) Loosen band adjusti ng screw l ocknut 5-6 turns
(Fi g. 70). Be sure adjusti ng screw turns freel y i n
l ever.
(4) Ti ghten adjusti ng screw to 8 Nm (72 i n. l bs.)
torque.
(5) Back off adjusti ng screw 4 turns.
(6) Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 Nm (25 ft. l bs.) torque.
(7) Posi ti on new gasket on oi l pan and i nstal l pan
on transmi ssi on. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.) torque.
(8) Lower vehi cl e and refi l l transmi ssi on wi th
Mopar ATF +4, type 9602, fl ui d.
Fig. 68 Rear Band
1 - ADJUSTING SCREW
2 - LOCKNUT
3 - LEVER
4 - REAR BAND
5 - REACTION PIN
6 - O-RINGS
7 - PIVOT PIN
Fig. 69 Front Band Adjustment Screw Location
1 - LOCK-NUT
2 - FRONT BAND ADJUSTER
Fig. 70 Rear Band Adjusting Screw Location
1 - ADJUSTING SCREW
2 - REAR BAND LEVER
3 - LOCKNUT
BANDS (Continued)
BRAKE TRANSMISSION SHIFT
INTERLOCK MECHANISM
DESCRIPTION
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 71).
OPERATION
The system l ocks the shi fter i nto the PARK posi -
ti on. The i nterl ock system i s engaged whenever the
i gni ti on swi tch i s i n the LOCK or ACCESSORY posi -
ti on. An addi ti onal el ectri cal l y acti vated feature wi l l
prevent shi fti ng out of the PARK posi ti on unl ess the
brake pedal i s depressed approxi matel y one-hal f an
i nch. A magneti c hol di ng devi ce i n the shi fter assem-
bl y i s energi zed when the i gni ti on i s i n the RUN
posi ti on. When the key i s i n the RUN posi ti on and
the brake pedal i s depressed, the shi fter i s unl ocked
and wi l l move i nto any posi ti on. The i nterl ock system
al so prevents the i gni ti on swi tch from bei ng turned
to the LOCK or ACCESSORY posi ti on, unl ess the
shi fter i s ful l y l ocked i nto the PARK posi ti on.
TRANSMISSION SHIFT INTERLOCK
(1) Veri fy that the key can onl y be removed i n the
PARK posi ti on
(2) When the shi ft l ever i s i n PARK And the shi ft
handl e pushbutton i s i n the OUT posi ti on, the i gni -
ti on key cyl i nder shoul d rotate freel y from OFF to
LOCK. When the shi fter i s i n any other gear or neu-
tral posi ti on, the i gni ti on key cyl i nder shoul d not
rotate to the LOCK posi ti on.
(3) Shi fti ng out of PARK shoul d not be possi bl e
when the i gni ti on key cyl i nder i s i n the OFF posi -
ti on.
whi l e appl yi ng normal pushbutton force and i gni ti on
key cyl i nder i s i n the RUN or START posi ti ons
unl ess the foot brake pedal i s depressed approxi -
matel y 1/2 i nch (12mm).
when the i gni ti on key cyl i nder i s i n the ACCESSORY
or LOCK posi ti ons.
(6) Shi fti ng between any gears, NEUTRAL or i nto
PARK may be done wi thout depressi ng foot brake
pedal wi th i gni ti on swi tch i n RUN or START posi -
ti ons.
Fig. 71 Ignition Interlock Cable
1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY
2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE
3 - ADJUSTMENT CLIP
SHIFT INTERLOCK
The park i nterl ock cabl e i s part of the brake/shi ft
l ever i nterl ock system. Correct cabl e adjustment i s
i mportant to proper i nterl ock operati on. The gear
shi ft and park l ock cabl es must both be correctl y
adjusted i n order to shi ft out of PARK.
ADJUSTMENT PROCEDURE
(1) Remove fl oor consol e as necessary for access to
the brake transmi ssi on shi ft i nterl ock cabl e. (Refer to
23 - BODY/I NTERI OR/FLOOR CONSOLE -
REMOVAL)
(2) Shi ft the transmi ssi on i nto the PARK posi ti on.
(3) Turn i gni ti on swi tch to LOCK posi ti on. Be
sure ignition key cylinder is in the LOCK posi-
tion. Cable will not adjust correctly in any
other position.
(4) Pul l cabl e l ock button up to rel ease cabl e (Fi g.
72).
(5) Ensure that the cabl e i s free to sel f-adjust by
pushi ng cabl e rearward and rel easi ng.
(6) Push l ock button down unti l i t snaps i n pl ace.
BTSI FUNCTION CHECK
(1) Veri fy removal of i gni ti on key al l owed i n PARK
posi ti on onl y.
(2) When the shi ft l ever i s i n PARK, and the shi ft
handl e push-button i s i n the out posi ti on, the i gni -
ti on key cyl i nder shoul d rotate freel y from off to l ock.
When the shi fter i s i n any other posi ti on, the i gni ti on
key shoul d not rotate from off to l ock.
(3) Shi fti ng out of PARK shoul d be possi bl e when
the i gni ti on key cyl i nder i s i n the off posi ti on.
whi l e appl yi ng normal push-button force, and i gni -
ti on key cyl i nder i s i n the run or start posi ti ons,
when the i gni ti on key cyl i nder i s i n the accessory or
l ock posi ti on.
(6) Shi fti ng between any gear and NEUTRAL, or
PARK, may be done wi thout depressi ng foot brake
wi th i gni ti on swi tch i n run or start posi ti ons.
(7) The fl oor shi fter l ever and gate posi ti ons
shoul d be i n al i gnment wi th al l transmi ssi on detent
posi ti ons.
Fig. 72 Brake Transmission Shift Interlock Cable
3 - ADJUSTMENT CLIP
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued)
(8) Engi ne starts must be possi bl e wi th shi fter
l ever i n PARK or NEUTRAL gate posi ti ons onl y.
Engi ne starts must not be possi bl e i n any other gate
posi ti ons other than PARK or NEUTRAL.
(9) Wi th shi fter l ever handl e push-button not
depressed and l ever detent i n:
PARK posi ti on- appl y forward force on center of
handl e and remove pressure. Engi ne start must be
possi bl e.
PARK posi ti on- appl y rearward force on center
of handl e and remove pressure. Engi ne start must be
possi bl e.
NEUTRAL posi ti on- engi ne start must be possi -
bl e.
NEUTRAL posi ti on, engi ne runni ng and brakes
appl i ed- Appl y forward force on center of shi ft han-
dl e. Transmi ssi on shoul d not be abl e to shi ft i nto
REVERSE detent.
ELECTRONIC GOVERNOR
DESCRIPTION
Governor pressure i s control l ed el ectroni cal l y. Com-
ponents used for governor pressure control i ncl ude:
Governor body
Val ve body transfer pl ate
Governor pressure sol enoi d val ve
Governor pressure sensor
Fl ui d temperature thermi stor
Transmi ssi on speed sensor
Powertrai n control modul e (PCM)
GOVERNOR PRESSURE SOLENOID VALVE
The sol enoi d val ve i s a duty-cycl e sol enoi d whi ch
regul ates the governor pressure needed for upshi fts
and downshi fts. I t i s an el ectro-hydraul i c devi ce
l ocated i n the governor body on the val ve body trans-
fer pl ate (Fi g. 73).
GOVERNOR PRESSURE SENSOR
The governor pressure sensor measures output
pressure of the governor pressure sol enoi d val ve (Fi g.
74).
GOVERNOR BODY AND TRANSFER PLATE
The transfer pl ate i s desi gned to suppl y transmi s-
si on l i ne pressure to the governor pressure sol enoi d
val ve and to return governor pressure.
The governor pressure sol enoi d val ve i s mounted i n
the governor body. The body i s bol ted to the l ower
si de of the transfer pl ate (Fi g. 74).
GOVERNOR PRESSURE CURVES
There are four governor pressure curves pro-
grammed i nto the transmi ssi on control modul e. The
di fferent curves al l ow the control modul e to adjust
governor pressure for varyi ng condi ti ons. One curve
i s used for operati on when fl ui d temperature i s at, or
bel ow, 1C (30F). A second curve i s used when fl ui d
temperature i s at, or above, 10C (50F) duri ng nor-
mal ci ty or hi ghway dri vi ng. A thi rd curve i s used
duri ng wi de-open throttl e operati on. The fourth curve
i s used when dri vi ng wi th the transfer case i n l ow
range.
OPERATION
Compensati on i s requi red for performance vari a-
ti ons of two of the i nput devi ces. Though the sl ope of
the transfer functi ons i s ti ghtl y control l ed, offset may
vary due to vari ous envi ronmental factors or manu-
facturi ng tol erances.
The pressure transducer i s affected by barometri c
pressure as wel l as temperature. Cal i brati on of the
zero pressure offset i s requi red to compensate for
shi fti ng output due to these factors.
Fig. 73 Governor Pressure Solenoid Valve
1 - SOLENOID FILTER
Fig. 74 Governor Pressure Sensor
1 - GOVERNOR BODY
2 - GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID
TEMPERATURE THERMISTOR
Normal cal i brati on wi l l be performed when sump
temperature i s above 50 degrees F, or i n the absence
of sump temperature data, after the fi rst 10 mi nutes
of vehi cl e operati on. Cal i brati on of the pressure
transducer offset occurs each ti me the output shaft
speed fal l s bel ow 200 RPM. Cal i brati on shal l be
repeated each 3 seconds the output shaft speed i s
bel ow 200 RPM. A 0.5 second pul se of 95% duty cycl e
i s appl i ed to the governor pressure sol enoi d val ve
and the transducer output i s read duri ng thi s pul se.
Averagi ng of the transducer si gnal i s necessary to
reject el ectri cal noi se.
Under col d condi ti ons (bel ow 50 degrees F sump),
the governor pressure sol enoi d val ve response may
be too sl ow to guarantee 0 psi duri ng the 0.5 second
cal i brati on pul se. Cal i brati on pul ses are conti nued
duri ng thi s peri od, however the transducer output
val ves are di scarded. Transducer offset must be read
at key-on, under condi ti ons whi ch promote a stabl e
readi ng. Thi s val ue i s retai ned and becomes the off-
set duri ng the col d peri od of operati on.
GOVERNOR PRESSURE SOLENOID VALVE
The i nl et si de of the sol enoi d val ve i s exposed to
normal transmi ssi on l i ne pressure. The outl et si de of
the val ve l eads to the val ve body governor ci rcui t.
The sol enoi d val ve regul ates l i ne pressure to pro-
duce governor pressure. The average current sup-
pl i ed to the sol enoi d control s governor pressure. One
amp current produces zero kPa/psi governor pres-
sure. Zero amps sets the maxi mum governor pres-
sure.
The powertrai n control modul e (PCM) turns on the
trans control rel ay whi ch suppl i es el ectri cal power to
the sol enoi d val ve. Operati ng vol tage i s 12 vol ts
(DC). The PCM control s the ground si de of the sol e-
noi d usi ng the governor pressure sol enoi d control ci r-
cui t.
GOVERNOR PRESSURE SENSOR
The sensor output si gnal provi des the necessary
feedback to the PCM. Thi s feedback i s needed to ade-
quatel y control governor pressure.
GOVERNOR BODY AND TRANSFER PLATE
The transfer pl ate channel s l i ne pressure to the
sol enoi d val ve through the governor body. I t al so
channel s governor pressure from the sol enoi d val ve
to the governor ci rcui t. I t i s the sol enoi d val ve that
devel ops the necessary governor pressure.
GOVERNOR PRESSURE CURVES
LOW TRANSMISSION FLUID TEMPERATURE
When the transmi ssi on fl ui d i s col d the conven-
ti onal governor can del ay shi fts, resul ti ng i n hi gher
than normal shi ft speeds and harsh shi fts. The el ec-
troni cal l y control l ed l ow temperature governor pres-
sure curve i s hi gher than normal to make the
transmi ssi on shi ft at normal speeds and sooner. The
PCM uses a temperature sensor i n the transmi ssi on
oi l sump to determi ne when l ow temperature gover-
nor pressure i s needed.
NORMAL OPERATION
Normal operati on i s refi ned through the i ncreased
computi ng power of the PCM and through access to
data on engi ne operati ng condi ti ons provi ded by the
PCM that were not avai l abl e wi th the previ ous
stand-al one el ectroni c modul e. Thi s faci l i tated the
devel opment of a l oad adapti ve shi ft strategy - the
abi l i ty to al ter the shi ft schedul e i n response to vehi -
cl e l oad condi ti on. One mani festati on of thi s capabi l -
i ty i s grade hunti ng preventi on - the abi l i ty of the
transmi ssi on l ogi c to del ay an upshi ft on a grade i f
the engi ne does not have suffi ci ent power to mai n-
tai n speed i n the hi gher gear. The 3-2 downshi ft and
the potenti al for hunti ng between gears occurs wi th a
heavi l y l oaded vehi cl e or on steep grades. When
hunti ng occurs, i t i s very objecti onabl e because shi fts
are frequent and accompani ed by l arge changes i n
noi se and accel erati on.
WIDE OPEN THROTTLE OPERATION
I n wi de-open throttl e (WOT) mode, adapti ve mem-
ory i n the PCM assures that up-shi fts occur at the
preprogrammed opti mum speed. WOT operati on i s
determi ned from the throttl e posi ti on sensor, whi ch
i s al so a part of the emi ssi on control system. The i ni -
ti al setti ng for the WOT upshi ft i s bel ow the opti -
mum engi ne speed. As WOT shi fts are repeated, the
PCM l earns the ti me requi red to compl ete the shi fts
by compari ng the engi ne speed when the shi fts occur
to the opti mum speed. After each shi ft, the PCM
adjusts the shi ft poi nt unti l the opti mum speed i s
reached. The PCM al so consi ders vehi cl e l oadi ng,
grade and engi ne performance changes due to hi gh
al ti tude i n determi ni ng when to make WOT shi fts. I t
does thi s by measuri ng vehi cl e and engi ne accel era-
ti on and then factori ng i n the shi ft ti me.
TRANSFER CASE LOW RANGE OPERATION
On four-wheel dri ve vehi cl es operati ng i n l ow
range, the engi ne can accel erate to i ts peak more
rapi dl y than i n Normal range, resul ti ng i n del ayed
shi fts and undesi rabl e engi ne fl are. The l ow range
governor pressure curve i s al so hi gher than normal
to i ni ti ate upshi fts sooner. The PCM compares el ec-
troni c vehi cl e speed si gnal used by the speedometer
to the transmi ssi on output shaft speed si gnal to
determi ne when the transfer case i s i n l ow range.
ELECTRONIC GOVERNOR (Continued)
REMOVAL
(2) Remove transmi ssi on fl ui d pan and fi l ter.
(3) Di sengage wi re connectors from pressure sen-
sor and sol enoi d (Fi g. 75).
(4) Remove screws hol di ng pressure sol enoi d
retai ner to governor body.
(5) Separate sol enoi d retai ner from governor (Fi g.
76).
(6) Pul l sol enoi d from governor body (Fi g. 77).
(7) Pul l pressure sensor from governor body.
(8) Remove bol ts hol di ng governor body to val ve
body.
(9) Separate governor body from val ve body (Fi g.
78).
(10) Remove governor body gasket.
INSTALLATION
Before i nstal l i ng the pressure sensor and sol enoi d
i n the governor body, repl ace o-ri ng seal s, cl ean the
gasket surfaces and repl ace gasket.
(1) Pl ace gasket i n posi ti on on back of governor
body (Fi g. 79).
(2) Pl ace governor body i n posi ti on on val ve body.
(3) I nstal l bol ts to hol d governor body to val ve
body.
(4) Lubri cate o-ri ng on pressure sensor wi th trans-
mi ssi on fl ui d.
(5) Al i gn pressure sensor to bore i n governor body.
Fig. 75 Governor Solenoid And Pressure Sensor
1 - PRESSURE SENSOR
2 - PRESSURE SOLENOID
3 - GOVERNOR
Fig. 76 Pressure Solenoid Retainer
1 - PRESSURE SOLENOID RETAINER
2 - GOVERNOR
Fig. 77 Pressure Solenoid and O-ring
2 - O-RING
3 - GOVERNOR
Fig. 78 Governor Body and Gasket
1 - GOVERNOR BODY
2 - GASKET
(6) Push pressure sensor i nto governor body.
(7) Lubri cate o-ri ng, on pressure sol enoi d, wi th
transmi ssi on fl ui d.
(8) Al i gn pressure sol enoi d to bore i n governor
body (Fi g. 80).
(9) Push sol enoi d i nto governor body.
(10) Pl ace sol enoi d retai ner i n posi ti on on governor
(Fi g. 81).
(11) I nstal l screws to hol d pressure sol enoi d
retai ner to governor body.
(12) Engage wi re connectors i nto pressure sensor
and sol enoi d (Fi g. 82).
(13) I nstal l transmi ssi on fl ui d pan and (new) fi l ter.
(14) Lower vehi cl e and road test to veri fy repai r.
EXTENSION HOUSING
BUSHING
REMOVAL
(1) Remove extensi on housi ng yoke seal .
(2) I nsert Remover 6957 i nto the extensi on hous-
i ng. Ti ghten tool to bushi ng and remove bushi ng
(Fi g. 83).
INSTALLATION
(1) Al i gn bushi ng oi l hol e wi th oi l sl ot i n extensi on
housi ng.
(2) Tap bushi ng i nto pl ace wi th I nstal l er 6951 and
Handl e C-4171.
Fig. 79 Governor Body and Gasket
1 - GOVERNOR BODY
2 - GASKET
Fig. 80 Pressure Solenoid and O-ring
2 - O-RING
3 - GOVERNOR
Fig. 81 Pressure Solenoid Retainer
1 - PRESSURE SOLENOID RETAINER
2 - GOVERNOR
Fig. 82 Governor Solenoid And Pressure Sensor
1 - PRESSURE SENSOR
3 - GOVERNOR
(3) I nstal l new oi l seal i n housi ng usi ng Seal
I nstal l er C-3995-A (Fi g. 84).
EXTENSION HOUSING SEAL
REMOVAL
(2) Mark propel l er shaft and axl e yoke for al i gn-
ment reference.
(3) Di sconnect and remove propel l er shaft.
(4) Remove ol d seal wi th Seal Remover C-3985-B
(Fi g. 85) from overdri ve housi ng.
INSTALLATION
(1) Pl ace seal i n posi ti on on overdri ve housi ng.
(2) Dri ve seal i nto overdri ve housi ng wi th Seal
I nstal l er C-3995-A (Fi g. 86).
(3) Careful l y gui de propel l er shaft sl i p yoke i nto
housi ng and onto output shaft spl i nes. Al i gn marks
made at removal and connect propel l er shaft to rear
axl e pi ni on yoke.
FLUID AND FILTER
INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve and cl utch operati on. Foami ng al so causes fl ui d
expansi on whi ch can resul t i n fl ui d overfl ow from the
transmi ssi on vent or fi l l tube. Fl ui d overfl ow can eas-
i l y be mi staken for a l eak i f i nspecti on i s not careful .
BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
Fig. 83 Bushing Removal - Typical
1 - REMOVER 6957
2 - EXTENSION HOUSING BUSHING
Fig. 84 Extension Housing Seal Installation
1 - SPECIAL TOOL C-3995-A OR C-3972-A
Fig. 85 Removing Overdrive Housing Yoke Seal
1 - SPECIAL TOOL C-3985-B
2 - SEAL
Fig. 86 Installing Overdrive Housing Seal
1 - SPECIAL TOOL C-3995-A OR C-3972-A
EXTENSION HOUSING BUSHING (Continued)
(1) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(2) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to reverse fl ush cool er and l i nes after
repai r
fai l ure to repl ace contami nated converter after
repai r
The use of non-recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on, an overhaul i s necessary.
The transmi ssi on cool er and l i nes shoul d be
reverse fl ushed whenever a mal functi on generates
sl udge and/or debri s. The torque converter shoul d
al so be repl aced at the same ti me.
Fai l ure to fl ush the cool er and l i nes wi l l resul t i n
recontami nati on. Fl ushi ng appl i es to auxi l i ary cool ers
as wel l . The torque converter shoul d al so be repl aced
whenever a fai l ure generates sl udge and debri s. Thi s
i s necessary because normal converter fl ushi ng proce-
dures wi l l not remove al l contami nants.
STANDARD PROCEDURE
CHECK
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th
the fl ui d. As i n any hydraul i c system, ai r bubbl es
make the fl ui d spongy, therefore, pressures wi l l be
l ow and bui l d up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transmssi on has too much fl ui d, the
geartrai n churns up foam and cause the same condi -
ti ons whi ch occur wi th a l ow fl ui d l evel .
I n ei ther case, ai r bubbl es can cause overheati ng
and/or fl ui d oxi dati on, and varni shi ng. Thi s can
i nterfere wi th normal val ve, cl utch, and accumul ator
operati on. Foami ng can al so resul t i n fl ui d escapi ng
from the transmi ssi on vent where i t may be mi s-
taken for a l eak.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
The transmi ssi on has a di psti ck to check oi l l evel .
I t i s l ocated on the ri ght si de of the engi ne. Be sure
to wi pe al l di rt from di psti ck handl e before removi ng.
Fl ui d l evel i s checked wi th the engi ne runni ng at
curb i dl e speed, the transmi ssi on i n NEUTRAL and
the transmi ssi on fl ui d at normal operati ng tempera-
ture. The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.
The transmi ssi on fl ui d l evel can be checked two
ways.
PROCEDURE ONE
(1) Transmi ssi on fl ui d must be at normal operat-
i ng temperature for accurate fl ui d l evel check. Dri ve
vehi cl e i f necessary to bri ng fl ui d temperature up to
normal hot operati ng temperature of 82C (180F).
(3) Start and run engi ne at curb i dl e speed.
(5) Shi ft transmi ssi on momentari l y i nto al l gear
ranges. Then shi ft transmi ssi on back to NEUTRAL.
(6) Cl ean top of fi l l er tube and di psti ck to keep
di rt from enteri ng tube.
(7) Remove di psti ck (Fi g. 87) and check fl ui d l evel
as fol l ows:
(a) Correct acceptabl e l evel i s i n crosshatch area.
(b) Correct maxi mum l evel i s to MAX arrow
mark.
(c) I ncorrect l evel i s at or bel ow MI N l i ne.
(d) I f fl ui d i s l ow, add onl y enough Mopar ATF
+4, type 9602, to restore correct l evel . Do not over-
fi l l .
FLUID AND FILTER (Continued)
PROCEDURE TWO
(1) Start engi ne and appl y parki ng brake.
(2) Shi ft the transmi ssi on i nto DRI VE for approxi -
matel y 2 seconds.
(3) Shi ft the transmi ssi on i nto REVERSE for
approxi matel y 2 seconds.
(4) Shi ft the transmi ssi on i nto PARK.
(5) Hook up DRB scan tool and sel ect engi ne.
(6) Sel ect sensors.
(7) Read the transmi ssi on temperature val ue.
(8) Compare the fl ui d temperature val ue wi th the
fi gure. (Fi g. 88)
(9) Adjust transmi ssi on fl ui d l evel shown on the
di psti ck accordi ng to the fi gure.
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmi ssi on for l eaks.
STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper servi ce i nterval s (Refer to LUBRI CA-
TI ON & MAI NTENANCE/MAI NTENANCE SCHED-
ULES - DESCRI PTI ON). The servi ce fl ui d fi l l after a
fi l ter change i s approxi matel y 3.8 l i ters (4.0 quarts).
REMOVAL
(2) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(3) Remove bol ts hol di ng front and si des of pan to
transmi ssi on (Fi g. 89).
(4) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
(5) Sl owl y separate front of pan and gasket away
from transmi ssi on al l owi ng the fl ui d to drai n i nto
drai n pan.
(6) Hol d up pan and remove remai ni ng bol t hol d-
i ng pan to transmi ssi on.
Fig. 88 42/44RE Fluid Fill Graph
Fig. 87 Dipstick Fluid Level Marks - Typical
1 - DIPSTICK
2 - MAXIMUM CORRECT FLUID LEVEL
3 - ACCEPTABLE FLUID LEVEL
(7) Whi l e hol di ng pan l evel , l ower pan and gasket
away from transmi ssi on.
(8) Pour remai ni ng fl ui d i n pan i nto drai n pan.
(9) Remove screws hol di ng fi l ter to val ve body
(Fi g. 90).
(10) Separate fi l ter from val ve body and pour fl ui d
i n fi l ter i nto drai n pan.
(11) Di spose of used trans fl ui d and fi l ter properl y.
INSTALLATION
(1) Posi ti on a new transmi ssi on oi l fi l ter onto the
val ve body.
(2) I nstal l the screws to hol d the fi l ter to the val ve
body. Ti ghten the screws to 4 Nm (35 i n.l bs.).
(3) Cl ean the gasket surfaces of the transmi ssi on
oi l pan and transmi ssi on pan rai l .
NOTE: The transmission pan oil gasket is reusable.
Inspect the sealing surfaces of the gasket. If the
sealing ribs on both surfaces appear to be in good
condition, clean the gasket of any foreign material
and reinstall.
(4) Posi ti on the oi l pan gasket onto the oi l pan.
(5) Posi ti on the oi l pan and gasket onto the trans-
mi ssi on and i nstal l several bol ts to hol d the pan and
gasket to the transmi ssi on.
(6) I nstal l the remai nder of the oi l pan bol ts.
Ti ghten the bol ts to 13.6 Nm (125 i n.l bs.).
(7) Lower vehi cl e and fi l l transmi ssi on. (Refer to
21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C/
FLUI D - STANDARD PROCEDURE)
FILL
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar ATF
+4, type 9602, to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 3
pints (1-1/2 quarts) of ATF +4 to transmi ssi on.
(b) I f transmi ssi on was compl etel y overhaul ed,
torque converter was repl aced or drai ned, and
cool er was fl ushed, add 12 pints (6 quarts) of ATF
+4 to transmi ssi on.
(4) Start and run engi ne at normal curb i dl e speed.
(5) Appl y servi ce brakes, shi ft transmi ssi on
through al l gear ranges then back to NEUTRAL, set
parki ng brake, and l eave engi ne runni ng at curb i dl e
speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick. Check to see i f the oi l l evel
i s equal on both si des of the di psti ck. I f one si de i s
noti cabl y hi gher than the other, the di psti ck has
pi cked up some oi l from the di psti ck tube. Al l ow the
oi l to drai n down the di psti ck tube and re-check.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow
mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
Fig. 89 Transmission Pan
1 - TRANSMISSION
2 - GASKET
3 - PAN
Fig. 90 Transmission Filter
1 - TRANSMISSION
2 - FILTER
FRONT CLUTCH
DESCRIPTION
The front cl utch assembl y (Fi g. 91) i s composed of
the front cl utch retai ner, pressure pl ate, cl utch
pl ates, dri vi ng di scs, pi ston, pi ston return spri ng,
return spri ng retai ner, and snap-ri ngs. The front
cl utch i s the forward-most component i n the trans-
mi ssi on geartrai n and i s di rectl y behi nd the oi l pump
and i s consi dered a dri vi ng component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
Fig. 91 Front Clutch Components
1 - SNAP-RING (WAVE) 7 - SEAL
2 - REACTION PLATE 8 - PISTON
3 - CLUTCH DISC 9 - SPRING
4 - CLUTCH PLATE 10 - SNAP-RING
5 - SEAL 11 - SPRING RETAINER
6 - CLUTCH RETAINER
OPERATION
To appl y the cl utch, pressure i s appl i ed between
the cl utch retai ner and pi ston. The fl ui d pressure i s
provi ded by the oi l pump, transferred through the
control val ves and passageways, and enters the
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved snap-ri ng i s
used to cushi on the appl i cati on of the cl utch pack.
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and one-way bal l -check-val ve l ocated i n the
cl utch retai ner. The check-val ve i s needed to el i mi -
nate the possi bi l i ty of pl ate drag caused by centri fu-
gal force acti ng on the resi dual fl ui d trapped i n the
cl utch pi ston retai ner.
DISASSEMBLY
(1) Remove waved snap-ri ng and remove pressure
pl ate, cl utch pl ates and cl utch di scs (Fi g. 92).
(2) Compress cl utch pi ston spri ng wi th Compressor
Tool C-3575-A (Fi g. 93). Be sure l egs of tool are
seated squarel y on spri ng retai ner before compress-
i ng spri ng.
(3) Remove retai ner snap-ri ng and remove com-
pressor tool .
(4) Remove spri ng retai ner and cl utch spri ng. Note
posi ti on of retai ner on spri ng for assembl y reference.
(5) Remove cl utch pi ston from cl utch retai ner.
Remove pi ston by rotati ng i t up and out of retai ner.
(6) Remove seal s from cl utch retai ner pi ston bore
and cl utch retai ner hub. Di scard both seal s as they
are not reusabl e.
INSPECTION
I nspect the front cl utch components. Repl ace the
cl utch di scs i f warped, worn, scored, burned or
charred, or i f the faci ng i s fl aki ng off. Repl ace the
steel pl ates i f heavi l y scored, warped, or broken. Be
sure the dri vi ng l ugs on the pl ates are i n good con-
di ti on. The l ugs must not be bent, cracked or dam-
aged i n any way.
Repl ace the cl utch spri ng and spri ng retai ner i f
ei ther i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged.
Check acti on of the check bal l i n the retai ner (Fi g.
94). The bal l must move freel y and not sti ck.
NOTE: Inspect the clutch retainer bushings care-
fully (Fig. 95). The retainer bushings are NOT ser-
viceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
ASSEMBLY
NOTE: The 42RE transmission uses four plates and
discs for the front clutch.
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal s i n the cl utch retai ner l ower
groove and on outer di ameter of the retai ner hub. Be
sure l i p of each seal faces i nteri or of cl utch retai ner.
(3) Lubri cate l i ps of the retai ner seal s wi th l i beral
quanti ty of Mopar Door Ease. Then l ubri cate
retai ner hub, bore and pi ston wi th l i ght coat of trans-
mi ssi on fl ui d.
(4) I nstal l cl utch pi ston i n retai ner (Fi g. 96). Use
twi sti ng moti on to seat pi ston i n bottom of retai ner.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip.
(5) Posi ti on spri ng i n cl utch pi ston (Fi g. 97).
(6) Posi ti on spri ng retai ner on top of pi ston spri ng.
Make sure retai ner i s properl y i nstal l ed (Fi g. 92).
(7) Compress pi ston spri ng and retai ner wi th Com-
pressor Tool C-3575-A (Fi g. 93). Then i nstal l new
snap-ri ng to secure spri ng retai ner and spri ng.
(8) I nstal l cl utch pl ates and di scs (Fi g. 92). I nstal l
steel pl ate then di sc unti l al l pl ates and di scs are
i nstal l ed. The front cl utch uses 4 cl utch di scs and
pl ates i n a 42RE transmi ssi on.
(9) I nstal l pressure pl ate and waved snap-ri ng
(Fi g. 92).
Cl earance shoul d be 1.70 to 3.40 mm (0.067 to
0.134 i n.). I f cl earance i s i ncorrect, cl utch di scs,
pl ates, pressure pl ates and snap-ri ng may have to be
changed.
FRONT CLUTCH (Continued)
Fig. 92 42RE Front Clutch Components
1 - SNAP-RING (WAVE) 7 - SEAL
2 - REACTION PLATE 8 - PISTON
3 - CLUTCH DISC 9 - SPRING
4 - CLUTCH PLATE 10 - SNAP-RING
5 - SEAL 11 - SPRING RETAINER
6 - CLUTCH RETAINER
Fig. 93 Compressing Front Clutch Piston Spring
1 - FRONT CLUTCH SPRING
2 - COMPRESSOR TOOL C-3575-A
3 - RETAINER SNAP-RING
4 - SPRING RETAINER
Fig. 94 Front Clutch Piston Retainer Check Ball
Location
1 - RETAINER CHECK BALL
Fig. 95 Retainer Bushing Location/Inspection
1 - FRONT CLUTCH RETAINER BUSHINGS (NON-
SERVICEABLE)
Fig. 96 Front Clutch Piston Installation
1 - CLUTCH PISTON
2 - FRONT CLUTCH RETAINER
Fig. 97 Clutch Piston Spring Installation
1 - RETAINER
2 - CLUTCH SPRING
3 - PISTON
FRONT SERVO
DESCRIPTION
The ki ckdown servo (Fi g. 98) consi sts of a two-l and
pi ston wi th an i nner pi ston, a pi ston rod and gui de,
and a return spri ng. The dual -l and pi ston uses seal
ri ngs on i ts outer di ameters and an O-ri ng for the
i nner pi ston.
OPERATION
The appl i cati on of the pi ston i s accompl i shed by
appl yi ng pressure between the two l ands of the pi s-
ton. The pressure acts agai nst the l arger l ower l and
to push the pi ston downward, al l owi ng the pi ston rod
to extend though i ts gui de agai nst the appl y l ever.
Rel ease of the servo at the 2-3 upshi ft i s accom-
pl i shed by a combi nati on of spri ng and l i ne pressure,
acti ng on the bottom of the l arger l and of the pi ston.
The smal l pi ston i s used to cushi on the appl i cati on of
the band by bl eedi ng oi l through a smal l ori fi ce i n
the l arger pi ston. The rel ease ti mi ng of the ki ckdown
servo i s very i mportant to obtai n a smooth but fi rm
shi ft. The rel ease has to be very qui ck, just as the
front cl utch appl i cati on i s taki ng pl ace. Otherwi se,
engi ne runaway or a shi ft hesi tati on wi l l occur. To
accompl i sh thi s, the band retai ns i ts hol di ng capaci ty
unti l the front cl utch i s appl i ed, gi vi ng a smal l
amount of overl ap between them.
DISASSEMBLY
(1) Remove seal ri ng from rod gui de (Fi g. 99).
(2) Remove smal l snap-ri ng from servo pi ston rod.
Then remove pi ston rod, spri ng and washer from pi s-
ton.
(3) Remove and di scard servo component o-ri ng
and seal ri ngs.
CLEANING
Cl ean the servo pi ston components (Fi g. 100) wi th
sol vent and dry them wi th compressed ai r.
INSPECTION
I nspect the servo components (Fi g. 101). Repl ace
the spri ngs i f col l apsed, di storted or broken. Repl ace
the gui de, rod and pi ston i f cracked, bent, or worn.
Di scard the servo snap-ri ng i f di storted or warped.
Check the servo pi ston bore for wear. I f the bore i s
severel y scored, or damaged, i t wi l l be necessary to
repl ace the case.
Repl ace any servo component i f doubt exi sts about
condi ti on. Do not reuse suspect parts.
ASSEMBLY
Cl ean and i nspect front servo components.
(1) Lubri cate new o-ri ng and seal ri ngs wi th petro-
l eum jel l y and i nstal l them on pi ston, gui de and rod.
(2) I nstal l rod i n pi ston. I nstal l spri ng and washer
on rod. Compress spri ng and i nstal l snap-ri ng (Fi g.
102).
Fig. 98 Front Servo
1 - VENT
2 -PISTON ROD
3 - PISTON
4 - SPRING
5 - RELEASE PRESSURE
6 - APPLY PRESSURE
Fig. 99 Front Servo
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
5 - PISTON ROD GUIDE
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
GEARSHIFT CABLE
CABLE
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti on - Appl y forward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(b) PARK posi ti on - Appl y rearward force on cen-
must be possi bl e.
(c) NEUTRAL posi ti on - Normal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti on - Engi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from NEUTRAL to REVERSE.
REMOVAL
(1) Shi ft transmi ssi on i nto PARK.
Fig. 100 Front Servo Piston
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
Fig. 101 Front Servo Piston
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
Fig. 102 Front Servo
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
FRONT SERVO (Continued)
(3) Remove the shi ft cabl e eyel et from the trans-
mi ssi on manual shi ft l ever (Fi g. 103).
(4) Remove shi ft cabl e from the cabl e support
bracket.
(6) Remove necessary consol e parts for access to
shi ft l ever assembl y and shi ft cabl e. (Refer to 23 -
BODY/I NTERI OR/FLOOR CONSOLE - REMOVAL)
(7) Di sconnect cabl e at shi ft l ever and shi fter
assembl y bracket (Fi g. 104).
(8) Remove the nuts hol di ng the shi ft cabl e seal
pl ate to the fl oor pan (Fi g. 105).
(9) Pul l cabl e through fl oor panel openi ng.
(10) Remove shi ft cabl e from vehi cl e.
INSTALLATION
(1) Route cabl e through hol e i n fl oor pan.
(2) I nstal l seal pl ate to studs i n fl oor pan.
(3) I nstal l nuts to hol d seal pl ate to fl oor pan.
Ti ghten nuts to 7 Nm (65 i n.l bs.).
(4) I nstal l the shi ft cabl e to the shi fter assembl y
bracket. Push cabl e i nto the bracket unti l secure.
(5) Pl ace the fl oor shi fter l ever i n PARK posi ti on.
(6) Loosen the adjustment screw on the shi ft cabl e.
(7) Snap the shi ft cabl e onto the shi ft l ever pi n.
(9) I nstal l the shi ft cabl e to the shi ft cabl e support
bracket.
(10) Shi ft the transmi ssi on i nto PARK. PARK i s
the rearmost detent posi ti on on the transmi ssi on
manual shi ft l ever.
(11) Snap the shi ft cabl e onto the transmi ssi on
(13) Veri fy that the shi ft l ever i s i n the PARK posi -
ti on.
(14) Ti ghten the adjustment screw to 7 Nm (65
i n.l bs.).
(15) Veri fy correct shi fter operati on.
(16) I nstal l any consol e parts removed for access to
BODY/I NTERI OR/FLOOR CONSOLE - I NSTALLA-
TI ON)
ADJUSTMENTS - GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n PARK
and NEUTRAL. Adjustment i s CORRECT i f the
engi ne starts onl y i n these posi ti ons. Adjustment i s
Fig. 103 Remove Shift Cable From Transmission
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
Fig. 104 Transmission Shift Cable at Shifter
1 - SHIFT LEVER PIN
3 - SHIFT CABLE
4 - SHIFTER ASSEMBLY BRACKET
Fig. 105 Shift Cables at Floor Pan
1 - SEAL PLATES
2 - TRANSMISSION SHIFT CABLE
GEARSHIFT CABLE (Continued)
I NCORRECT i f the engi ne starts i n one but not both
posi ti ons. I f the engi ne starts i n any posi ti on other
than PARK or NEUTRAL, or i f the engi ne wi l l not
start at al l , the park/neutral posi ti on swi tch or TRS
may be faul ty.
the shi ft cabl e adjustment. (Refer to 23 - BODY/I N-
TERI OR/FLOOR CONSOLE - REMOVAL)
(3) Loosen the shi ft cabl e adjustment screw (Fi g.
106).
(5) Unsnap cabl e eyel et from transmi ssi on shi ft
l ever (Fi g. 107).
(6) Veri fy transmi ssi on shi ft l ever i s i n PARK
detent by movi ng l ever ful l y rearward. Last rearward
detent i s PARK posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Snap cabl e eyel et onto transmi ssi on shi ft l ever.
(9) Lower vehi cl e
(10) Ti ghten the shi ft cabl e adjustment screw to 7
Nm (65 i n.l bs.).
(11) Veri fy correct operati on.
(12) I nstal l any fl oor consol e components removed
for access. (Refer to 23 - BODY/I NTERI OR/FLOOR
CONSOLE - I NSTALLATI ON)
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 108) i s l ocated i n the pump
housi ng i nsi de the bel l housi ng of the transmi ssi on
case. The oi l pump consi sts of an i nner and outer
gear (Fi g. 109), a housi ng, and a cover that al so
serves as the reacti on shaft support.
OPERATION
As the torque converter rotates, the converter hub
rotates the i nner and outer gears. As the gears
rotate, the cl earance between the gear teeth
i ncreases i n the crescent area, and creates a sucti on
at the i nl et si de of the pump. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
cl earance between the gear teeth i n the crescent area
decreases, i t forces pressuri zed fl ui d i nto the pump
outl et and to the val ve body.
Fig. 106 Shift Cable at the Shifter
1 - SHIFT LEVER PIN
3 - SHIFT CABLE
Fig. 107 Shift Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT(S)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
7 - TRANSMISSION FLUID LINES
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuri ng the oi l pump output vol ume wi l l deter-
mi ne i f suffi ci ent oi l fl ow to the transmi ssi on oi l
cool er exi sts, and whether or not an i nternal trans-
mi ssi on fai l ure i s present.
Veri fy that the transmi ssi on fl ui d i s at the proper
l evel . Refer to the Fl ui d Level Check procedure i n
thi s secti on. I f necessary, fi l l the transmi ssi on to the
proper l evel wi th Mopar ATF +4, type 9602, Auto-
mati c Transmi ssi on Fl ui d.
(1) Di sconnect the To cooler l i ne at the cool er
i nl et and pl ace a col l ecti ng contai ner under the di s-
connected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed, wi th the
shi ft sel ector i n neutral .
(3) I f one quart of transmi ssi on fl ui d i s col l ected i n
the contai ner i n 20 seconds or l ess, oi l pump fl ow vol -
ume i s wi thi n acceptabl e l i mi ts. I f fl ui d fl ow i s i nter-
mi ttent, or i t takes more than 20 seconds to col l ect
one quart of fl ui d, refer to the Hydraul i c Pressure
tests i n thi s secti on for further di agnosi s.
(4) Re-connect the To cooler l i ne to the transmi s-
si on cool er i nl et.
(5) Refi l l the transmi ssi on to proper l evel .
DISASSEMBLY
(1) Remove seal ri ng from housi ng and reacti on
shaft support (Fi g. 110).
(2) Mark pump housi ng and support assembl y for
al i gnment reference.
(3) Remove bol ts attachi ng pump body to support
(Fi g. 111).
(4) Separate support from pump housi ng (Fi g.
112).
(5) Remove i nner and outer gears from reacti on
shaft support (Fi g. 113).
Fig. 108 Oil Pump and Reaction Shaft Support
1 - REACTION SHAFT SUPPORT
2 - PUMP
Fig. 109 Pump Gear Removal
2 - INNER GEAR
3 - OUTER GEAR
Fig. 110 Removing Pump Seal Ring
1 - PUMP HOUSING SEAL RING
Fig. 111 Pump Support Bolts
2 - PUMP
(6) I f pump seal was not removed duri ng transmi s-
si on di sassembl y, remove seal wi th punch and ham-
mer.
(7) Remove front cl utch thrust washer from sup-
port hub (Fi g. 114).
OIL PUMP BUSHING REPLACEMENT
(1) Remove pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng Remover SP-3551 from Tool Set
C-3887-J (Fi g. 115).
(2) I nstal l new pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng I nstal l er SP-5117 (Fi g. 115).
Bushi ng shoul d be fl ush wi th pump housi ng bore.
(3) Stake new pump bushi ng i n two pl aces wi th
bl unt punch (Fi g. 116). Remove burrs from stake
poi nts wi th kni fe bl ade afterward.
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assembl e Bushi ng Remover Tool s SP-1191,
3633 and 5324 (Fi g. 117). Do not cl amp any part of
reacti on shaft or support i n vi se.
(2) Hol d Cup Tool SP-3633 fi rml y agai nst reacti on
shaft and thread remover SP-5324 i nto bushi ng as
far as possi bl e by hand. Then thread remover tool 3-4
addi ti onal turns i nto bushi ng wi th a wrench.
(3) Turn remover tool hex nut down agai nst
remover cup to pul l bushi ng from shaft. Cl ean al l
chi ps from shaft after bushi ng removal .
Fig. 112 Separating Pump Housing From Reaction
Shaft Support
2 - PUMP HOUSING
Fig. 113 Pump Gear Removal
2 - INNER GEAR
3 - OUTER GEAR
Fig. 114 Support Hub Thrust Washer
1 - BUSHING
3 - THRUST WASHER
4 - HUB
Fig. 115 Removing Oil Pump Bushing
2 - SPECIAL TOOL SP-3551
3 - BUSHING
5 - BUSHING
7 - PUMP HOUSING
(4) Li ghtl y gri p ol d bushi ng i n vi se or wi th pl i ers
and back remover tool out of bushi ng.
(5) Assembl e Bushi ng I nstal l er Tool s C-4171 and
SP-5325 (Fi g. 117).
(6) Sl i de new bushi ng onto I nstal l er Tool SP-5325.
(7) Posi ti on reacti on shaft support upri ght on a
cl ean smooth surface.
(8) Al i gn bushi ng i n bore. Then tap bushi ng i nto
pl ace unti l Bushi ng I nstal l er SP-5325 bottoms.
(9) Cl ean reacti on shaft support thoroughl y after
i nstal l i ng bushi ng.
CLEANING
Cl ean pump and support components wi th sol vent
and dry them wi th compressed ai r.
INSPECTION
Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
I nspect the pump and support components. Repl ace
the pump or support i f the seal ri ng grooves or
machi ned surfaces are worn, scored, pi tted, or dam-
aged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
I nspect the pump bushi ng. Then check the reacti on
shaft support bushi ng. Repl ace ei ther bushi ng onl y i f
heavi l y worn, scored or damaged. I t i s not necessary
to repl ace the bushi ngs unl ess they are actual l y dam-
aged.
Cl earance between outer gear and reacti on shaft
housi ng shoul d be 0.010 to 0.063 mm (0.0004 to
0.0025 i n.). Cl earance between i nner gear and reac-
ti on shaft housi ng shoul d be 0.010 to 0.063 mm
(0.0004 to 0.0025 i n.). Both cl earances can be mea-
sured at the same ti me by i nstal l i ng the gears i n the
pump body and measure pump component cl earances
as fol l ows:
(1) Posi ti on an appropri ate pi ece of Pl asti gage
across both gears.
(2) Al i gn the pl asti gage to a fl at area on the reac-
ti on shaft housi ng.
(3) I nstal l the reacti on shaft to the pump housi ng.
(4) Separate the reacti on shaft housi ng from the
pump housi ng and measure the Pl asti gage fol l ow-
i ng the i nstructi ons suppl i ed wi th i t.
Cl earance between i nner gear tooth and outer gear
shoul d be 0.08 to 0.19 mm (0.0035 to 0.0075 i n.).
Measure cl earance wi th an appropri ate feel er gauge.
Cl earance between outer gear and pump housi ng
shoul d be 0.10 to 0.19 mm (0.004 to 0.0075 i n.). Mea-
sure cl earance wi th an appropri ate feel er gauge.
ASSEMBLY
(1) Lubri cate gear bore i n pump housi ng wi th
(2) Lubri cate pump gears wi th transmi ssi on fl ui d.
(3) Support pump housi ng on wood bl ocks (Fi g.
118).
(4) I nstal l outer gear i n pump housi ng (Fi g. 118).
Gear can be i nstal l ed ei ther way (i t i s not a one-way
fi t).
(5) I nstal l pump i nner gear (Fi g. 119).
Fig. 116 Staking Oil Pump Bushing
1 - NARROW BLADE
2 - BLUNT PUNCH
3 - TWO STAKES
Fig. 117 Replacing Reaction Shaft Support Bushing
5 - REACTION SHAFT
7 - BUSHING
CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter
(I.D.) is chamfered. Be sure the chamfered side
faces forward (to front of pump).
(6) I nstal l new thrust washer on hub of reacti on
shaft support. Lubri cate washer wi th transmi ssi on
fl ui d or petrol eum jel l y.
(7) I f reacti on shaft seal ri ngs are bei ng repl aced,
i nstal l new seal ri ngs on support hub (Fi g. 120).
Lubri cate seal ri ngs wi th transmi ssi on fl ui d or petro-
l eum jel l y after i nstal l ati on. Squeeze each ri ng unti l
ri ng ends are securel y hooked together.
CAUTION: The reaction shaft support seal rings will
break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.
(8) I nstal l reacti on shaft support on pump housi ng
(Fi g. 121).
(9) Al i gn reacti on support on pump housi ng. Use
al i gnment marks made at di sassembl y. Or, rotate
support unti l bol t hol es i n support and pump housi ng
are al l al i gned (hol es are offset for one-way fi t).
(10) I nstal l al l bol ts that attach support to pump
housi ng. Then ti ghten bol ts fi nger ti ght.
(11) Ti ghten support-to-pump bol ts to requi red
torque as fol l ows:
(a) Reverse pump assembl y and i nstal l i t i n
transmi ssi on case. Posi ti on pump so bol ts are fac-
i ng out and are accessi bl e.
(b) Secure pump assembl y i n case wi th 2 or 3
bol ts, or wi th pi l ot studs.
(c) Ti ghten support-to-pump bol ts to 20 Nm (15
ft. l bs.).
(d) Remove pump assembl y from transmi ssi on
case.
Fig. 118 Supporting Pump And Installing Outer Gear
1 - OUTER GEAR
2 - PUMP HOUSING
3 - WOOD BLOCKS
Fig. 119 Pump Inner Gear Installation
1 - OUTER GEAR
2 - INNER GEAR
Fig. 120 Hub Seal Ring Position
1 - SEAL RINGS
2 - SUPPORT HUB
Fig. 121 Assembling Reaction Shaft Support And
Pump Housing
1 - PUMP HOUSING
(12) I nstal l new oi l seal i n pump wi th Speci al Tool
C-4193 and Tool Handl e C-4171 (Fi g. 122). Be sure
seal l i p faces i nward.
(13) I nstal l new seal ri ng around pump housi ng.
Be sure seal i s properl y seated i n groove.
(14) Lubri cate l i p of pump oi l seal and O-ri ng seal
wi th transmi ssi on fl ui d.
OUTPUT SHAFT FRONT
BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e.
(2) Remove overdri ve geartrai n from housi ng.
(3) Remove snap-ri ng hol di ng output shaft front
beari ng to overdri ve geartrai n. (Fi g. 123).
(4) Pul l beari ng from output shaft.
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on on
geartrai n wi th l ocati ng retai ner groove toward the
rear.
(2) Push beari ng onto shaft unti l the snap-ri ng
groove i s vi si bl e.
(3) I nstal l snap-ri ng to hol d beari ng onto output
shaft.
(4) I nstal l overdri ve geartrai n i nto housi ng.
(5) I nstal l overdri ve uni t i n vehi cl e.
OUTPUT SHAFT REAR
BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e. (Refer
to 21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C/
OVERDRI VE - REMOVAL)
(2) Remove overdri ve geartrai n from housi ng.
(3) Remove snap-ri ng hol di ng output shaft rear
beari ng i nto overdri ve housi ng (Fi g. 124).
(4) Usi ng a sui tabl e dri ver i nserted through the
rear end of housi ng, dri ve beari ng from housi ng.
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on i n hous-
i ng.
(2) Usi ng a sui tabl e dri ver, dri ve beari ng i nto
housi ng unti l the snap-ri ng groove i s vi si bl e.
(3) I nstal l snap-ri ng to hol d beari ng i nto housi ng
(Fi g. 124).
(4) I nstal l overdri ve geartrai n i nto housi ng.
(5) I nstal l overdri ve uni t i n vehi cl e.
Fig. 122 Pump Oil Seal Installation
1 - PUMP BODY
2 - PUMP SEAL
Fig. 123 Output Shaft Front Bearing
1 - OUTPUT SHAFT FRONT BEARING
2 - SNAP-RING
3 - OUTPUT SHAFT
4 - GROOVE TO REAR
5 - OVERDRIVE GEARTRAIN
Fig. 124 Output Shaft Rear Bearing
1 - OUTPUT SHAFT REAR BEARING
2 - OVERDRIVE HOUSING
3 - SNAP-RING
OVERDRIVE CLUTCH
DESCRIPTION
The overdri ve cl utch (Fi g. 125) i s composed of the
pressure pl ate, cl utch pl ates, hol di ng di scs, overdri ve
pi ston retai ner, pi ston, pi ston spacer, and snap-ri ngs.
The overdri ve cl utch i s the forwardmost component
i n the transmi ssi on overdri ve uni t and i s consi dered
a hol di ng component. The overdri ve pi ston retai ner,
pi ston, and pi ston spacer are l ocated on the rear of
the mai n transmi ssi on case.
OPERATION
the pi ston retai ner and pi ston. The fl ui d pressure i s
cl utch through passages at the l ower rear porti on of
the val ve body area. Wi th pressure appl i ed between
the pi ston retai ner and pi ston, the pi ston moves
away from the pi ston retai ner and compresses the
cl utch pack. Thi s acti on appl i es the cl utch pack,
al l owi ng torque to fl ow through the i ntermedi ate
shaft i nto the overdri ve pl anetary gear set. The over-
dri ve cl utch di scs are attached to the overdri ve cl utch
hub whi l e the overdri ve cl utch pl ates, reacti on pl ate,
and pressure pl ate are l ugged to the overdri ve hous-
i ng. Thi s al l ows the i ntermedi ate shaft to transfer
the engi ne torque to the pl anetary gear and overrun-
ni ng cl utch. Thi s dri ves the pl anetary gear i nsi de the
annul us, whi ch i s attached to the overdri ve cl utch
drum and output shaft, creati ng the desi red gear
rati o. The waved snap-ri ng i s used to cushi on the
appl i cati on of the cl utch pack.
OVERDRIVE OFF SWITCH
DESCRIPTION
The overdri ve OFF (control ) swi tch i s l ocated i n
the shi fter handl e. The swi tch i s a momentary con-
tact devi ce that si gnal s the PCM to toggl e current
status of the overdri ve functi on.
OPERATION
At key-on, fourth gear operati on i s al l owed. Press-
i ng the swi tch once causes the overdri ve OFF mode
to be entered and the overdri ve OFF swi tch l amp to
be i l l umi nated. Pressi ng the swi tch a second ti me
causes normal overdri ve operati on to be restored and
the overdri ve l amp to be turned off. The overdri ve
OFF mode defaul ts to ON after the i gni ti on swi tch i s
cycl ed OFF and ON. The normal posi ti on for the con-
trol swi tch i s the ON posi ti on. The swi tch must be i n
thi s posi ti on to energi ze the sol enoi d and al l ow
upshi fts to fourth gear. The control swi tch i ndi cator
l i ght i l l umi nates onl y when the overdri ve swi tch i s
turned to the OFF posi ti on, or when i l l umi nated by
the powertrai n control modul e.
Fig. 125 Overdrive Clutch
1 - REACTION PLATE 2 - PRESSURE PLATE
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS
The overdri ve off swi tch, val ve body sol enoi d, case
connectors and rel ated wi ri ng can al l be tested wi th
a 12 vol t test l amp or a vol t/ohmmeter. Check conti -
nui ty of each component when di agnosi s i ndi cates
thi s i s necessary.
Swi tch and sol enoi d conti nui ty shoul d be checked
whenever the transmi ssi on fai l s to shi ft i nto fourth
gear range.
OVERDRIVE UNIT
REMOVAL
(3) Remove transfer case, i f equi pped.
(4) Mark propel l er shaft uni versal joi nt(s) and axl e
pi ni on yoke, or the compani on fl ange and fl ange
yoke, for al i gnment reference at i nstal l ati on, i f necc-
esary.
(5) Di sconnect and remove the rear propel l er shaft,
i f necessary. (Refer to 3 - DI FFERENTI AL & DRI V-
ELI NE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(6) Remove transmi ssi on oi l pan, remove gasket,
drai n oi l and rei nstal l pan.
(7) I f overdri ve uni t had mal functi oned, or i f fl ui d
i s contami nated, remove enti re transmi ssi on. I f di ag-
nosi s i ndi cated overdri ve probl ems onl y, remove just
the overdri ve uni t.
(8) Support transmi ssi on wi th transmi ssi on jack.
(9) Remove bol ts attachi ng overdri ve uni t to trans-
mi ssi on (Fi g. 126).
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.
(10) Careful l y work overdri ve uni t off i ntermedi ate
shaft. Do not ti l t uni t duri ng removal . Keep i t as
l evel as possi bl e.
(11) I f overdri ve uni t does not requi re servi ce,
i mmedi atel y i nsert Al i gnment Tool 6227-2 i n spl i nes
of pl anetary gear and overrunni ng cl utch to prevent
spl i nes from rotati ng out of al i gnment. I f mi sal i gn-
ment occurs, overdri ve uni t wi l l have to be di sassem-
bl ed i n order to real i gn spl i nes.
(12) Remove and retai n overdri ve pi ston thrust
beari ng. Beari ng may remai n on pi ston or i n cl utch
hub duri ng removal .
(13) Posi ti on drai n pan on workbench.
(14) Pl ace overdri ve uni t over drai n pan. Ti l t uni t
to drai n resi dual fl ui d from case.
(15) Exami ne fl ui d for cl utch materi al or metal
fragments. I f fl ui d contai ns these i tems, overhaul wi l l
be necessary.
(16) I f overdri ve uni t does not requi re any servi ce,
l eave al i gnment tool i n posi ti on. Tool wi l l prevent
acci dental mi sal i gnment of pl anetary gear and over-
runni ng cl utch spl i nes.
Fig. 126 Overdrive Unit Bolts
1 - OVERDRIVE UNIT
2 - ATTACHING BOLTS (7)
OVERDRIVE OFF SWITCH (Continued)
DISASSEMBLY
(1) Remove transmi ssi on speed sensor and O-ri ng
seal from overdri ve case (Fi g. 127).
(2) Remove overdri ve pi ston thrust beari ng (Fi g.
128).
OVERDRIVE PISTON
(1) Remove overdri ve pi ston thrust pl ate (Fi g.
129). Retai n thrust pl ate. I t i s a sel ect fi t part and
may possi bl y be reused.
(2) Remove i ntermedi ate shaft spacer (Fi g. 130).
Retai n spacer. I t i s a sel ect fi t part and may possi bl y
be reused.
(3) Remove overdri ve pi ston from retai ner (Fi g.
131).
Fig. 127 Transmission Speed Sensor Removal
1 - SOCKET AND WRENCH
2 - SPEED SENSOR
3 - O-RING
Fig. 128 Overdrive Piston Thrust Bearing Removal
1 - THRUST BEARING
2 - OVERDRIVE PISTON
3 - THRUST PLATE
Fig. 129 Overdrive Piston Thrust Plate Removal
2 - OVERDRIVE PISTON SPACER (SELECT FIT)
Fig. 130 Intermediate Shaft Spacer Location
1 - INTERMEDIATE SHAFT
2 - INTERMEDIATE SHAFT SPACER (SELECT FIT)
OVERDRIVE UNIT (Continued)
OVERDRIVE CLUTCH PACK
(1) Remove overdri ve cl utch pack wi re retai ni ng
ri ng (Fi g. 132).
(2) Remove overdri ve cl utch pack (Fi g. 133).
NOTE: The 42RE transmission has three clutch
discs and two clutch plates.
(3) Note posi ti on of cl utch pack components for
assembl y reference (Fi g. 134).
Fig. 131 Overdrive Piston Removal
1 - PISTON RETAINER
Fig. 132 Removing Overdrive Clutch Pack Retaining
Ring
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 133 Overdrive Clutch Pack Removal
1 - OVERDRIVE CLUTCH PACK
Fig. 134 42RE Overdrive Clutch Component
Position
1 - PRESSURE PLATE (TO FRONT)
2 - OVERDRIVE CLUTCH PACK
3 - CLUTCH DISC (3)
4 - CLUTCH PLATE (2)
5 - REACTION PLATE (TO REAR)
OVERDRIVE GEARTRAIN
(1) Remove overdri ve cl utch wave spri ng (Fi g.
135).
(2) Remove overdri ve cl utch reacti on snap-ri ng
(Fi g. 136). Note that snap-ri ng i s l ocated i n same
groove as wave spri ng.
(3) Remove Torx head screws that attach access
cover and gasket to overdri ve case (Fi g. 137).
(4) Remove access cover and gasket (Fi g. 138).
(5) Expand output shaft beari ng snap-ri ng wi th
expandi ng-type snap-ri ng pl i ers. Then push output
shaft forward to rel ease shaft beari ng from l ocati ng
ri ng (Fi g. 139).
(6) Li ft gear case up and off geartrai n assembl y
(Fi g. 140).
(7) Remove snap-ri ng that retai ns rear beari ng on
output shaft.
(8) Remove rear beari ng from output shaft (Fi g.
141).
Fig. 135 Overdrive Clutch Wave
1 - WAVE SPRING
Fig. 136 Overdrive Clutch Reaction Snap-Ring
Removal
1 - REACTION RING
2 - CLUTCH HUB
Fig. 137 Access Cover Screw Removal
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 138 Access Cover And Gasket Removal
1 - ACCESS COVER AND GASKET
Fig. 139 Releasing Bearing From Locating Ring
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
DIRECT CLUTCH, HUB AND SPRING
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXI-
MATELY 830 POUNDS. USE SPRING COMPRESSOR
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES.
THE PRESS MUST ALSO HAVE A BED THAT CAN
BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrai n assembl y i n shop press (Fi g.
142).
(2) Posi ti on Compressor Tool 6227-1 on cl utch hub
(Fi g. 142). Support output shaft fl ange wi th steel
press pl ates as shown and center assembl y under
press ram.
(3) Appl y press pressure sl owl y. Compress hub and
spri ng far enough to expose cl utch hub retai ni ng ri ng
and rel i eve spri ng pressure on cl utch pack snap-ri ng
(Fi g. 142).
(4) Remove di rect cl utch pack snap-ri ng (Fi g. 143).
(5) Remove di rect cl utch hub retai ni ng ri ng (Fi g.
144).
(6) Rel ease press l oad sl owl y and compl etel y (Fi g.
145).
(7) Remove Speci al Tool 6227-1. Then remove
cl utch pack from hub (Fi g. 145).
GEARTRAIN
(1) Remove di rect cl utch hub and spri ng (Fi g. 146).
Fig. 140 Removing Gear Case From Geartrain
Assembly
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 141 Rear Bearing Removal
1 - OUTPUT SHAFT
2 - REAR BEARING
3 - SNAP-RING
Fig. 142 Geartrain Mounted In Shop Press
1 - PRESS RAM
2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL)
3 - CLUTCH HUB
4 - PLATES
5 - PRESS BED
6 - SPECIAL TOOL 6227-1
(2) Remove sun gear and spri ng pl ate. Then
remove pl anetary thrust beari ng and pl anetary gear
(Fi g. 147).
(3) Remove overrunni ng cl utch assembl y wi th
expandi ng type snap-ri ng pl i ers (Fi g. 148). I nsert pl i -
ers i nto cl utch hub. Expand pl i ers to gri p hub spl i nes
and remove cl utch wi th countercl ockwi se, twi sti ng
moti on.
(4) Remove thrust beari ng from overrunni ng
cl utch hub.
Fig. 143 Direct Clutch Pack Snap-Ring Removal
1 - CLUTCH HUB
3 - DIRECT CLUTCH PACK SNAP-RING
4 - PRESS PLATES
5 - CLUTCH DRUM
Fig. 144 Direct Clutch Hub Retaining Ring Removal
2 - CLUTCH HUB RETAINING RING
3 - PRESS BED
4 - PRESS PLATES
Fig. 145 Direct Clutch Pack Removal
2 - DIRECT CLUTCH HUB
3 - DIRECT CLUTCH PACK
Fig. 146 Direct Clutch Hub And Spring Removal
1 - DIRECT CLUTCH SPRING
2 - DIRECT CLUTCH HUB
(5) Remove overrunni ng cl utch from hub.
(6) Mark posi ti on of annul us gear and di rect cl utch
drum for assembl y al i gnment reference (Fi g. 149).
Use smal l center punch or scri ber to make al i gnment
marks.
(7) Remove di rect cl utch drum rear retai ni ng ri ng
(Fi g. 150).
(8) Remove di rect cl utch drum outer retai ni ng ri ng
(Fi g. 151).
(9) Mark annul us gear and output shaft for assem-
bl y al i gnment reference (Fi g. 152). Use punch or
scri ber to mark gear and shaft.
Fig. 147 Removing Sun Gear, Thrust Bearing And
Planetary Gear
1 - PLANETARY GEAR
2 - PLANETARY THRUST BEARING
3 - CLUTCH SPRING PLATE
4 - SPRING PLATE SNAP-RING
5 - SUN GEAR
Fig. 148 Overrunning Clutch
1 - OVERRUNNING CLUTCH
2 - NEEDLE BEARING
Fig. 149 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
1 - DIRECT CLUTCH DRUM
2 - HAMMER
3 - PUNCH
Fig. 150 Clutch Drum Inner Retaining Ring Removal
1 - INNER RETAINING RING
2 - DIRECT CLUTCH DRUM
3 - ANNULUS GEAR
(10) Remove snap-ri ng that secures annul us gear
on output shaft (Fi g. 153). Use two screwdri vers to
unseat and work snap-ri ng out of groove as shown.
(11) Remove annul us gear from output shaft (Fi g.
154). Use rawhi de or pl asti c mal l et to tap gear off
shaft.
Fig. 151 Clutch Drum Outer Retaining Ring Removal
1 - OUTER RETAINING RING
Fig. 152 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 - OUTPUT SHAFT
2 - HAMMER
3 - PUNCH
Fig. 153 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 154 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
GEAR CASE AND PARK LOCK
(1) Remove l ocati ng ri ng from gear case.
(2) Remove park pawl shaft retai ni ng bol t and
remove shaft, pawl and spri ng.
(3) Remove reacti on pl ug snap-ri ng and remove
reacti on pl ug.
(4) Remove output shaft seal .
CLEANING
Cl ean the geartrai n and case components wi th sol -
vent. Dry al l parts except the beari ngs wi th com-
pressed ai r. Al l ow beari ngs to ai r dry.
Do not use shop towel s for wi pi ng parts dry unl ess
the towel s are made from a l i nt-free materi al . A suf-
fi ci ent quanti ty of l i nt (from shop towel s, cl oths, rags,
etc.) coul d pl ug the transmi ssi on fi l ter and fl ui d pas-
sages.
Di scard the ol d case gasket and seal s. Do not
attempt to sal vage these parts. They are not reus-
abl e. Repl ace any of the overdri ve uni t snap-ri ngs i f
di storted or damaged.
Mi nor ni cks or scratches on components can be
smoothed wi th crocus cl oth. However, do not attempt
to reduce severe scori ng on any components wi th
abrasi ve materi al s. Repl ace severel y scored compo-
nents; do not try to sal vage them.
INSPECTION
Check condi ti on of the park l ock components and
the overdri ve case.
Check the bushi ngs i n the overdri ve case. Repl ace
the bushi ngs i f severel y scored or worn. Al so repl ace
the case seal i f l oose, di storted, or damaged.
Exami ne the overdri ve and di rect cl utch di scs and
pl ates. Repl ace the di scs i f the faci ng i s worn,
severel y scored, or burned and fl aki ng off. Repl ace
the cl utch pl ates i f worn, heavi l y scored, or cracked.
Check the l ugs on the cl utch pl ates for wear. The
pl ates shoul d sl i de freel y i n the drum. Repl ace the
pl ates or drum i f bi ndi ng occurs.
Check condi ti on of the annul us gear, di rect cl utch
hub, cl utch drum and cl utch spri ng. Repl ace the gear,
hub and drum i f worn or damaged. Repl ace the
spri ng i f col l apsed, di storted, or cracked.
Be sure the spl i nes and l ugs on the gear, drum and
hub are i n good condi ti on. The cl utch pl ates and
di scs shoul d sl i de freel y i n these components.
I nspect the thrust beari ngs and spri ng pl ate.
Repl ace the pl ate i f worn or scored. Repl ace the bear-
i ngs i f rough, noi sy, bri nnel l ed, or worn.
I nspect the pl anetary gear assembl y and the sun
gear and bushi ngs. I f ei ther the sun gear or the
bushi ngs are damaged, repl ace the gear and bush-
i ngs as an assembl y. The gear and bushi ngs are not
servi ced separatel y.
The pl anetary carri er and pi ni ons must be i n good
condi ti on. Al so be sure the pi ni on pi ns are secure and
i n good condi ti on. Repl ace the carri er i f worn or dam-
aged.
I nspect the overrunni ng cl utch and race. The race
surface shoul d be smooth and free of scores. Repl ace
the overrunni ng cl utch assembl y or the race i f ei ther
assembl y i s worn or damaged i n any way.
Repl ace the shaft pi l ot bushi ng and i nner bushi ng
i f damaged. Repl ace ei ther shaft beari ng i f rough or
noi sy. Repl ace the beari ng snap-ri ngs i f di storted or
cracked.
Check the machi ned surfaces on the output shaft.
These surfaces shoul d cl ean and smooth. Very mi nor
ni cks or scratches can be smoothed wi th crocus cl oth.
Repl ace the shaft i f worn, scored or damaged i n any
way.
I nspect the output shaft bushi ngs. The smal l bush-
i ng i s the i ntermedi ate shaft pi l ot bushi ng. The l arge
bushi ng i s the overrunni ng cl utch hub bushi ng.
Repl ace ei ther bushi ng i f scored, pi tted, cracked, or
worn.
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak di rect cl utch and overdri ve cl utch di scs i n
Mopar ATF +4, type 9602, transmi ssi on fl ui d. Al l ow
di scs to soak for 10-20 mi nutes.
(2) I nstal l new pi l ot bushi ng and cl utch hub bush-
i ng i n output shaft i f necessary (Fi g. 155). Lubri cate
bushi ngs wi th petrol eum jel l y, or transmi ssi on fl ui d.
(3) I nstal l annul us gear on output shaft, i f
removed. Then i nstal l annul us gear retai ni ng snap-
ri ng (Fi g. 156).
Fig. 155 Output Shaft Pilot Bushing
1 - OUTPUT SHAFT HUB
2 - OVERRUNNING CLUTCH HUB BUSHING
3 - INTERMEDIATE SHAFT PILOT BUSHING
(4) Al i gn and i nstal l cl utch drum on annul us gear
(Fi g. 157). Be sure drum i s engaged i n annul us gear
l ugs.
(5) I nstal l cl utch drum outer retai ni ng ri ng (Fi g.
157).
(6) Sl i de cl utch drum forward and i nstal l i nner
retai ni ng ri ng (Fi g. 158).
(7) I nstal l rear beari ng and snap-ri ng on output
shaft (Fi g. 159). Be sure l ocati ng ri ng groove i n bear-
i ng i s toward rear.
(8) I nstal l overrunni ng cl utch on hub (Fi g. 160).
Note that cl utch onl y fi ts one-way. Shoul der on cl utch
shoul d seat i n smal l recess at edge of hub.
(9) I nstal l thrust beari ng on overrunni ng cl utch
hub. Use generous amount of petrol eum jel l y to hol d
beari ng i n pl ace for i nstal l ati on. Beari ng fi ts one-way
onl y. Be sure beari ng i s seated squarel y agai nst hub.
Rei nstal l beari ng i f i t does not seat squarel y.
(10) I nstal l overrunni ng cl utch i n output shaft
(Fi g. 161). I nsert snap-ri ng pl i ers i n hub spl i nes.
Expand pl i ers to gri p hub. Then i nstal l assembl y
wi th countercl ockwi se, twi sti ng moti on.
(11) I nstal l pl anetary gear i n annul us gear (Fi g.
162). Be sure pl anetary pi ni ons are ful l y seated i n
annul us gear before proceedi ng.
(12) Coat pl anetary thrust beari ng and beari ng
contact surface of spri ng pl ate wi th generous amount
of petrol eum jel l y. Thi s wi l l hel p hol d beari ng i n
pl ace duri ng i nstal l ati on.
Fig. 156 Annulus Gear Installation
1 - SNAP-RING
3 - ANNULUS GEAR
Fig. 157 Clutch Drum And Outer Retaining Ring
Installation
1 - ANNULUS GEAR
2 - OUTER SNAP-RING
3 - CLUTCH DRUM
Fig. 158 Clutch Drum Inner Retaining Ring
Installation
1 - ANNULUS GEAR
2 - INNER SNAP-RING
3 - CLUTCH DRUM
Fig. 159 Rear Bearing And Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING
(13) I nstal l pl anetary thrust beari ng on sun gear
(Fi g. 163). Sl i de beari ng onto gear and seat i t agai nst
spri ng pl ate as shown. Beari ng fi ts one-way onl y. I f i t
does not seat squarel y agai nst spri ng pl ate, remove
and reposi ti on beari ng.
(14) I nstal l assembl ed sun gear, spri ng pl ate and
thrust beari ng (Fi g. 164). Be sure sun gear and
thrust beari ng are ful l y seated before proceedi ng.
Fig. 160 Assembling Overrunning Clutch And Hub
1 - CLUTCH HUB
Fig. 161 Overrunning Clutch Installation
1 - CLUTCH DRUM
3 - EXPANDING-TYPE SNAP-RING PLIERS
4 - CLUTCH DRUM
5 - ANNULUS GEAR
6 - OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT
SHAFT
Fig. 162 Planetary Gear Installation
1 - PLANETARY GEAR
2 - ANNULUS GEAR
Fig. 163 Planetary Thrust Bearing Installation
1 - SPRING PLATE
2 - PLANETARY THRUST BEARING
3 - SUN GEAR
(15) Mount assembl ed output shaft, annul us gear,
and cl utch drum i n shop press. Di rect cl utch spri ng,
hub and cl utch pack are easi er to i nstal l wi th assem-
bl y mounted i n press.
(16) Al i gn spl i nes i n hubs of pl anetary gear and
overrunni ng cl utch wi th Al i gnment tool 6227-2 (Fi g.
165). I nsert tool through sun gear and i nto spl i nes of
both hubs. Be sure al i gnment tool i s ful l y seated
before proceedi ng.
(17) I nstal l di rect cl utch spri ng (Fi g. 166). Be sure
spri ng i s properl y seated on spri ng pl ate.
NOTE: The 42RE transmission has 6 direct clutch
discs and 5 clutch plates.
(18) Assembl e and i nstal l di rect cl utch pack on
hub as fol l ows:
(a) Assembl e cl utch pack components (Fi g. 167).
(b) I nstal l di rect cl utch reacti on pl ate on cl utch
hub fi rst. Note that one si de of reacti on pl ate i s
counterbored. Be sure thi s si de faces rearward.
Spl i nes at rear of hub are rai sed sl i ghtl y. Counter-
bore i n pl ate fi ts over rai sed spl i nes. Pl ate shoul d
be fl ush wi th thi s end of hub (Fi g. 168).
(c) I nstal l fi rst cl utch di sc fol l owed by a steel
pl ate unti l al l di scs and pl ates have been i nstal l ed.
(d) I nstal l pressure pl ate. Thi s i s l ast cl utch
pack i tem to be i nstal l ed. Be sure pl ate i s i nstal l ed
wi th shoul der si de faci ng upward (Fi g. 169).
(19) I nstal l cl utch hub and cl utch pack on di rect
cl utch spri ng (Fi g. 170). Be sure hub i s started on
sun gear spl i nes before proceedi ng.
Fig. 164 Sun Gear Installation
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
Fig. 165 Alignment Tool Installation
2 - PRESS PLATES
3 - ASSEMBLED DRUM AND ANNULUS GEAR
4 - SUN GEAR
Fig. 166 Direct Clutch Spring Installation
2 - DIRECT CLUTCH SPRING
3 - CLUTCH HUB
4 - PRESS PLATES
Fig. 167 42RE Direct Clutch Pack Components
Fig. 168 Correct Position Of Direct Clutch Reaction
Plate
1 - REACTION PLATE COUNTERBORE
2 - DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF
HUB)
3 - CLUTCH HUB
Fig. 169 Correct Position Of Direct Clutch Pressure
Plate
1 - DIRECT CLUTCH PRESSURE PLATE
2 - CLUTCH PACK
3 - BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
WARNING: THE NEXT STEP IN GEARTRAIN
ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 830 POUNDS. USE COMPRES-
SOR TOOL C-6227-1 AND A HYDRAULIC-TYPE
SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6
INCHES. THE PRESS MUST ALSO HAVE A BED
THAT CAN BE ADJUSTED UP OR DOWN AS
REQUIRED. RELEASE CLUTCH SPRING TENSION
SLOWLY AND COMPLETELY TO AVOID PERSONAL
INJURY.
(20) Posi ti on Compressor Tool 6227-1 on cl utch
hub.
(21) Compress cl utch hub and spri ng just enough
to pl ace tensi on on hub and hol d i t i n pl ace.
(22) Sl owl y compress cl utch hub and spri ng. Com-
press spri ng and hub onl y enough to expose ri ng
grooves for cl utch pack snap ri ng and cl utch hub
retai ni ng ri ng.
(23) Real i gn cl utch pack on hub and seat cl utch
di scs and pl ates i n cl utch drum.
(24) I nstal l di rect cl utch pack snap-ri ng (Fi g. 171).
Be very sure snap-ri ng i s ful l y seated i n cl utch drum
ri ng groove.
(25) I nstal l cl utch hub retai ni ng ri ng (Fi g. 172). Be
very sure retai ni ng ri ng i s ful l y seated i n sun gear
ri ng groove.
(26) Sl owl y rel ease press ram, remove compressor
tool s and remove geartrai n assembl y.
GEAR CASE
(1) Posi ti on park pawl and spri ng i n case and
i nstal l park pawl shaft. Veri fy that end of spri ng
wi th 90 bend i s hooked to pawl and strai ght end of
spri ng i s seated agai nst case.
(2) I nstal l pawl shaft retai ni ng bol t. Ti ghten bol t
(3) I nstal l park l ock reacti on pl ug. Note that pl ug
has l ocati ng pi n at rear (Fi g. 173). Be sure pi n i s
seated i n hol e i n case before i nstal l i ng snap-ri ng.
(4) I nstal l reacti on pl ug snap-ri ng (Fi g. 174). Com-
press snap ri ng onl y enough for i nstal l ati on; do not
di stort i t.
Fig. 170 Direct Clutch
1 - CLUTCH HUB
2 - DIRECT CLUTCH PACK
3 - CLUTCH DRUM
Fig. 171 Direct Clutch Pack Snap-Ring Installation
2 - DIRECT CLUTCH PACK SNAP-RING
Fig. 172 Clutch Hub Retaining Ring Installation
2 - CLUTCH HUB RETAINING RING
(5) I nstal l new seal i n gear case. On 4x4 gear case,
use Tool Handl e C-4171 and I nstal l er C-3860-A to
seat seal i n case. On 4 x 2 gear case, use same Han-
dl e C-4171 and I nstal l er C-3995-A to seat seal i n
case.
(6) Veri fy that tab ends of rear beari ng l ocati ng
ri ng extend i nto access hol e i n gear case (Fi g. 175).
(7) Support geartrai n on Tool 6227-1 (Fi g. 176). Be
sure tool i s securel y seated i n cl utch hub.
(8) I nstal l overdri ve gear case on geartrai n (Fi g.
176).
(9) Expand front beari ng l ocati ng ri ng wi th snap-
ri ng pl i ers (Fi g. 177). Then sl i de case downward unti l
l ocati ng ri ng l ocks i n beari ng groove and rel ease
snap-ri ng.
(10) I nstal l l ocati ng ri ng access cover and gasket
i n overdri ve uni t case (Fi g. 178).
OVERDRIVE CLUTCH
(1) I nstal l overdri ve cl utch reacti on ri ng fi rst.
Reacti on ri ng i s fl at wi th notched ends (Fi g. 179).
(2) I nstal l wave spri ng on top of reacti on ri ng (Fi g.
180). Reacti on ri ng and wave ri ng both fi t i n same
ri ng groove. Use screwdri ver to seat each ri ng
securel y i n groove. Al so ensure that the ends of the
two ri ngs are offset from each other.
NOTE: The 42RE transmission has 3 overdrive
clutch discs and 2 plates.
(3) Assembl e overdri ve cl utch pack (Fi g. 181).
(4) I nstal l overdri ve cl utch reacti on pl ate fi rst.
Fig. 173 Reaction Plug Locating Pin And Snap-Ring
1 - REACTION PLUG SNAP-RING (DO NOT OVERCOMPRESS
TO INSTALL)
2 - LOCATING PIN
3 - PARK LOCK REACTION PLUG
Fig. 174 Reaction Plug And Snap-Ring Installation
1 - REACTION PLUG SNAP-RING
2 - SNAP-RING PLIERS
Fig. 175 Correct Rear Bearing Locating Ring
Position
1 - CASE ACCESS HOLE
2 - TAB ENDS OF LOCATING RING
Fig. 176 Overdrive Gear Case Installation
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
NOTE: The reaction plate is thinner than the pres-
sure plate in a 42RE transmission.
(5) I nstal l fi rst cl utch di sc fol l owed by fi rst cl utch
pl ate. Then i nstal l remai ni ng cl utch di scs and pl ates
i n same order.
(6) I nstal l cl utch pack pressure pl ate.
(7) I nstal l cl utch pack wi re-type retai ni ng ri ng
(Fi g. 182).
INTERMEDIATE SHAFT SPACER SELECTION
(1) Pl ace overdri ve uni t i n verti cal posi ti on. Mount
i t on bl ocks, or i n workbench wi th appropri ate si ze
mounti ng hol e cut i nto i t. Be sure uni t i s faci ng
upward for access to di rect cl utch hub. Al so be sure
output shaft i s not l oaded and i nternal components
are moved rearward for accurate measurement.
(2) Determi ne correct thi ckness i ntermedi ate shaft
spacer as fol l ows:
(a) I nsert Speci al Tool 6312 through sun gear,
pl anetary gear and i nto pi l ot bushi ng i n output
shaft. Be sure tool bottoms agai nst pl anetary
shoul der.
(b) Posi ti on Gauge Tool 6311 across face of over-
dri ve case (Fi g. 183). Then posi ti on Di al Cal i per
C-4962 over gauge tool .
(c) Extend sl i di ng scal e of di al cal i per downward
through gauge tool sl ot unti l scal e contacts end of
Gauge Al i gnment Tool 6312. Lock scal e i n pl ace.
Remove di al cal i per tool and note di stance mea-
sured (Fi g. 183).
(d) Sel ect proper thi ckness end pl ay spacer from
spacer chart based on di stance measured (Fi g.
184).
(e) Remove Gauge Al i gnment Tool 6312.
Fig. 177 Seating Locating Ring In Rear Bearing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 178 Locating Ring Access Cover And Gasket
Installation
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 179 Overdrive Clutch Reaction Ring Installation
1 - REACTION RING
2 - CLUTCH HUB
Fig. 180 Overdrive Clutch Wave Spring Installation
1 - WAVE SPRING
OD THRUST PLATE SELECTION
(1) Pl ace overdri ve uni t i n verti cal posi ti on. Mount
i t on bl ocks, or i n workbench wi th appropri ate si ze
mounti ng hol e cut i nto i t. Be sure uni t i s faci ng
upward for access to di rect cl utch hub. Al so be sure
output shaft i s not l oaded and i nternal components
are moved rearward for accurate measurement.
(2) Determi ne correct thi ckness overdri ve pi ston
thrust pl ate as fol l ows:
(a) Posi ti on Gauge Tool 6311 across face of over-
dri ve case. Then posi ti on Di al Cal i per C-4962 over
gauge tool (Fi g. 185).
(b) Measure di stance to cl utch hub thrust bear-
i ng seat at four poi nts 90 apart. Then average
measurements by addi ng them and di vi di ng by 4.
(c) Sel ect and i nstal l requi red thrust pl ate from
i nformati on i n thrust pl ate chart (Fi g. 186).
Fig. 181 42RE Overdrive Clutch Components
Fig. 182 Overdrive Clutch Pack Retaining Ring
Installation
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 183 Shaft End Play Measurement
(3) Leave Al i gnment Tool 6227-2 i n pl ace. Tool wi l l
keep pl anetary and cl utch hub spl i nes i n al i gnment
unti l overdri ve uni t i s ready for i nstal l ati on on trans-
mi ssi on.
(4) Transmi ssi on speed sensor can be i nstal l ed at
thi s ti me i f desi red. However, i t i s recommended that
sensor not be i nstal l ed unti l after overdri ve uni t i s
secured to transmi ssi on.
OVERDRIVE PISTON
(1) I nstal l new seal s on over dri ve pi ston.
(2) Stand transmi ssi on case upri ght on bel l hous-
i ng.
(3) Posi ti on Gui de Ri ng 8114-1 on outer edge of
overdri ve pi ston retai ner.
(4) Posi ti on Seal Gui de 8114-2 on i nner edge of
(5) I nstal l overdri ve pi ston i n overdri ve pi ston
retai ner by: al i gni ng l ocati ng l ugs on overdri ve pi ston
to the two mati ng hol es i n retai ner.
(a) Al i gni ng l ocati ng l ugs on overdri ve pi ston to
the two mati ng hol es i n retai ner.
(b) Lubri cate overdri ve pi ston seal s wi th Mopar
Door Ease, or equi val ent.
(c) I nstal l pi ston over Seal Gui de 8114-2 and
i nsi de Gui de Ri ng 8114-1.
(d) Push overdri ve pi ston i nto posi ti on i n
retai ner.
(e) Veri fy that the l ocati ng l ugs entered the l ug
bores i n the retai ner.
(6) I nstal l i ntermedi ate shaft spacer on i ntermedi -
ate shaft.
(7) I nstal l overdri ve pi ston thrust pl ate on over-
dri ve pi ston.
(8) I nstal l overdri ve pi ston thrust beari ng on over-
dri ve pi ston.
(9) I nstal l transmi ssi on speed sensor and O-ri ng
seal i n overdri ve case (Fi g. 127).
INSTALLATION
(1) Be sure overdri ve uni t Al i gnment Tool 6227-2
i s ful l y seated before movi ng uni t. I f tool i s not
seated and gear spl i nes rotate out of al i gnment, over-
dri ve uni t wi l l have to be di sassembl ed i n order to
real i gn spl i nes.
(2) I f overdri ve pi ston retai ner was not removed
duri ng servi ce and ori gi nal case gasket i s no l onger
reusabl e, prepare new gasket by tri mmi ng i t.
(3) Cut out ol d case gasket around pi ston retai ner
wi th razor kni fe (Fi g. 187).
(4) Use ol d gasket as templ ate and tri m new gas-
ket to fi t.
(5) Posi ti on new gasket over pi ston retai ner and
on transmi ssi on case. Use petrol eum jel l y to hol d
gasket i n pl ace i f necessary. Do not use any type of
seal er to secure gasket. Use petrol eum jel l y onl y.
(6) I nstal l sel ecti ve spacer on i ntermedi ate shaft, i f
removed. Spacer goes i n groove just rearward of
shaft rear spl i nes (Fi g. 188).
(7) I nstal l thrust beari ng i n overdri ve uni t sl i di ng
hub. Use petrol eum jel l y to hol d beari ng i n posi ti on.
Fig. 184 Intermediate Shaft End Play Spacer
Selection
Fig. 185 Overdrive Piston Thrust Plate Measurement
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT
Fig. 186 Overdrive Piston Thrust Plate Selection
CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Veri fy that spl i nes i n overdri ve pl anetary gear
and overrunni ng cl utch hub are al i gned wi th Al i gn-
ment Tool 6227-2. Overdri ve uni t cannot be i nstal l ed
i f spl i nes are not al i gned. I f spl i nes have rotated out
of al i gnment, uni t wi l l have to be di sassembl ed to
(9) Careful l y sl i de Al i gnment Tool 6227-2 out of
overdri ve pl anetary gear and overrunni ng cl utch
spl i nes.
(10) Rai se overdri ve uni t and careful l y sl i de i t
strai ght onto i ntermedi ate shaft. I nsert park rod i nto
park l ock reacti on pl ug at same ti me. Avoi d ti l ti ng
overdri ve duri ng i nstal l ati on as thi s coul d cause
pl anetary gear and overrunni ng cl utch spl i nes to
rotate out of al i gnment. I f thi s occurs, i t wi l l be nec-
essary to remove and di sassembl e overdri ve uni t to
(11) Work overdri ve uni t forward on i ntermedi ate
shaft unti l seated agai nst transmi ssi on case.
(12) I nstal l bol ts attachi ng overdri ve uni t to trans-
mi ssi on uni t. Ti ghten bol ts i n di agonal pattern to 34
Nm (25 ft-l bs).
(13) Connect the transmi ssi on speed sensor and
overdri ve wi ri ng connectors.
(14) I nstal l the transfer case, i f equi pped.
(15) Al i gn and i nstal l rear propel l er shaft, i f nec-
essary. (Refer to 3 - DI FFERENTI AL & DRI VELI NE/
PROPELLER SHAFT/PROPELLER SHAFT -
I NSTALLATI ON)
OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunni ng cl utch (Fi g. 189) consi sts of an
i nner race, an outer race (or cam), rol l ers and
spri ngs, and the spri ng retai ner. The number of rol l -
ers and spri ngs depends on what transmi ssi on and
whi ch overrunni ng cl utch i s bei ng deal t wi th.
OPERATION
As the i nner race i s rotated i n a cl ockwi se di recti on
(as vi ewed from the front of the transmi ssi on), the
race causes the rol l ers to rol l toward the spri ngs,
causi ng them to compress agai nst thei r retai ner. The
compressi on of the spri ngs i ncreases the cl earance
Fig. 187 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 188 Intermediate Shaft Selective Spacer
Location
1 - SELECTIVE SPACER
2 - SPACER GROOVE
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
between the rol l ers and cam. Thi s i ncreased cl ear-
ance between the rol l ers and cam resul ts i n a free-
wheel i ng condi ti on. When the i nner race attempts to
rotate countercl ockwi se, the acti on causes the rol l ers
to rol l i n the same di recti on as the race, ai ded by the
pushi ng of the spri ngs. As the rol l ers try to move i n
the same di recti on as the i nner race, they are
wedged between the i nner and outer races due to the
desi gn of the cam. I n thi s condi ti on, the cl utch i s
l ocked and acts as one uni t.
DISASSEMBLY
NOTE: To service the overrunning clutch cam and
the overdrive piston retainer, the transmission
geartrain and the overdrive unit must be removed
from the transmission.
(1) Remove the overdri ve pi ston (Fi g. 190).
(2) Remove the overdri ve pi ston retai ner bol ts.
(3) Remove overdri ve pi ston retai ner.
(4) Remove case gasket.
(5) Mark the posi ti on of the overrunni ng cl utch
cam i n the case (Fi g. 191).
(6) Remove the overrunni ng cl utch cam bol ts.
(7) Remove the overrunni ng cl utch cam.
CLEANING
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
l ow-reverse drum, and overdri ve pi ston retai ner i n
sol vent. Dry them wi th compressed ai r after cl ean-
i ng.
INSPECTION
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse drum i f the cl utch race,
rol l er surface or i nsi de di ameter i s scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Exami ne the overdri ve pi ston retai ner careful l y for
wear, cracks, scori ng or other damage. Be sure the
retai ner hub i s a snug fi t i n the case and drum.
Repl ace the retai ner i f worn or damaged.
ASSEMBLY
(1) Exami ne bol t hol es i n overrunni ng cl utch cam.
Note that one hol e i s not threaded (Fi g. 192). Thi s
hol e must al i gn wi th bl ank area i n cl utch cam bol t
ci rcl e (Fi g. 193). Mark hol e l ocati on on cl utch cam
and bl ank area i n case wi th grease penci l , pai nt
stri pe, or scri be mark for assembl y reference.
(2) Mark l ocati on of non-threaded hol e i n cl utch
cam and bl ank area i n bol t ci rcl e wi th grease penci l .
(3) Al i gn and i nstal l overrunni ng cl utch and cam
i n case (Fi g. 194). Be sure cam i s correctl y i nstal l ed.
Bol t hol es i n cam are sl i ghtl y countersunk on one
si de. Be sure thi s si de of cam faces rearward (toward
pi ston retai ner).
(4) Veri fy that non-threaded hol e i n cl utch cam i s
properl y al i gned. Check al i gnment by threadi ng a
bol t i nto each bol t hol e. Adjust cl utch cam posi ti on i f
necessary.
Fig. 190 Overdrive Piston Removal
1 - OVERDRIVE CLUTCH PISTON
3 - SELECTIVE SPACER
4 - PISTON RETAINER
Fig. 191 Overrunning Clutch Cam Removal
1 - ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)
(5) I nstal l and ti ghten overrunni ng cl utch cam
bol ts to 17 Nm (13 ft. l bs.) torque. Note that cl utch
cam bol ts are shorter than pi ston retai ner bol ts.
(6) I nstal l new gasket at rear of transmi ssi on case.
Use petrol eum jel l y to hol d gasket i n pl ace. Be sure
to al i gn governor feed hol es i n gasket wi th feed pas-
sages i n case (Fi g. 195). Al so i nstal l gasket before
overdri ve pi ston retai ner. Center hol e i n gasket i s
smal l er than retai ner and cannot be i nstal l ed over
retai ner.
(7) Posi ti on overdri ve pi ston retai ner on transmi s-
si on case and al i gn bol t hol es i n retai ner, gasket and
case (Fi g. 196). Then i nstal l and ti ghten retai ner
Fig. 192 Location Of Non-Threaded Hole In Clutch
Cam
1 - NON-THREADED HOLE
2 - OVERRUNNING CLUTCH CAM
Fig. 193 Location Of Blank Area In Clutch Cam Bolt
Circle
1 - OVERRUNNING CLUTCH CAM SEAT IN CASE
2 - NON-THREADED HOLE IN CLUTCH CAM ALIGNS HERE
(BLANK AREA) OF SEAT
Fig. 194 Overrunning Clutch Installation
1 - ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
Fig. 195 Installing/Aligning Case Gasket
1 - CASE GASKET
2 - BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND
GASKET ARE ALIGNED
(8) I nstal l new seal s on over dri ve pi ston.
(9) Stand transmi ssi on case upri ght on bel l hous-
i ng.
(10) Posi ti on Gui de Ri ng 8114-1 on outer edge of
(11) Posi ti on Seal Gui de 8114-2 on i nner edge of
(12) I nstal l overdri ve pi ston i n overdri ve pi ston
retai ner by: al i gni ng l ocati ng l ugs on overdri ve pi ston
to the two mati ng hol es i n retai ner.
(a) Al i gni ng l ocati ng l ugs on overdri ve pi ston to
the two mati ng hol es i n retai ner.
(b) Lubri cate overdri ve pi ston seal s wi th Mopar
Door Ease, or equi val ent.
(c) I nstal l pi ston over Seal Gui de 8114-2 and
i nsi de Gui de Ri ng 8114-1.
(d) Push overdri ve pi ston i nto posi ti on i n
retai ner.
(e) Veri fy that the l ocati ng l ugs entered the l ug
bores i n the retai ner.
NOTE: Install the remaining transmission compo-
nents and the overdrive unit.
PARK LOCK CABLE
REMOVAL
(1) Pl ace the shi fter i n the PARK posi ti on.
(2) Lower the steeri ng col umn cover.
(3) Wi th the i gni ti on swi tch i n the RUN posi ti on
depress the park l ock cabl e l ocki ng tab, l ocated on
top of the cabl e connector at the steeri ng col umn and
pul l the park l ock cabl e strai ght out.
(4) Remove the park l ock cabl e from steeri ng col -
umn (Fi g. 197).
(5) Remove the fl oor consol e and rel ated tri m.
(Refer to 23 - BODY/I NTERI OR/FLOOR CONSOLE -
REMOVAL)
(6) Di sconnect the park l ock cabl e from the shi ft
BTSI l ever and remove the cabl e from the shi fter
assembl y bracket.
(7) Rel ease the park l ock cabl e from any remai ni ng
cl i ps.
(8) Remove park l ock cabl e from the vehi cl e.
INSTALLATION
NOTE: The gearshift cable must be secured into
position and properly adjusted before the installa-
tion of the Park Lock Cable.
(1) Veri fy that the shi fter i s i n the PARK posi ti on.
(2) Push the park l ock cabl e strai ght i nto the
square mounti ng hol e i n the steeri ng col umn unti l
cabl e snaps i n pl ace.
(3) Route park l ock cabl e to the shi fter mecha-
ni sm.
(4) I nstal l the park l ock cabl e end fi tti ng i nto
shi fter BTSI l ever.
(5) Pul l rearward on the cabl e housi ng to snap
park l ock cabl e adjuster ears i nto fl oor shi fter
bracket.
(6) Pl ace the i gni ti on key cyl i nder i n the ACCES-
SORY posi ti on.
(7) Push the cabl e adjuster l ock cl amp downward
to l ock i t.
(8) Test the park l ock cabl e operati on.
(9) I nstal l the fl oor consol e and rel ated tri m.
I NSTALLATI ON)
Fig. 196 Aligning Overdrive Piston Retainer
1 - PISTON RETAINER
2 - GASKET
3 - RETAINER BOLTS
PARK/NEUTRAL POSITION
SWITCH
DIAGNOSIS AND TESTING - PARK/NEUTRAL
POSITION SWITCH
The center termi nal of the park/neutral posi ti on
swi tch i s the starter-ci rcui t termi nal . I t provi des the
ground for the starter sol enoi d ci rcui t through the
sel ector l ever i n PARK and NEUTRAL posi ti ons onl y.
The outer termi nal s on the swi tch are for the backup
l amp ci rcui t.
SWITCH TEST
To test the swi tch, remove the wi ri ng connector.
Test for conti nui ty between the center termi nal and
the transmi ssi on case. Conti nui ty shoul d exi st onl y
when the transmi ssi on i s i n PARK or NEUTRAL.
Shi ft the transmi ssi on i nto REVERSE and test
conti nui ty at the swi tch outer termi nal s. Conti nui ty
shoul d exi st onl y when the transmi ssi on i s i n
REVERSE. Conti nui ty shoul d not exi st between the
outer termi nal s and the case.
Check gearshi ft l i nkage adjustment before repl ac-
i ng a swi tch that tests faul ty.
REMOVAL
(1) Rai se vehi cl e and posi ti on drai n pan under
swi tch.
(2) Di sconnect swi tch wi res.
(3) Remove swi tch from case.
INSTALLATION
(1) Move shi ft l ever to PARK and NEUTRAL posi -
ti ons. Veri fy that swi tch operati ng l ever fi ngers are
centered i n swi tch openi ng i n case (Fi g. 198).
Fig. 197 Brake Transmission Shift Interlock
3 - ADJUSTMENT CLIP
PARK LOCK CABLE (Continued)
(2) I nstal l new seal on swi tch and i nstal l swi tch i n
case. Ti ghten swi tch to 34 Nm (25 ft. l bs.) torque.
(3) Test conti nui ty of new swi tch wi th 12V test
l amp.
(4) Connect swi tch wi res and l ower vehi cl e.
(5) Top off transmi ssi on fl ui d l evel .
PISTONS
DESCRIPTION
There are several si zes and types of pi stons used i n
an automati c transmi ssi on. Some pi stons are used to
appl y cl utches. They al l have i n common the fact
that they are round or ci rcul ar i n shape, l ocated
wi thi n a smooth wal l ed cyl i nder, whi ch i s cl osed at
one end and converts fl ui d pressure i nto mechani cal
movement. The fl ui d pressure exerted on the pi ston
i s contai ned wi thi n the system through the use of
pi ston ri ngs or seal s.
OPERATION
The pri nci pal whi ch makes thi s operati on possi bl e
i s known as Pascal s Law. Pascal s Law can be stated
as: Pressure on a confi ned fl ui d i s transmi tted
equal l y i n al l di recti ons and acts wi th equal force on
equal areas.
PRESSURE
Pressure (Fi g. 199) i s nothi ng more than force
(l bs.) di vi ded by area (i n or ft.), or force per uni t
area. Gi ven a 100 l b. bl ock and an area of 100 sq. i n.
on the fl oor, the pressure exerted by the bl ock i s: 100
l bs. 100 i n or 1 pound per square i nch, or PSI as i t i s
commonl y referred to.
PRESSURE ON A CONFINED FLUID
Pressure i s exerted on a confi ned fl ui d (Fi g. 200)
by appl yi ng a force to some gi ven area i n contact
wi th the fl ui d. A good exampl e of thi s i s a cyl i nder
fi l l ed wi th fl ui d and equi pped wi th a pi ston that i s
cl osel y fi tted to the cyl i nder wal l . I f a force i s appl i ed
to the pi ston, pressure wi l l be devel oped i n the fl ui d.
Of course, no pressure wi l l be created i f the fl ui d i s
not confi ned. I t wi l l si mpl y l eak past the pi ston.
There must be a resi stance to fl ow i n order to create
pressure. Pi ston seal i ng i s extremel y i mportant i n
hydraul i c operati on. Several ki nds of seal s are used
to accompl i sh thi s wi thi n a transmi ssi on. These
i ncl ude but are not l i mi ted to O-ri ngs, D-ri ngs, l i p
seal s, seal i ng ri ngs, or extremel y cl ose tol erances
between the pi ston and the cyl i nder wal l . The force
exerted i s downward (gravi ty), however, the pri nci pl e
remai ns the same no matter whi ch di recti on i s taken.
The pressure created i n the fl ui d i s equal to the force
appl i ed, di vi ded by the pi ston area. I f the force i s 100
l bs., and the pi ston area i s 10 sq. i n., then the pres-
sure created equal s 10 PSI . Another i nterpretati on of
Pascal s Law i s that regardl ess of contai ner shape or
si ze, the pressure wi l l be mai ntai ned throughout, as
l ong as the fl ui d i s confi ned. I n other words, the
pressure i n the fl ui d i s the same everywhere wi thi n
the contai ner.
Fig. 198 Park/Neutral Position Switch
1 - NEUTRAL CONTACT
2 - MANUAL LEVER AND SWITCH PLUNGER IN REVERSE
POSITION
3 - PARK CONTACT
4 - SWITCH
Fig. 199 Force and Pressure Relationship
PARK/NEUTRAL POSITION SWITCH (Continued)
FORCE MULTIPLICATION
Usi ng the 10 PSI exampl e used i n the i l l ustrati on
(Fi g. 201), a force of 1000 l bs. can be moved wi th a
force of onl y 100 l bs. The secret of force mul ti pl i ca-
ti on i n hydraul i c systems i s the total fl ui d contact
area empl oyed. The i l l ustrati on, (Fi g. 201), shows an
area that i s ten ti mes l arger than the ori gi nal area.
The pressure created wi th the smal l er 100 l b. i nput
i s 10 PSI . The concept pressure i s the same every-
where means that the pressure underneath the
l arger pi ston i s al so 10 PSI . Pressure i s equal to the
force appl i ed di vi ded by the contact area. Therefore,
by means of si mpl e al gebra, the output force may be
found. Thi s concept i s extremel y i mportant, as i t i s
al so used i n the desi gn and operati on of al l shi ft
val ves and l i mi ti ng val ves i n the val ve body, as wel l
as the pi stons, of the transmi ssi on, whi ch acti vate
the cl utches and bands. I t i s nothi ng more than
usi ng a di fference of area to create a di fference i n
pressure to move an object.
PISTON TRAVEL
The rel ati onshi p between hydraul i c l ever and a
mechani cal l ever i s the same. Wi th a mechani cal
l ever i ts a wei ght-to-di stance output rather than a
pressure-to-area output. Usi ng the same forces and
areas as i n the previ ous exampl e, the smal l er pi ston
(Fi g. 202) has to move ten ti mes the di stance
requi red to move the l arger pi ston one i nch. There-
fore, for every i nch the l arger pi ston moves, the
smal l er pi ston moves ten i nches. Thi s pri nci pl e i s
true i n other i nstances al so. A common garage fl oor
jack i s a good exampl e. To rai se a car wei ghi ng 2000
l bs., an effort of onl y 100 l bs. may be requi red. For
every i nch the car moves upward, the i nput pi ston at
the jack handl e must move 20 i nches downward.
Fig. 200 Pressure on a Confined Fluid
Fig. 201 Force Multiplication
Fig. 202 Piston Travel
PISTONS (Continued)
PLANETARY GEARTRAIN/
OUTPUT SHAFT
DESCRIPTION
The pl anetary gearsets (Fi g. 203) are desi gnated as
the front, rear, and overdri ve pl anetary gear assem-
bl i es and l ocated i n such order. A si mpl e pl anetary
gearset consi sts of three mai n members:
The sun gear whi ch i s at the center of the sys-
tem.
The pl anet carri er wi th pl anet pi ni on gears
whi ch are free to rotate on thei r own shafts and are
i n mesh wi th the sun gear.
The annul us gear, whi ch rotates around and i s
i n mesh wi th the pl anet pi ni on gears.
NOTE: The number of pinion gears does not affect
the gear ratio, only the duty rating.
OPERATION
Wi th any gi ven pl anetary gearset, several condi -
ti ons must be met for power to be abl e to fl ow:
One member must be hel d.
Another member must be dri ven or used as an
i nput.
The thi rd member may be used as an output for
power fl ow.
For di rect dri ve to occur, two gear members i n
the front pl anetary gearset must be dri ven.
NOTE: Gear ratios are dependent on the number of
teeth on the annulus and sun gears.
DISASSEMBLY
(1) Remove pl anetary snap-ri ng (Fi g. 204).
(2) Remove front annul us and pl anetary assembl y
from dri vi ng shel l (Fi g. 204).
(3) Remove snap-ri ng that retai ns front pl anetary
gear i n annul us gear (Fi g. 205).
(4) Remove tabbed thrust washer and tabbed
thrust pl ate from hub of front annul us (Fi g. 206).
(5) Separate front annul us and pl anetary gears
(Fi g. 206).
(6) Remove front pl anetary gear front thrust
washer from annul us gear hub.
(7) Separate and remove dri vi ng shel l , rear pl ane-
tary and rear annul us from output shaft (Fi g. 207).
(8) Remove front pl anetary rear thrust washer
from dri vi ng shel l .
(9) Remove tabbed thrust washers from rear pl an-
etary gear.
(10) Remove l ock ri ng that retai ns sun gear i n
dri vi ng shel l . Then remove sun gear, spacer and
thrust pl ates.
Fig. 203 Planetary Gearset
1 - ANNULUS GEAR
2 - SUN GEAR
3 - PLANET CARRIER
4 - PLANET PINIONS (4)
Fig. 204 Front Annulus And Planetary Assembly
Removal
1 - DRIVING SHELL
2 - FRONT ANNULUS AND PLANETARY ASSEMBLY
3 - PLANETARY SNAP-RING
Fig. 205 Front Planetary Snap-Ring Removal
1 - FRONT ANNULUS GEAR
2 - PLANETARY SNAP-RING
INSPECTION
Check sun gear and dri vi ng shel l condi ti on.
Repl ace the gear i f damaged or i f the bushi ngs are
scored or worn. The bushi ngs are not servi ceabl e.
Repl ace the dri vi ng shel l i f worn, cracked or dam-
aged.
Repl ace pl anetary gear sets i f gears, pi ni on pi ns, or
carri er are damaged i n any way. Repl ace the annul us
gears and supports i f ei ther component i s worn or
damaged.
I nspect the geartrai n spacers, thrust pl ates, snap-
ri ngs, and thrust washers. Repl ace any of these parts
that are worn, di storted or damaged. Do not attempt
to reuse these parts.
The pl anetary gear thrust washers are di fferent
si zes. The l arge di ameter washers go on the front
pl anetary and the smal l er washers go on the rear
pl anetary. Al l the washers have four l ocati ng tabs on
them. These tabs fi t i n the hol es or sl ots provi ded i n
each pl anetary gear.
I nspect the output shaft careful l y. Pay parti cul ar
attenti on to the machi ned bushi ng/beari ng surfaces
on the shaft and the governor val ve shaft bore at the
shaft rear.
Repl ace the output shaft i f the machi ned surfaces
are scored, pi tted, or damaged i n any way. Al so
repl ace the shaft i f the spl i nes are damaged, or
exhi bi ts cracks at any l ocati on (especi al l y at the gov-
ernor val ve shaft bore).
The annul us gears can be removed from thei r sup-
ports i f necessary. Just remove the snap-ri ngs and
separate the two parts when repl acement i s neces-
sary. I n addi ti on, the annul us gear bushi ngs can be
repl aced i f severel y worn, or scored. However i t i s not
necessary to repl ace the bushi ngs i f they onl y exhi bi t
normal wear. Check bushi ng fi t on the output shaft
to be sure.
ASSEMBLY
(1) Lubri cate output shaft and pl anetary compo-
nents wi th transmi ssi on fl ui d. Use petrol eum jel l y to
l ubri cate and hol d thrust washers and pl ates i n posi -
ti on.
(2) Assembl e rear annul us gear and support i f di s-
assembl ed. Be sure support snap-ri ng i s seated and
that shoul der-si de of support faces rearward (Fi g.
208).
(3) I nstal l rear thrust washer on rear pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace. Al so be sure al l four washer tabs are properl y
engaged i n gear sl ots.
(4) I nstal l rear annul us over and onto rear pl ane-
tary gear (Fi g. 208).
(5) I nstal l assembl ed rear pl anetary and annul us
gear on output shaft (Fi g. 209). Veri fy that assembl y
i s ful l y seated on shaft.
Fig. 206 Front Planetary And Annulus Gear
Disassembly
1 - FRONT ANNULUS
2 - THRUST WASHER
3 - THRUST PLATE
4 - FRONT THRUST WASHER
5 - FRONT PLANETARY
Fig. 207 Removing Driving Shell, Rear Planetary
And Rear Annulus
1 - REAR ANNULUS
2 - REAR PLANETARY
3 - DRIVING SHELL
4 - OUTPUT SHAFT
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)
(6) I nstal l front thrust washer on rear pl anetary
gear (Fi g. 210). Use enough petrol eum jel l y to hol d
washer on gear. Be sure al l four washer tabs are
seated i n sl ots.
(7) I nstal l spacer on sun gear (Fi g. 211).
(8) I nstal l thrust pl ate on sun gear (Fi g. 212). Note
that dri vi ng shel l thrust pl ates are i nterchangeabl e.
Use ei ther pl ate on sun gear and at front/rear of
shel l .
(9) Hol d sun gear i n pl ace and i nstal l thrust pl ate
over sun gear at rear of dri vi ng shel l (Fi g. 213).
(10) Posi ti on wood bl ock on bench and support sun
gear on bl ock (Fi g. 214). Thi s makes i t easi er to al i gn
and i nstal l sun gear l ock ri ng. Keep wood bl ock
handy as i t wi l l al so be used for geartrai n end pl ay
check.
Fig. 208 Assembling Rear Annulus And Planetary
Gear
1 - REAR ANNULUS GEAR
2 - TABBED THRUST WASHER
3 - REAR PLANETARY
Fig. 209 Installing Rear Annulus And Planetary On
Output Shaft
1 - REAR ANNULUS AND PLANETARY GEAR ASSEMBLY
2 - OUTPUT SHAFT
Fig. 210 Installing Rear Planetary Front Thrust
Washer
1 - FRONT TABBED THRUST WASHER
2 - REAR PLANETARY GEAR
Fig. 211 Installing Spacer On Sun Gear
1 - SUN GEAR
2 - SUN GEAR SPACER
(11) Al i gn rear thrust pl ate on dri vi ng shel l and
i nstal l sun gear l ock ri ng. Be sure ri ng i s ful l y seated
i n sun gear ri ng groove (Fi g. 215).
(12) I nstal l assembl ed dri vi ng shel l and sun gear
on output shaft (Fi g. 216).
(13) I nstal l rear thrust washer on front pl anetary
gear (Fi g. 217). Use enough petrol eum jel l y to hol d
washer i n pl ace and be sure al l four washer tabs are
seated.
Fig. 212 Installing Driving Shell Front Thrust Plate
On Sun Gear
1 - SPACER
2 - SUN GEAR
3 - THRUST PLATE
Fig. 213 Installing Driving Shell Rear Thrust Plate
1 - DRIVING SHELL
2 - SUN GEAR
3 - REAR THRUST PLATE
Fig. 214 Supporting Sun Gear On Wood Block
1 - SUN GEAR
2 - DRIVING SHELL
3 - WOOD BLOCK
Fig. 215 Installing Sun Gear Lock Ring
1 - LOCK RING GROOVE
2 - SUN GEAR LOCK RING
3 - DRIVING SHELL
4 - REAR THRUST PLATE
(14) I nstal l front pl anetary gear on output shaft
and i n dri vi ng shel l (Fi g. 218).
(15) I nstal l front thrust washer on front pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace and be sure al l four washer tabs are seated.
(16) Assembl e front annul us gear and support, i f
necessary. Be sure support snap-ri ng i s seated.
(17) I nstal l front annul us on front pl anetary (Fi g.
218).
(18) Posi ti on thrust pl ate on front annul us gear
support (Fi g. 219). Note that pl ate has two tabs on i t.
These tabs fi t i n notches of annul us hub.
(19) I nstal l thrust washer i n front annul us (Fi g.
220). Al i gn fl at on washer wi th fl at on pl anetary hub.
Al so be sure washer tab i s faci ng up.
(20) I nstal l front annul us snap-ri ng (Fi g. 221). Use
snap-ri ng pl i ers to avoi d di storti ng ri ng duri ng
i nstal l ati on. Al so be sure ri ng i s ful l y seated.
(21) I nstal l pl anetary sel ecti ve snap-ri ng wi th
snap-ri ng pl i ers (Fi g. 222). Be sure ri ng i s ful l y
seated.
(22) Turn pl anetary geartrai n assembl y over so
dri vi ng shel l i s faci ng workbench. Then support
geartrai n on wood bl ock posi ti oned under forward
end of output shaft. Thi s al l ows geartrai n compo-
nents to move forward for accurate end pl ay check.
(23) Check pl anetary geartrai n end pl ay wi th
feel er gauge (Fi g. 223). Gauge goes between shoul der
on output shaft and end of rear annul us support.
(24) Geartrai n end pl ay shoul d be 0.12 to 1.22 mm
(0.005 to 0.048 i n.). I f end pl ay i s i ncorrect, snap-ri ng
(or thrust washers) may have to be repl aced. Snap-
ri ngs are avai l abl e i n three di fferent thi cknesses for
adjustment purposes.
Fig. 216 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
1 - SUN GEAR/DRIVING SHELL ASSEMBLY
2 - OUTPUT SHAFT
Fig. 217 Installing Rear Thrust Washer On Front
Planetary Gear
1 - FRONT PLANETARY GEAR
2 - REAR TABBED THRUST WASHER
Fig. 218 Installing Front Planetary And Annulus
Gears
1 - FRONT PLANETARY GEAR
2 - FRONT THRUST WASHER
3 - FRONT ANNULUS GEAR
Fig. 219 Positioning Thrust Plate On Front Annulus
Support
1 - FRONT ANNULUS
2 - THRUST PLATE
Fig. 220 Installing Front Annulus Thrust Washer
1 - WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB
2 - FRONT ANNULUS THRUST WASHER
3 - TAB FACES FRONT
Fig. 221 Installing Front Annulus Snap-Ring
2 - FRONT ANNULUS SNAP-RING
Fig. 222 Installing Planetary Selective Snap-Ring
1 - SELECTIVE SNAP-RING
Fig. 223 Checking Planetary Geartrain End Play
1 - OUTPUT SHAFT
2 - REAR ANNULUS GEAR
3 - FEELER GAUGE
REAR CLUTCH
DESCRIPTION
The rear cl utch assembl y (Fi g. 224) i s composed of
the rear cl utch retai ner, pressure pl ate, cl utch pl ates,
dri vi ng di scs, pi ston, Bel l evi l l e spri ng, and snap-
ri ngs. The Bel l evi l l e spri ng acts as a l ever to mul ti -
pl y the force appl i ed on to i t by the appl y pi ston. The
i ncreased appl y force on the rear cl utch pack, i n com-
pari son to the front cl utch pack, i s needed to hol d
agai nst the greater torque l oad i mposed onto the rear
pack. The rear cl utch i s di rectl y behi nd the front
cl utch and i s consi dered a dri vi ng component.
OPERATION
the cl utch retai ner and pi ston. The fl ui d pressure i s
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved spri ng i s
used to cushi on the appl i cati on of the cl utch pack.
The snap-ri ng i s sel ecti ve and used to adjust cl utch
pack cl earance.
Fig. 224 Rear Clutch
1 - PISTON SPRING 10 - TOP PRESSURE PLATE
2 - REAR CLUTCH PISTON 11 - CLUTCH DISCS (4)
3 - CLUTCH PISTON SEALS 12 - BOTTOM PRESSURE PLATE
4 - OUTPUT SHAFT THRUST WASHER (METAL) 13 - WAVE SPRING
5 - INPUT SHAFT SNAP-RING 14 - CLUTCH PLATES (3)
6 - REAR CLUTCH RETAINER 15 - RETAINER SEAL RING
7 - INPUT SHAFT 16 - SHAFT REAR SEAL RING (PLASTIC)
8 - REAR CLUTCH THRUST WASHER (FIBER) 17 - SHAFT FRONT SEAL RING (TEFLON)
9 - CLUTCH PACK SNAP-RING (SELECTIVE)
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and one-way bal l -check-val ve l ocated i n the pi s-
ton. The check-val ve i s needed to el i mi nate the pos-
si bi l i ty of pl ate drag caused by centri fugal force
acti ng on the resi dual fl ui d trapped i n the cl utch pi s-
ton retai ner.
DISASSEMBLY
(1) Remove fi ber thrust washer from forward si de
of cl utch retai ner.
(2) Remove i nput shaft front/rear seal ri ngs.
(3) Remove sel ecti ve cl utch pack snap-ri ng (Fi g.
225).
(4) Remove top pressure pl ate, cl utch di scs, steel
pl ates, bottom pressure pl ate and wave snap-ri ng
and wave spri ng (Fi g. 225).
(5) Remove cl utch pi ston wi th rotati ng moti on.
(6) Remove and di scard pi ston seal s.
(7) Remove i nput shaft snap-ri ng (Fi g. 226). I t
may be necessary to press the i nput shaft i n sl i ghtl y
to rel i eve tensi on on the snap-ri ng
(8) Press i nput shaft out of retai ner wi th shop
press and sui tabl e si ze press tool . Use a sui tabl y
si zed press tool to support the retai ner as cl ose to the
i nput shaft as possi bl e.
CLEANING
Cl ean the cl utch components wi th sol vent and dry
them wi th compressed ai r. Do not use rags or shop
towel s to dry any of the cl utch parts. Li nt from such
materi al s wi l l adhere to component surfaces and
coul d restri ct or bl ock fl ui d passages after assembl y.
Fig. 225 Rear Clutch Components
1 - PISTON SPRING 10 - TOP PRESSURE PLATE
2 - REAR CLUTCH PISTON 11 - CLUTCH DISCS (4)
3 - CLUTCH PISTON SEALS 12 - BOTTOM PRESSURE PLATE
4 - OUTPUT SHAFT THRUST WASHER (METAL) 13 - WAVE SPRING
5 - INPUT SHAFT SNAP-RING 14 - CLUTCH PLATES (3)
6 - REAR CLUTCH RETAINER 15 - RETAINER SEAL RING
7 - INPUT SHAFT 16 - SHAFT REAR SEAL RING (PLASTIC)
8 - REAR CLUTCH THRUST WASHER (FIBER) 17 - SHAFT FRONT SEAL RING (TEFLON)
9 - CLUTCH PACK SNAP-RING (SELECTIVE)
REAR CLUTCH (Continued)
INSPECTION
Repl ace the cl utch di scs i f warped, worn, scored,
burned/charred, the l ugs are damaged, or i f the fac-
i ng i s fl aki ng off. Repl ace the top and bottom pres-
sure pl ates i f scored, warped, or cracked. Be sure the
dri vi ng l ugs on the pressure and cl utch pl ates are
al so i n good condi ti on. The l ugs must not be bent,
cracked or damaged i n any way.
Repl ace the pi ston spri ng and wave spri ng i f ei ther
part i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
cl utch and pressure pl ates shoul d sl i de freel y i n the
sl ots. Repl ace the retai ner i f the grooves are worn or
damaged. Al so check acti on of the check bal l s i n the
retai ner and pi ston. Each check bal l must move
freel y and not sti ck.
Repl ace the retai ner bushi ng i f worn, scored, or
doubt exi sts about bushi ng condi ti on.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
Check condi ti on of the fi ber thrust washer and
metal output shaft thrust washer. Repl ace ei ther
washer i f worn or damaged.
Check condi ti on of the seal ri ngs on the i nput shaft
and cl utch retai ner hub. Repl ace the seal ri ngs onl y
i f worn, di storted, or damaged. The i nput shaft front
seal ri ng i s tefl on wi th chamfered ends. The rear ri ng
i s metal wi th i nterl ocki ng ends.
Check the i nput shaft for wear, or damage. Repl ace
the shaft i f worn, scored or damaged i n any way.
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal ri ngs on cl utch retai ner hub
and i nput shaft, i f necessary, (Fi g. 227) and (Fi g.
228).
(a) Be sure cl utch hub seal ri ng i s ful l y seated i n
groove and i s not twi sted.
(3) Lubri cate spl i ned end of i nput shaft and cl utch
retai ner wi th transmi ssi on fl ui d. Then press i nput
shaft i nto retai ner (Fi g. 229). Use a sui tabl y si zed
press tool to support retai ner as cl ose to i nput shaft
as possi bl e.
(4) I nstal l i nput shaft snap-ri ng (Fi g. 226).
(5) I nvert retai ner and press i nput shaft i n oppo-
si te di recti on unti l snap-ri ng i s seated.
(6) I nstal l new seal s on cl utch pi ston. Be sure l i p
of each seal faces i nteri or of cl utch retai ner.
(7) Lubri cate l i p of pi ston seal s wi th generous
quanti ty of Mopar Door Ease. Then l ubri cate
retai ner hub and bore wi th l i ght coat of transmi ssi on
fl ui d.
(8) I nstal l cl utch pi ston i n retai ner. Use twi sti ng
moti on to seat pi ston i n bottom of retai ner. A thi n
stri p of pl asti c (about 0.020 thi ck), can be used to
gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) I nstal l pi ston spri ng i n retai ner and on top of
pi ston (Fi g. 230). Concave si de of spri ng faces down-
ward (toward pi ston).
(10) I nstal l wave spri ng i n retai ner (Fi g. 230). Be
sure spri ng i s compl etel y seated i n retai ner groove.
(11) I nstal l bottom pressure pl ate (Fi g. 225).
Ri dged si de of pl ate faces downward (toward pi ston)
and fl at si de toward cl utch pack.
(12) I nstal l fi rst cl utch di sc i n retai ner on top of
bottom pressure pl ate. Then i nstal l a cl utch pl ate fol -
l owed by a cl utch di sc unti l enti re cl utch pack i s
i nstal l ed (4 di scs and 3 pl ates are requi red) (Fi g.
225).
(13) I nstal l top pressure pl ate.
(14) I nstal l sel ecti ve snap-ri ng. Be sure snap-ri ng
i s ful l y seated i n retai ner groove.
(15) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pack cl earance (Fi g. 231).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 231).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and rel ease i t.
Fig. 226 Removing Input Shaft Snap-Ring
2 - INPUT SHAFT SNAP-RING
(c) Zero the di al i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
snap-ri ng and record the di al i ndi cator readi ng.
Cl earance shoul d be 0.559 - 0.914 mm (0.022 -
0.036 i n.). I f cl earance i s i ncorrect, steel pl ates, di scs,
sel ecti ve snap ri ng and pressure pl ates may have to
be changed.
Fig. 227 Rear Clutch Retainer And Input Shaft Seal
Ring Installation
1 - REAR CLUTCH RETAINER HUB SEAL RING
2 - INPUT SHAFT SEAL RINGS
Fig. 228 Input Shaft Seal Ring Identification
1 - PLASTIC REAR SEAL RING
2 - TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER
SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)
Fig. 229 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
3 - PRESS RAM
Fig. 230 Piston Spring/Wave Spring Position
2 - PISTON SPRING
3 - WAVE SPRING
4 - CLUTCH PISTON
The sel ecti ve snap-ri ng thi cknesses are:
0.107-0.109 i n.
0.098-0.100 i n.
0.095-0.097 i n.
0.083-0.085 i n.
0.076-0.078 i n.
0.071-0.073 i n.
0.060-0.062 i n.
(16) Coat rear cl utch thrust washer wi th petro-
l eum jel l y and i nstal l washer over i nput shaft and
i nto cl utch retai ner (Fi g. 232). Use enough petrol eum
jel l y to hol d washer i n pl ace.
REAR SERVO
DESCRIPTION
The rear (l ow/reverse) servo consi sts of a si ngl e
stage or di ameter pi ston and a spri ng l oaded pl ug.
The spri ng i s used to cushi on the appl i cati on of the
rear (l ow/reverse) band.
OPERATION
Whi l e i n the de-energi zed state (no pressure
appl i ed), the pi ston i s hel d up i n i ts bore by the pi s-
ton spri ng. The pl ug i s hel d down i n i ts bore, i n the
pi ston, by the pl ug spri ng. When pressure i s appl i ed
to the top of the pi ston, the pl ug i s forced down i n i ts
bore, taki ng up any cl earance. As the pi ston moves, i t
causes the pl ug spri ng to compress, and the pi ston
moves down over the pl ug. The pi ston conti nues to
move down unti l i t hi ts the shoul der of the pl ug and
ful l y appl i es the band. The peri od of ti me from the
i ni ti al appl i cati on, unti l the pi ston i s agai nst the
shoul der of the pl ug, represents a reduced shocki ng
of the band that cushi ons the shi ft.
DISASSEMBLY
(1) Remove smal l snap-ri ng and remove pl ug and
spri ng from servo pi ston (Fi g. 233).
(2) Remove and di scard servo pi ston seal ri ng.
CLEANING
Remove and di scard the servo pi ston seal ri ng (Fi g.
234). Then cl ean the servo components wi th sol vent
and dry wi th compressed ai r. Repl ace ei ther spri ng i f
col l apsed, di storted or broken. Repl ace the pl ug and
pi ston i f cracked, bent, or worn. Di scard the servo
snap-ri ngs and use new ones at assembl y.
Fig. 231 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4 - STAND
5 - REAR CLUTCH
6 - GAUGE BAR
Fig. 232 Installing Rear Clutch Thrust Washer
2 - REAR CLUTCH THRUST WASHER
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
ASSEMBLY
(1) Lubri cate pi ston and gui de seal s (Fi g. 235)
wi th petrol eum jel l y. Lubri cate other servo parts wi th
Mopar ATF +4, type 9602, transmi ssi on fl ui d.
(2) I nstal l new seal ri ng on servo pi ston.
(3) Assembl e pi ston, pl ug, spri ng and new snap-
ri ng.
(4) Lubri cate pi ston seal l i p wi th petrol eum jel l y.
SHIFT MECHANISM
DESCRIPTION
The gear shi ft mechani sm provi des si x shi ft posi -
ti ons whi ch are:
PARK (P)
REVERSE (R)
NEUTRAL (N)
DRI VE (D)
Manual SECOND (2)
Manual LOW (1)
OPERATION
Manual LOW (1) range provi des fi rst gear onl y.
Overrun braki ng i s al so provi ded i n thi s range. Man-
ual SECOND (2) range provi des fi rst and second gear
onl y.
DRI VE range provi des fi rst, second thi rd and over-
dri ve fourth gear ranges. The shi ft i nto overdri ve
fourth gear range occurs onl y after the transmi ssi on
has compl eted the shi ft i nto D thi rd gear range. No
further movement of the shi ft mechani sm i s requi red
to compl ete the 3-4 shi ft.
The fourth gear upshi ft occurs automati cal l y when
the overdri ve sel ector swi tch i s i n the ON posi ti on.
No upshi ft to fourth gear wi l l occur i f any of the fol -
l owi ng are true:
The transmi ssi on fl ui d temperature i s bel ow 10
C (50 F) or above 121 C (250 F).
The shi ft to thi rd i s not yet compl ete.
Vehi cl e speed i s too l ow for the 3-4 shi ft to occur.
Battery temperature i s bel ow -5 C (23 F).
REMOVAL
(1) Remove any necessary consol e parts for access
to shi ft l ever assembl y and shi fter cabl es. (Refer to
REMOVAL)
(3) Di sconnect the transmi ssi on shi ft cabl e at shi ft
l ever and shi fter assembl y bracket (Fi g. 236).
(4) Di sconnect the park l ock cabl e from the shi fter
BTSI l ever and the shi fter assembl y bracket. (Fi g.
237)
(5) Di sconnect the transfer case shi ft cabl e from
the transfer case shi ft l ever pi n (Fi g. 238), i f
equi pped.
(6) Remove the cl i p hol di ng the transfer case shi ft
cabl e to the shi fter assembl y bracket, i f equi pped.
(7) Remove the transfer case shi ft cabl e from the
shi fter assembl y bracket, i f equi pped.
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
REAR SERVO (Continued)
1 - SHIFT LEVER PIN
3 - SHIFT CABLE
Fig. 237 Brake Transmission Interlock Cable
3 - ADJUSTMENT CLIP
1 - CLIP
2 - SHIFTER
3 - TRANSFER CASE SHIFT LEVER PIN
SHIFT MECHANISM (Continued)
(8) Di sengage al l wi ri ng connectors from the
shi fter assembl y.
(9) Remove al l nuts hol di ng the shi fter assembl y to
the fl oor pan (Fi g. 239).
(10) Remove the shi fter assembl y from the vehi cl e.
INSTALLATION
(3) Veri fy that the park l ock cabl e adjustment tab
i s pul l ed upward to the unl ocked posi ti on.
(4) I nstal l wi ri ng harness to the shi fter assembl y
bracket. Engage any wi re connectors removed from
the shi fter assembl y.
shi fter assembl y bracket. I nstal l cl i p to hol d cabl e to
the bracket.
(6) Snap the transfer case shi ft cabl e, i f equi pped,
onto the transfer case shi ft l ever pi n.
(7) I nstal l the park l ock cabl e i nto the shi fter
assembl y bracket and i nto the shi fter BTSI l ever.(Re-
fer to 21 - TRANSMI SSI ON/TRANSAXLE/AUTO-
MATI C/SHI FT I NTERLOCK MECHANI SM -
ADJUSTMENTS)
(9) I nstal l shi fter assembl y onto the shi fter assem-
bl y studs on the fl oor pan.
(10) I nstal l the nuts to hol d the shi fter assembl y
onto the fl oor pan. Ti ghten nuts to 28 Nm (250
i n.l bs.).
ti on.
i n.l bs.).
(14) Pl ace the key i n the accessory posi ti on.
(15) Push downward on the park l ock cabl e adjust-
ment tab to l ock the adjustment.
(16) Veri fy correct shi fter, park l ock, and BTSI
operati on.
shi ft l ever assembl y and shi ft cabl es. (Refer to 23 -
TI ON)
SOLENOID
DESCRIPTION
The typi cal el ectri cal sol enoi d used i n automoti ve
appl i cati ons i s a l i near actuator. I t i s a devi ce that
produces moti on i n a strai ght l i ne. Thi s strai ght l i ne
moti on can be ei ther forward or backward i n di rec-
ti on, and short or l ong di stance.
A sol enoi d i s an el ectromechani cal devi ce that uses
a magneti c force to perform work. I t consi sts of a coi l
of wi re, wrapped around a magneti c core made from
steel or i ron, and a spri ng l oaded, movabl e pl unger,
whi ch performs the work, or strai ght l i ne moti on.
The sol enoi ds used i n transmi ssi on appl i cati ons
are attached to val ves whi ch can be cl assi fi ed as nor-
mally open or normally closed. The normally
open sol enoi d val ve i s defi ned as a val ve whi ch
al l ows hydraul i c fl ow when no current or vol tage i s
appl i ed to the sol enoi d. The normally closed sol e-
noi d val ve i s defi ned as a val ve whi ch does not al l ow
hydraul i c fl ow when no current or vol tage i s appl i ed
to the sol enoi d. These val ves perform hydraul i c con-
trol functi ons for the transmi ssi on and must there-
fore be durabl e and tol erant of di rt parti cl es. For
these reasons, the val ves have hardened steel pop-
pets and bal l val ves. The sol enoi ds operate the val ves
di rectl y, whi ch means that the sol enoi ds must have
very hi gh outputs to cl ose the val ves agai nst the si z-
abl e fl ow areas and l i ne pressures found i n current
transmi ssi ons. Fast response ti me i s al so necessary
to ensure accurate control of the transmi ssi on.
The strength of the magneti c fi el d i s the pri mary
force that determi nes the speed of operati on i n a par-
ti cul ar sol enoi d desi gn. A stronger magneti c fi el d wi l l
cause the pl unger to move at a greater speed than a
weaker one. There are basi cal l y two ways to i ncrease
the force of the magneti c fi el d:
1. I ncrease the amount of current appl i ed to the
coi l or
2. I ncrease the number of turns of wi re i n the coi l .
The most common practi ce i s to i ncrease the num-
ber of turns by usi ng thi n wi re that can compl etel y
fi l l the avai l abl e space wi thi n the sol enoi d housi ng.
The strength of the spri ng and the l ength of the
pl unger al so contri bute to the response speed possi -
bl e by a parti cul ar sol enoi d desi gn.
Fig. 239 Shifter Assembly
1 - FLOOR PAN
2 - SHIFTER ASSEMBLY
A sol enoi d can al so be descri bed by the method by
whi ch i t i s control l ed. Some of the possi bi l i ti es
i ncl ude vari abl e force, pul se-wi dth modul ated, con-
stant ON, or duty cycl e. The vari abl e force and pul se-
wi dth modul ated versi ons uti l i ze si mi l ar methods to
control the current fl ow through the sol enoi d to posi -
ti on the sol enoi d pl unger at a desi red posi ti on some-
where between ful l ON and ful l OFF. The constant
ON and duty cycl ed versi ons control the vol tage
across the sol enoi d to al l ow ei ther ful l fl ow or no fl ow
through the sol enoi ds val ve.
OPERATION
When an el ectri cal current i s appl i ed to the sol e-
noi d coi l , a magneti c fi el d i s created whi ch produces
an attracti on to the pl unger, causi ng the pl unger to
move and work agai nst the spri ng pressure and the
l oad appl i ed by the fl ui d the val ve i s control l i ng. The
pl unger i s normal l y di rectl y attached to the val ve
whi ch i t i s to operate. When the current i s removed
from the coi l , the attracti on i s removed and the
pl unger wi l l return to i ts ori gi nal posi ti on due to
spri ng pressure.
The pl unger i s made of a conducti ve materi al and
accompl i shes thi s movement by provi di ng a path for
the magneti c fi el d to fl ow. By keepi ng the ai r gap
between the pl unger and the coi l to the mi ni mum
necessary to al l ow free movement of the pl unger, the
magneti c fi el d i s maxi mi zed.
SPEED SENSOR
DESCRIPTION
The speed sensor (Fi g. 240) i s l ocated i n the over-
dri ve gear case. The sensor i s posi ti oned over the
park gear and moni tors transmi ssi on output shaft
rotati ng speed.
OPERATION
Speed sensor si gnal s are tri ggered by the park
gear l ugs as they rotate past the sensor pi ckup face.
I nput si gnal s from the sensor are sent to the trans-
mi ssi on control modul e for processi ng. Si gnal s from
thi s sensor are shared wi th the powertrai n control
modul e.
THROTTLE VALVE CABLE
DESCRIPTION
Transmi ssi on throttl e val ve cabl e adjustment i s
extremel y i mportant to proper operati on. Thi s adjust-
ment posi ti ons the throttl e val ve, whi ch control s shi ft
speed, qual i ty, and part-throttl e downshi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve.
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 241). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A retai ni ng cl i p at the engi ne-end of the cabl e
i s removed to provi de for cabl e adjustment. The
retai ni ng cl i p i s then i nstal l ed back onto the throttl e
val ve cabl e to l ock i n the adjustment.
ADJUSTMENTS - TRANSMISSION THROTTLE
VALVE CABLE
A correctl y adjusted throttl e val ve cabl e (Fi g. 242)
wi l l cause the throttl e l ever on the transmi ssi on to
move si mul taneousl y wi th the throttl e body l ever
from the i dl e posi ti on. Proper adjustment wi l l al l ow
Fig. 240 Transmission Output Speed Sensor
1 - TRANSMISSION OUTPUT SHAFT SPEED SENSOR
2 - SEAL
3 - THROTTLE BODY
SOLENOID (Continued)
si mul taneous movement wi thout causi ng the trans-
mi ssi on throttl e l ever to ei ther move ahead of, or l ag
behi nd the l ever on the throttl e body.
ADJUSTMENT VERIFICATION
(1) Turn i gni ti on key to OFF posi ti on.
(2) Remove ai r cl eaner.
(3) Veri fy that l ever on throttl e body (Fi g. 242) i s
at curb i dl e posi ti on. Then veri fy that the transmi s-
si on throttl e l ever (Fi g. 243) i s al so at i dl e (ful l y for-
ward) posi ti on.
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on (Fi g. 244).
I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) Pry the T.V. cabl e l ock (A) i nto the UP posi ti on
(Fi g. 244). Thi s wi l l unl ock the cabl e and al l ow for
readjustment.
(6) Appl y just enough tensi on on the T.V. cabl e (B)
to remove any sl ack i n the cabl e.Pulling too tight
will cause the T.V. lever on the transmission to
move out of its idle position, which will result
in an incorrect T.V. cable adjustment. Sl i de the
sheath of the T.V. cabl e (D) back and forth unti l the
centerl i nes of the T.V. cabl e end (B) and the throttl e
bel l crank l ever (C) are al i gned wi thi n one mi l l i meter
(1mm) (Fi g. 244).
(7) Whi l e hol di ng the T.V. cabl e i n the set posi ti on
push the T.V. cabl e l ock (A) i nto the down posi ti on
(Fi g. 244). Thi s wi l l l ock the present T.V. cabl e
adjustment.
3 - THROTTLE BODY
Fig. 243 Throttle Valve Cable at Transmission
BOLT(S)
THROTTLE VALVE CABLE (Continued)
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(8) Reconnect the T.V. cabl e (B) to the throttl e
bel l crank l ever (C).
(9) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 245) i s a hydraul i c
devi ce that coupl es the engi ne crankshaft to the
transmi ssi on. The torque converter consi sts of an
outer shel l wi th an i nternal turbi ne, a stator, an
overrunni ng cl utch, an i mpel l er and an el ectroni cal l y
appl i ed converter cl utch. The converter cl utch pro-
vi des reduced engi ne speed and greater fuel economy
when engaged. Cl utch engagement al so provi des
reduced transmi ssi on fl ui d temperatures. The torque
converter hub dri ves the transmi ssi on oi l (fl ui d)
pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the all transmission fluid
cooler(s) and lines.
Fig. 244 Throttle Valve Cable at Throttle Linkage
1 - THROTTLE LINKAGE
2 - THROTTLE VALVE CABLE LOCKING CLIP
Fig. 245 Torque Converter Assembly
1 - TURBINE
2 - IMPELLER
3 - HUB
4 - STATOR
5 - FRONT COVER
6 - CONVERTER CLUTCH DISC
7 - DRIVE PLATE
THROTTLE VALVE CABLE (Continued)
IMPELLER
The i mpel l er (Fi g. 246) i s an i ntegral part of the
converter housi ng. The i mpel l er consi sts of curved
bl ades pl aced radi al l y al ong the i nsi de of the housi ng
on the transmi ssi on si de of the converter. As the con-
verter housi ng i s rotated by the engi ne, so i s the
i mpel l er, because they are one and the same and are
the dri vi ng members of the system.
Fig. 246 Impeller
1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
5 - ENGINE ROTATION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
TORQUE CONVERTER (Continued)
TURBINE
The turbi ne (Fi g. 247) i s the output, or dri ven,
member of the converter. The turbi ne i s mounted
wi thi n the housi ng opposi te the i mpel l er, but i s not
attached to the housi ng. The i nput shaft i s i nserted
through the center of the i mpel l er and spl i ned i nto
the turbi ne. The desi gn of the turbi ne i s si mi l ar to
the i mpel l er, except the bl ades of the turbi ne are
curved i n the opposi te di recti on.
Fig. 247 Turbine
1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
STATOR
The stator assembl y (Fi g. 248) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator i s l ocated between the i mpel l er and
turbi ne wi thi n the torque converter case (Fi g. 249).
The stator contai ns an over-runni ng cl utch, whi ch
al l ows the stator to rotate onl y i n a cl ockwi se di rec-
ti on. When the stator i s l ocked agai nst the over-run-
ni ng cl utch, the torque mul ti pl i cati on feature of the
torque converter i s operati onal .
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fi g. 250) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shock-free power transfer, i t i s
natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel l er
and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston was added to the turbi ne, and a fri cti on mate-
ri al was added to the i nsi de of the front cover to pro-
vi de thi s mechani cal l ock-up.
Fig. 248 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 249 Stator Location
1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 250 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
OPERATION
The converter i mpel l er (Fi g. 251) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi nes bl ades i t con-
ti nues i n a hi nderi ng di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n such a
di recti on that i t woul d tend to sl ow i t down.
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
stators over-runni ng cl utch to i ts shaft (Fi g. 252).
Under stal l condi ti ons (the turbi ne i s stati onary), the
oi l l eavi ng the turbi ne bl ades stri kes the face of the
stator bl ades and tri es to rotate them i n a counter-
cl ockwi se di recti on. When thi s happens the overrun-
ni ng cl utch of the stator l ocks and hol ds the stator
from rotati ng. Wi th the stator l ocked, the oi l stri kes
the stator bl ades and i s redi rected i nto a hel pi ng
di recti on before i t enters the i mpel l er. Thi s ci rcul a-
ti on of oi l from i mpel l er to turbi ne, turbi ne to stator,
and stator to i mpel l er, can produce a maxi mum
torque mul ti pl i cati on of about 2.4:1. As the turbi ne
begi ns to match the speed of the i mpel l er, the fl ui d
that was hi tti ng the stator i n such as way as to
cause i t to l ock-up i s no l onger doi ng so. I n thi s con-
di ti on of operati on, the stator begi ns to free wheel
and the converter acts as a fl ui d coupl i ng.
Fig. 251 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
The torque converter cl utch i s hydraul i cal l y
appl i ed and i s rel eased when fl ui d i s vented from the
hydraul i c ci rcui t by the torque converter control
(TCC) sol enoi d on the val ve body. The torque con-
verter cl utch i s control l ed by the Powertrai n Control
Modul e (PCM). The torque converter cl utch engages
i n fourth gear, and i n thi rd gear under vari ous con-
di ti ons, such as when the O/D swi tch i s OFF, when
the vehi cl e i s crui si ng on a l evel surface after the
vehi cl e has warmed up. The torque converter cl utch
wi l l di sengage momentari l y when an i ncrease i n
engi ne l oad i s sensed by the PCM, such as when the
vehi cl e begi ns to go uphi l l or the throttl e pressure i s
i ncreased.
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
Fig. 252 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
Fig. 253 Checking Torque Converter Seating -
Typical
1 - SCALE
2 - STRAIGHTEDGE
TORQUE CONVERTER
DRAINBACK VALVE
DESCRIPTION
The drai nback val ve i s l ocated i n the transmi ssi on
cool er outl et (pressure) l i ne.
OPERATION
The val ve prevents fl ui d from drai ni ng from the
converter i nto the cool er and l i nes when the vehi cl e
i s shut down for l engthy peri ods. Producti on val ves
have a hose ni ppl e at one end, whi l e the opposi te end
i s threaded for a fl are fi tti ng. Al l val ves have an
arrow (or si mi l ar mark) to i ndi cate di recti on of fl ow
through the val ve.
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE
The converter drai nback check val ve i s l ocated i n
the cool er outl et (pressure) l i ne near the radi ator
tank. The val ve prevents fl ui d drai nback when the
vehi cl e i s parked for l engthy peri ods. The val ve check
bal l i s spri ng l oaded and has an openi ng pressure of
approxi matel y 2 psi .
The val ve i s servi ced as an assembl y; i t i s not
repai rabl e. Do not cl ean the val ve i f restri cted, or
contami nated by sl udge, or debri s. I f the val ve fai l s,
or i f a transmi ssi on mal functi on occurs that gener-
ates si gni fi cant amounts of sl udge and/or cl utch par-
ti cl es and metal shavi ngs, the val ve must be
repl aced.
The val ve must be removed whenever the cool er
and l i nes are reverse fl ushed. The val ve can be fl ow
tested when necessary. The procedure i s exactl y the
same as for fl ow testi ng a cool er.
I f the val ve i s restri cted, i nstal l ed backwards, or i n
the wrong l i ne, i t wi l l cause an overheati ng condi ti on
and possi bl e transmi ssi on fai l ure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
Transmi ssi on fl ui d temperature readi ngs are sup-
pl i ed to the transmi ssi on control modul e by the ther-
mi stor (Fi g. 254). The temperature readi ngs are used
to control engagement of the fourth gear overdri ve
cl utch, the converter cl utch, and governor pressure.
Normal resi stance val ue for the thermi stor at room
temperature i s approxi matel y 2000 ohms.
The thermi stor i s part of the governor pressure
sensor assembl y and i s i mmersed i n transmi ssi on
fl ui d at al l ti mes.
OPERATION
The PCM prevents engagement of the converter
cl utch and overdri ve cl utch, when fl ui d temperature
i s bel ow approxi matel y 10C (50F).
I f fl ui d temperature exceeds 126C (260F), the
PCM causes a 4-3 downshi ft and engage the con-
verter cl utch. Engagement i s accordi ng to the thi rd
gear converter cl utch engagement schedul e.
The overdri ve OFF l amp i n the i nstrument panel
i l l umi nates when the shi ft back to thi rd occurs. The
transmi ssi on wi l l not al l ow fourth gear operati on
unti l fl ui d temperature decreases to approxi matel y
110C (230F).
Fig. 254 Governor Pressure Sensor
1 - GOVERNOR BODY
2 - GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID
TEMPERATURE THERMISTOR
VALVE BODY
DESCRIPTION
The val ve body consi sts of a cast al umi num val ve
body, a separator pl ate, and transfer pl ate. The val ve
body contai ns val ves and check bal l s that control
fl ui d del i very to the torque converter cl utch, bands,
and fri cti onal cl utches. The val ve body contai ns the
fol l owi ng components (Fi g. 255), (Fi g. 256), (Fi g.
257), and (Fi g. 258):
Regul ator val ve
Regul ator val ve throttl e pressure pl ug
Li ne pressure pl ug and sl eeve
Ki ckdown val ve
Ki ckdown l i mi t val ve
1-2 shi ft val ve
1-2 control val ve
2-3 shi ft val ve
2-3 governor pl ug
3-4 shi ft val ve
3-4 ti mi ng val ve
3-4 qui ck fi l l val ve
3-4 accumul ator
Throttl e val ve
Throttl e pressure pl ug
Swi tch val ve
Manual val ve
Converter cl utch l ock-up val ve
Converter cl utch l ock-up ti mi ng Val ve
Shuttl e val ve
Shuttl e val ve throttl e pl ug
Boost Val ve
10 check bal l s
By adjusti ng the spri ng pressure acti ng on the reg-
ul ator val ve, transmi ssi on l i ne pressure can be
adjusted.
Fig. 255 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
Fig. 256 Shuttle and Boost Valve Locations
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
VALVE BODY (Continued)
Fig. 257 Upper Housing Shift Valve and Pressure Plug Locations
1 - UPPER HOUSING 8 - RETAINER
2 - 1-2 SHIFT VALVE AND SPRING 9 - 1-2 SHIFT CONTROL VALVE AND SPRING
3 - 2-3 SHIFT VALVE AND SPRING 10 - PRESSURE PLUG COVER
4 - 2-3 THROTTLE PLUG 11 - LINE PRESSURE PLUG
5 - LIMIT VALVE HOUSING 12 - PLUG SLEEVE
6 - LIMIT VALVE COVER 13 - THROTTLE PRESSURE SPRING AND PLUG
7 - LIMIT VALVE AND SPRING
Fig. 258 Lower Housing Shift Valves and Springs
1 - 3-4 ACCUMULATOR HOUSING 11 - TIMING VALVE COVER
2 - 3-4 SHIFT VALVE AND SPRING 12 - PLUG
3 - PLUG 13 - 3-4 TIMING VALVE AND SPRING
4 - SPRING RETAINER 14 - LOWER HOUSING
5 - CONVERTER CLUTCH VALVE AND SPRING 15 - ACCUMULATOR END PLATE
6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 16 - 3-4 ACCUMULATOR PISTON AND SPRING
7 - OVERDRIVE SEPARATOR PLATE 17 - E-CLIP
8 - CASE CONNECTOR 18 - 3-4 QUICK FILL SPRING AND VALVE
9 - CONVERTER CLUTCH SOLENOID 19 - SOLENOID GASKET
10 - OVERDRIVE SOLENOID 20 - HARNESS
OPERATION
NOTE: Refer to the Hydraulic Schematics for a
visual aid in determining valve location, operation
and design.
CHECK BALLS
CHECK BALL NUMBER DESCRIPTION
1 Allows either the manual valve to put line pressure on the 1-2 governor plug or
the KD Valve to put WOT line pressure on the 1-2 governor plug.
2 Allows either the manual valve to put line pressure on the 2-3 governor plug or
the KD Valve to put WOT line pressure on the 2-3 governor plug.
3 Allows either the Reverse circuit or the 3rd gear circuit to pressurize the front
clutch.
4 Allows either the Manual Low circuit from the Manual Valve or the Reverse
from the Manual Valve circuit to pressurize the rear servo.
5 Directs line pressure to the spring end of the 2-3 shift valve in either Manual
Low or Manual 2nd, forcing the downshift to 2nd gear regardless of governor
pressure.
6 Provides a by-pass around the front servo orifice so that the servo can release
quickly.
7 Provides a by-pass around the rear clutch orifice so that the clutch can release
quickly.
8 Directs reverse line pressure through an orifice to the throttle valve eliminating
the extra leakage and insuring that Reverse line pressure pressure will be
sufficient.
9 Provides a by-pass around the rear servo orifice so that the servo can release
quickly.
ECE (10) Allows the lockup clutch to used at WOT in 3rd gear by putting line pressure
from the 3-4 Timing Valve on the interlock area of the 2-3 shift valve, thereby
preventing a 3rd gear Lock-up to 2nd gear kickdown.
REGULATOR VALVE
The pressure regul ator val ve i s needed to control
the hydraul i c pressure wi thi n the system and reduce
the amount of heat produced i n the fl ui d. The pres-
sure regul ator val ve i s l ocated i n the val ve body near
the manual val ve. The pressure regul ator val ve trai n
control s the maxi mum pressure i n the l i nes by
meteri ng the dumpi ng of fl ui d back i nto the sump.
Regul ated pressure i s referred to as l i ne pressure.
The regul ator val ve (Fi g. 259) has a spri ng on one
end that pushes the val ve to the l eft. Thi s cl oses a
dump (vent) that i s used to l ower pressure. The cl os-
i ng of the dump wi l l cause the oi l pressure to
i ncrease. Oi l pressure on the opposi te end of the
val ve pushes the val ve to the ri ght, openi ng the
dump and l oweri ng oi l pressure. The resul t i s spri ng
pressure worki ng agai nst oi l pressure to mai ntai n
the oi l at speci fi c pressures. Wi th the engi ne run-
ni ng, fl ui d fl ows from the pump to the pressure reg-
ul ator val ve, manual val ve, and the i nterconnected
ci rcui ts. As fl ui d i s sent through passages to the reg-
ul ator val ve, the pressure pushes the val ve to the
ri ght agai nst the l arge spri ng. I t i s al so sent to the
reacti on areas on the l eft si de of the throttl e pressure
pl ug and the l i ne pressure pl ug. Wi th the gear sel ec-
tor i n the PARK posi ti on, fl ui d reci rcul ates through
the regul ator and manual val ves back to the sump.
Fig. 259 Regulator Valve in PARK Position
Meanwhi l e, the torque converter i s fi l l ed sl owl y. I n
al l other gear posi ti ons (Fi g. 260), fl ui d fl ows
between two ri ght si de l ands to the swi tch val ve and
torque converter. At l ow pump speeds, the fl ow i s
control l ed by the pressure val ve groove to reduce
pressure to the torque converter. After the torque
converter and swi tch val ve fi l l wi th fl ui d, the swi tch
val ve becomes the control l i ng meteri ng devi ce for
torque converter pressure. The regul ator val ve then
begi ns to control the l i ne pressure for the other
transmi ssi on ci rcui ts. The bal ance of the fl ui d pres-
sure pushi ng the val ve to the ri ght and the spri ng
pressure pushi ng to the l eft determi nes the si ze of
the meteri ng passage at l and #2 (l and #1 bei ng at
the far ri ght of the val ve i n the di agram). As fl ui d
l eaks past the l and, i t moves i nto a groove connected
to the fi l ter or sump. As the l and meters the fl ui d to
the sump, i t causes the pressure to reduce and the
spri ng decreases the si ze of the meteri ng passage.
When the si ze of the meteri ng passage i s reduced,
the pressure ri ses agai n and the si ze of the l and i s
i ncreased agai n. Pressure i s regul ated by thi s con-
stant bal ance of hydraul i c and spri ng pressure.
The meteri ng at l and #2 establ i shes the l i ne pres-
sure throughout the transmi ssi on. I t i s vari ed accord-
i ng to changes i n throttl e posi ti on and the
transmi ssi ons i nternal condi ti on wi thi n a range of
57-94 psi (except i n REVERSE) (Fi g. 261). The regu-
l ated l i ne pressure i n REVERSE (Fi g. 262) i s hel d at
much hi gher pressures than i n the other gear posi -
ti ons: 145-280 psi . The hi gher pressure for
REVERSE i s achi eved by the manual val ve bl ocki ng
the suppl y of l i ne pressure to the reacti on area l eft of
l and #4. Wi th thi s pressure bl ocked, there i s l ess
area for pressure to act on to bal ance the force of the
spri ng on the ri ght. Thi s al l ows l i ne pressure to push
the val ve trai n to the ri ght, reduci ng the amount of
fl ui d returned to the pumps i nl et, i ncreasi ng l i ne
pressure.
Fig. 260 Regulator Valve in NEUTRAL Position
Fig. 261 Regulator Valve in DRIVE Position
Fig. 262 Regulator Valve in REVERSE Position
KICKDOWN VALVE
When the throttl e val ve i s as far over to the l eft as
i t can go, the maxi mum l i ne pressure possi bl e wi l l
enter the throttl e pressure ci rcui t. I n thi s case, throt-
tl e pressure wi l l equal l i ne pressure. Wi th the ki ck-
down val ve (Fi g. 263) pushed i nto the bore as far as
i t wi l l go, fl ui d i ni ti al l y fl ows through the annul ar
groove of the 2-3 shi ft val ve (whi ch wi l l be i n the
di rect dri ve posi ti on to the ri ght).
After passi ng the annul ar groove, the fl ui d i s
routed to the spri ng end of the 2-3 shi ft val ve. Fl ui d
pressure reacti ng on the area of l and #1 overcomes
governor pressure, downshi fti ng the 2-3 shi ft val ve
i nto the ki ckdown, or second gear stage of operati on.
The val ve i s hel d i n the ki ckdown posi ti on by throttl e
pressure routed from a seated check bal l (#2). Agai n,
i f vehi cl e speed i s l ow enough, throttl e pressure wi l l
al so push the 1-2 shi ft val ve l eft to seat i ts governor
pl ug, and downshi ft to dri ve breakaway.
Fig. 263 Kickdown Valve-Wide Open Throttle
KICKDOWN LIMIT VALVE
The purpose of the l i mi t val ve i s to prevent a 3-2
downshi ft at hi gher speeds when a part-throttl e
downshi ft i s not desi rabl e. At these hi gher speeds
onl y a ful l throttl e 3-2 downshi ft wi l l occur. At l ow
road speeds (Fi g. 264) the l i mi t val ve does not come
i nto pl ay and does not affect the downshi fts. As the
vehi cl es speed i ncreases (Fi g. 265), the governor
pressure al so i ncreases. The i ncreased governor pres-
sure acts on the reacti on area of the bottom l and of
the l i mi t val ve overcomi ng the spri ng force tryi ng to
push the val ve toward the bottom of i ts bore. Thi s
pushes the val ve upward agai nst the spri ng and bot-
toms the val ve agai nst the top of the housi ng. Wi th
the val ve bottomed agai nst the housi ng, the throttl e
pressure suppl i ed to the val ve wi l l be cl osed off by
the bottom l and of the l i mi t val ve. When the suppl y
of throttl e pressure has been shut off, the 3-2 part
throttl e downshi ft pl ug becomes i noperati ve, because
no pressure i s acti ng on i ts reacti on area.
Fig. 264 Kickdown Limit Valve-Low Speeds
Fig. 265 Kickdown Limit Valve-High Speeds
1-2 SHIFT VALVE
The 1-2 shi ft val ve assembl y (Fi g. 266), or mecha-
ni sm, consi sts of: the 1-2 shi ft val ve, governor pl ug,
and a spri ng on the end of the val ve. After the man-
ual val ve has been pl aced i nto a forward gear range,
l i ne pressure i s di rected to the 1-2 shi ft val ve. As the
throttl e i s depressed, throttl e pressure i s appl i ed to
the ri ght si de of the 1-2 shi ft val ve assembl y. Wi th
throttl e pressure appl i ed to the ri ght si de of the
val ve, there i s now both spri ng pressure and throttl e
pressure acti ng on the val ve, hol di ng i t agai nst the
governor pl ug. As the vehi cl e begi ns to move and
bui l d speed, governor pressure i s created and i s
appl i ed to the l eft of the val ve at the governor pl ug.
When governor pressure bui l ds to a poi nt where i t
can overcome the combi ned force of the spri ng and
throttl e pressure on the other si de of the val ve, the
val ve wi l l begi n to move over to the ri ght. As the
val ve moves to the ri ght, the mi ddl e l and of the val ve
wi l l cl ose off the ci rcui t suppl yi ng the throttl e pres-
sure to the ri ght si de of the val ve. When the throttl e
pressure i s cl osed off, the val ve wi l l move even far-
ther to the ri ght, al l owi ng l i ne pressure to enter
another ci rcui t and energi ze the front servo, appl yi ng
the front band (Fi g. 267).
The governor pl ug serves a dual purpose:
I t al l ows the shi ft val ves to move ei ther l eft or
ri ght, al l owi ng both upshi fts and downshi fts.
When i n a manual sel ecti on posi ti on, i t wi l l be
hydraul i cal l y bl ocked i nto posi ti on so no upshi ft can
occur.
The physi cal bl ocki ng of the upshi ft whi l e i n the
manual 1 posi ti on i s accompl i shed by the di recti ng
of l i ne pressure between both l ands of the governor
pl ug. The l i ne pressure reacts agai nst the l arger l and
of the pl ug, pushi ng the pl ug back agai nst the end
pl ate overcomi ng governor pressure. Wi th the combi -
nati on of the l i ne pressure and spri ng pressure, the
val ve cannot move, preventi ng any upshi ft.
Fig. 266 1-2 Shift Valve-Before Shift
Fig. 267 1-2 Shift Valve-After Shift
1-2 SHIFT CONTROL VALVE
I t contai ns a val ve wi th four l ands and a spri ng. I t
i s used as both a rel ay and bal anced val ve.
The val ve has two speci fi c operati ons (Fi g. 268):
Ai d i n qual i ty of the 1-2 upshi ft.
Ai d i n the qual i ty and ti mi ng of the 3-2 ki ck-
down ranges.
When the manual val ve i s set to the DRI VE posi -
ti on and the transmi ssi on i s i n the fi rst or second
gear range, 1-2 shi ft control or modul ated throttl e
pressure i s suppl i ed to the mi ddl e of the accumul a-
tor pi ston by the 1-2 shi ft control val ve. Duri ng the
1-2 upshi ft, thi s pressure i s used to control the ki ck-
down servo appl y pressure that i s needed to appl y
the ki ckdown and accumul ator pi stons. Thus, the 1-2
shi ft poi nt i s cushi oned and the qual i ty i s
i mproved. Duri ng a WOT ki ckdown, ki ckdown pres-
sure i s appl i ed between the ki ckdown val ve and the
1-2 shi ft control val ve. Thi s addi ti onal pressure i s
di rected to the 1-2 shi ft control s spri ng cavi ty, add-
i ng to the spri ng l oad on the val ve. The resul t of thi s
i ncreased modul ated throttl e pressure i s a fi rmer
WOT upshi ft.
Fig. 268 1-2 Shift Control Valve
2-3 SHIFT VALVE
The 2-3 shi ft val ve mechani sm (Fi g. 269) consi sts
of the 2-3 shi ft val ve, governor pl ug and spri ng, and
a throttl e pl ug. After the 1-2 shi ft val ve has com-
pl eted i ts operati on and appl i ed the front band, l i ne
pressure i s di rected to the 2-3 shi ft val ve through the
connecti ng passages from the 1-2 shi ft val ve. The l i ne
pressure wi l l then deadend at l and #2 unti l the 2-3
val ve i s ready to make i ts shi ft. Now that the vehi cl e
i s i n moti on and under accel erati on, there i s throttl e
pressure bei ng appl i ed to the spri ng si de of the val ve
and between l ands #3 and #4.
Fig. 269 2-3 Shift Valve-Before Shift
As vehi cl e speed i ncreases, governor pressure
i ncreases proporti onatel y, unti l i t becomes great
enough to overcome the combi ned throttl e and spri ng
pressure on the ri ght si de of the val ve. Si nce the
throttl e pressure end of the 2-3 shi ft val ve i s l arger
i n di ameter than the 1-2 shi ft val ve, the 2-3 shi ft wi l l
al ways happen at a greater speed than the 1-2 shi ft.
When thi s happens, the governor pl ug i s forced
agai nst the shi ft val ve movi ng i t to the ri ght. The
shi ft val ve causes l and #4 to cl ose the passage sup-
pl yi ng throttl e pressure to the 2-3 shi ft val ve. Wi th-
out throttl e pressure present i n the ci rcui t now, the
governor pl ug wi l l push the val ve over far enough to
bottom the val ve i n i ts bore. Thi s al l ows l and #2 to
di rect l i ne pressure to the front cl utch.
After the shi ft (Fi g. 270), l i ne pressure i s di rected
to the l and between the shi ft val ve and the governor
pl ug, and to the rel ease si de of the ki ckdown servo.
Thi s rel eases the front band and appl i es the front
cl utch, shi fti ng i nto thi rd gear or di rect dri ve. The
rear cl utch remai ns appl i ed, as i t has been i n the
other gears. Duri ng a manual 1 or manual 2 gear
sel ecti on, l i ne pressure i s sent between the two l ands
of the 2-3 governor pl ug. Thi s l i ne pressure at the
governor pl ug l ocks the shi ft val ve i nto the second
gear posi ti on, preventi ng an upshi ft i nto di rect dri ve.
The theory for the bl ocki ng of the val ve i s the same
as that of the 1-2 shi ft val ve.
Fig. 270 2-3 Shift Valve-After Shift
3-4 SHIFT VALVE
The PCM energi zes the overdri ve sol enoi d duri ng
the 3-4 upshi ft (Fi g. 271). Thi s causes the sol enoi d
check bal l to cl ose the vent port al l owi ng l i ne pres-
sure from the 2-3 shi ft val ve to act di rectl y on the 3-4
upshi ft val ve. Li ne pressure on the 3-4 shi ft val ve
overcomes val ve spri ng pressure movi ng the val ve to
the upshi ft posi ti on (Fi g. 272). Thi s acti on exposes
the feed passages to the 3-4 ti mi ng val ve, 3-4 qui ck
fi l l val ve, 3-4 accumul ator, and ul ti matel y to the
overdri ve pi ston.
3-4 TIMING VALVE
The 3-4 ti mi ng val ve i s moved by l i ne pressure
comi ng through the 3-4 shi ft val ve (Fi g. 272). After
the shi ft, the ti mi ng val ve hol ds the 2-3 shi ft val ve i n
an upshi ft posi ti on. The purpose i s to prevent the 2-3
val ve from downshi fti ng before the 3-4 val ve (Fi g.
271).
3-4 QUICK FILL VALVE
The 3-4 qui ck fi l l val ve provi des faster engagement
of the overdri ve cl utch duri ng 3-4 upshi fts. The val ve
temporari l y bypasses the cl utch pi ston feed ori fi ce at
the start of a 3-4 upshi ft (Fi g. 271). Thi s exposes a
l arger passage i nto the pi ston retai ner resul ti ng i n a
much faster cl utch fi l l and appl y sequence. The qui ck
fi l l val ve does not bypass the regul ar cl utch feed ori -
fi ce throughout the 3-4 upshi ft. I nstead, once a pre-
determi ned pressure devel ops wi thi n the cl utch, the
val ve cl oses the bypass (Fi g. 272). Cl utch fi l l i s then
compl eted through the regul ar feed ori fi ce.
Fig. 271 3-4 Shift Valve Before Shift
Fig. 272 3-4 Shift Valve After Shift
THROTTLE VALVE
I n al l gear posi ti ons the throttl e val ve (Fi g. 273) i s
bei ng suppl i ed wi th l i ne pressure. The throttl e val ve
meters and reduces the l i ne pressure that now
becomes throttl e pressure. The throttl e val ve i s
moved by a spri ng and the ki ckdown val ve, whi ch i s
mechani cal l y connected to the throttl e. The l arger
the throttl e openi ng, the hi gher the throttl e pressure
(to a maxi mum of l i ne pressure). The smal l er the
throttl e openi ng, the l ower the throttl e pressure (to a
mi ni mum of zero at i dl e). As engi ne speed i ncreases,
the i ncrease i n pump speed i ncreases pump output.
The i ncrease i n pressure and vol ume must be regu-
l ated to mai ntai n the bal ance wi thi n the transmi s-
si on. To do thi s, throttl e pressure i s routed to the
reacti on area on the ri ght si de of the throttl e pres-
sure pl ug (i n the regul ator val ve).
The hi gher engi ne speed and l i ne pressure woul d
open the vent too far and reduce l i ne pressure too
much. Throttl e pressure, whi ch i ncreases wi th engi ne
speed (throttl e openi ng), i s used to oppose the move-
ment of the pressure val ve to hel p control the meter-
i ng passage at the vent. The throttl e pressure i s
combi ned wi th spri ng pressure to reduce the force of
the throttl e pressure pl ug on the pressure val ve. The
l arger spri ng at the ri ght cl oses the regul ator val ve
passage and mai ntai ns or i ncreases l i ne pressure.
The i ncreased l i ne pressure works agai nst the reac-
ti on area of the l i ne pressure pl ug and the reacti on
area l eft of l and #3 si mul taneousl y moves the regu-
l ator val ve trai n to the ri ght and control s the meter-
i ng passage.
The ki ckdown val ve, al ong wi th the throttl e val ve,
serve to del ay upshi fts unti l the correct vehi cl e speed
has been reached. I t al so control s downshi fts upon
dri ver demand, or i ncreased engi ne l oad. I f these
val ves were not i n pl ace, the shi ft poi nts woul d be at
the same speed for al l throttl e posi ti ons. The ki ck-
down val ve i s actuated by a cam connected to the
throttl e. Thi s i s accompl i shed through ei ther a l i nk-
age or a cabl e. The cam forces the ki ckdown val ve
toward the throttl e val ve compressi ng the spri ng
between them and movi ng the throttl e val ve. As the
throttl e val ve l and starts to uncover i ts port, l i ne
pressure i s metered out i nto the ci rcui ts and vi ewed
as throttl e pressure. Thi s i ncreased throttl e pressure
i s metered out i nto the ci rcui ts i t i s appl i ed to: the
1-2 and 2-3 shi ft val ves. When the throttl e pressure
i s hi gh enough, a 3-2 downshi ft wi l l occur. I f the
vehi cl e speed i s l ow enough, a 2-1 downshi ft wi l l
occur.
Fig. 273 Throttle Valve
SWITCH VALVE
When the transmi ssi on i s i n Dri ve Second before
the TCC appl i cati on occurs (Fi g. 274), the pressure
regul ator val ve i s suppl yi ng torque converter pres-
sure to the swi tch val ve. The swi tch val ve di rects
thi s pressure through the transmi ssi on i nput shaft,
i nto the converter, through the converter, back out
between the i nput shaft and the reacti on shaft, and
back up to the swi tch val ve. From the swi tch val ve,
the fl ui d pressure i s di rected to the transmi ssi on
cool er, and l ubri cati on pressure returns from the
cool er to l ubri cate di fferent porti ons of the transmi s-
si on.
Fig. 274 Switch Valve-Torque Converter Unlocked
Once the TCC control val ve has moved to the ri ght
(Fi g. 275), l i ne pressure i s di rected to the ti p of the
swi tch val ve, forci ng the val ve to the ri ght. The
swi tch val ve now vents oi l from the front of the pi s-
ton i n the torque converter, and suppl i es l i ne pres-
sure to the (rear) appl y si de of the torque converter
pi ston. Thi s pressure di fferenti al causes the pi ston to
appl y agai nst the fri cti on materi al , cutti ng off any
further fl ow of l i ne pressure oi l . After the swi tch
val ve i s shuttl ed ri ght al l owi ng l i ne pressure to
engage the TCC, torque converter pressure i s
di rected past the swi tch val ve i nto the transmi ssi on
cool er and l ubri cati on ci rcui ts.
Fig. 275 Switch Valve-Torque Converter Locked
MANUAL VALVE
The manual val ve (Fi g. 276) i s a rel ay val ve. The
purpose of the manual val ve i s to di rect fl ui d to the
correct ci rcui t needed for a speci fi c gear or dri vi ng
range. The manual val ve, as the name i mpl i es, i s
manual l y operated by the dri ver wi th a l ever l ocated
on the si de of the val ve body. The val ve i s connected
mechani cal l y by ei ther a cabl e or l i nkage to the gear-
shi ft mechani sm. The val ve i s hel d i n each of i ts
posi ti ons by a spri ng-l oaded rol l er or bal l that
engages the roostercomb of the manual val ve l ever.
CONVERTER CLUTCH LOCK-UP VALVE
The torque converter cl utch (TCC) l ock-up val ve
control s the back (ON) si de of the torque converter
cl utch. When the PCM energi zes the TCC sol enoi d to
engage the converter cl utch pi ston, pressure i s
appl i ed to the TCC l ock-up val ve whi ch moves to the
ri ght and appl i es pressure to the torque converter
cl utch.
CONVERTER CLUTCH LOCK-UP TIMING VALVE
The torque converter cl utch (TCC) l ock-up ti mi ng
val ve i s there to bl ock any 4-3 downshi ft unti l the
TCC i s compl etel y unl ocked and the cl utch i s di sen-
gaged.
SHUTTLE VALVE
The assembl y i s contai ned i n a bore i n the val ve
body above the shi ft val ves. When the manual val ve
i s posi ti oned i n the Dri ve range, throttl e pressure
acts on the throttl e pl ug of the shuttl e val ve (Fi g.
268) to move i t agai nst a spri ng, i ncreasi ng the
spri ng force on the shuttl e val ve. Duri ng a part or
ful l throttl e 1-2 upshi ft, the throttl e pl ug i s bottomed
by throttl e pressure, hol di ng the shuttl e val ve to the
ri ght agai nst governor pressure, and openi ng a
bypass ci rcui t. The shuttl e val ve control s the qual -
i ty of the ki ckdown shi ft by restri cti ng the rate of
fl ui d di scharge from the front cl utch and servo
rel ease ci rcui ts. Duri ng a 3-2 ki ckdown, fl ui d di s-
charges through the shuttl e by-pass ci rcui t. When
the shuttl e val ve cl oses the by-pass ci rcui t, fl ui d di s-
charge i s restri cted and control l ed for the appl i cati on
of the front band. Duri ng a 2-3 l i ft foot upshi ft, the
shuttl e val ve by-passes the restri cti on to al l ow ful l
fl ui d fl ow through the by-pass groove for a faster
rel ease of the band.
Fig. 276 Manual Valve
BOOST VALVE
The boost val ve (Fi g. 277) provi des i ncreased fl ui d
appl y pressure to the overdri ve cl utch duri ng 3-4
upshi fts (Fi g. 278), and when accel erati ng i n fourth
gear. The boost val ve al so serves to i ncrease l i ne
pressure duri ng torque converter l ock-up.
REMOVAL
The val ve body can be removed for servi ce wi thout
havi ng to remove the transmi ssi on assembl y.
The val ve body can be di sassembl ed for cl eani ng
and i nspecti on of the i ndi vi dual components.
The onl y repl aceabl e val ve body components are:
Manual l ever.
Manual l ever washer, seal , E-cl i p, and shaft
seal .
Manual l ever detent bal l .
Throttl e l ever.
Fl ui d fi l ter.
Pressure adjusti ng screw bracket.
Governor pressure sol enoi d.
Governor pressure sensor (i ncl udes transmi ssi on
temperature thermi stor).
Converter cl utch/overdri ve sol enoi d assembl y
and harness.
Governor housi ng gasket.
Sol enoi d case connector O-ri ngs.
(1) Shi ft transmi ssi on i nto NEUTRAL.
(3) Remove gearshi ft and throttl e l evers from shaft
of val ve body manual l ever.
(4) Di sconnect wi res at sol enoi d case connector
(Fi g. 279).
(5) Posi ti on drai n pan under transmi ssi on oi l pan.
(6) Remove transmi ssi on oi l pan and gasket.
(7) Remove fl ui d fi l ter from val ve body.
(8) Remove bol ts attachi ng val ve body to transmi s-
si on case.
(9) Lower val ve body enough to remove accumul a-
tor pi ston and spri ngs.
(10) Work manual l ever shaft and el ectri cal con-
nector out of transmi ssi on case.
(11) Lower val ve body, rotate val ve body away
from case, pul l park rod out of sprag, and remove
val ve body (Fi g. 280).
Fig. 277 Boost Valve Before Lock-up
Fig. 278 Boost Valve After Lock-up
Fig. 279 Transmission Case Connector
1 - SOLENOID CASE CONNECTOR
2 - PARK/NEUTRAL POSITION SWITCH
DISASSEMBLY
CAUTION: Do not clamp any valve body component
in a vise. This practice can damage the component
resulting in unsatisfactory operation after assembly
and installation. Do not use pliers to remove any of
the valves, plugs or springs and do not force any of
the components out or into place. The valves and
valve body housings will be damaged if force is
used. Tag or mark the valve body springs for refer-
ence as they are removed. Do not allow them to
become intermixed.
(1) Di sconnect wi res from governor pressure sen-
sor and sol enoi d.
(2) Remove screws attachi ng governor body and
retai ner pl ate to transfer pl ate.
(3) Remove retai ner pl ate, governor body and gas-
ket from transfer pl ate.
(4) Remove governor pressure sensor from gover-
nor body.
(5) Remove governor pressure sol enoi d by pul l i ng
i t strai ght out of bore i n governor body. Remove and
di scard sol enoi d O-ri ngs i f worn, cut, or torn.
(6) Remove smal l shoul der bol t that secures sol e-
noi d harness case connector to 3-4 accumul ator hous-
i ng (Fi g. 281). Retai n shoul der bol t. Ei ther tape i t to
harness or thread i t back i nto accumul ator housi ng
after connector removal .
(7) Unhook overdri ve/converter sol enoi d harness
from 3-4 accumul ator cover pl ate (Fi g. 282).
(8) Turn val ve body over and remove screws that
attach overdri ve/converter sol enoi d assembl y to val ve
body (Fi g. 283).
(9) Remove sol enoi d and harness assembl y from
val ve body (Fi g. 284).
(10) Remove boost val ve cover (Fi g. 285).
(11) Remove boost val ve retai ner, val ve spri ng and
boost val ve (Fi g. 286).
Fig. 280 Valve Body
1 - VALVE BODY
2 - WIRE HARNESS
3 - PARK ROD
Fig. 281 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
Fig. 282 Unhooking Solenoid Harness From
Accumulator Cover Plate
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
(12) Secure detent bal l and spri ng wi th Retai ner
Tool 6583 (Fi g. 287).
(13) Remove park rod E-cl i p and separate rod from
manual l ever (Fi g. 288).
(14) Remove E-cl i p and washer that retai ns throt-
tl e l ever shaft i n manual l ever (Fi g. 289).
(15) Remove manual l ever and throttl e l ever (Fi g.
290). Rotate and l i ft manual l ever off val ve body and
throttl e l ever shaft. Then sl i de throttl e l ever out of
val ve body.
Fig. 283 Solenoid Assembly Screws
1 - OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 - HARNESS
Fig. 284 Solenoid Assembly
1 - GOVERNOR SOLENOID WIRES
2 - CONVERTER CLUTCH SOLENOID
3 - SOLENOID SCREWS
4 - GOVERNOR SENSOR WIRES
5 - OVERDRIVE SOLENOID
6 - HARNESS
7 - CASE CONNECTOR
Fig. 285 Boost Valve
1 - BOOST VALVE HOUSING AND COVER
2 - BOOST VALVE TUBE
Fig. 286 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
(16) Posi ti on penci l magnet next to detent housi ng
to catch detent bal l and spri ng. Then careful l y
remove Retai ner Tool 6583 and remove detent bal l
and spri ng (Fi g. 291).
(17) Remove screws attachi ng pressure adjusti ng
screw bracket to val ve body and transfer pl ate (Fi g.
292). Hol d bracket fi rml y agai nst spri ng tensi on
whi l e removi ng l ast screw.
Fig. 287 Detent Ball And Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 288 Park Rod
1 - MANUAL LEVER
2 - E-CLIP
3 - PARK ROD
Fig. 289 Throttle Lever E-Clip And Washer
1 - THROTTLE LEVER SHAFT
2 - E-CLIP AND WASHER
3 - MANUAL SHAFT
Fig. 290 Manual And Throttle Lever
1 - PARK ROD
2 - MANUAL LEVER ASSEMBLY
3 - THROTTLE LEVER
(18) Remove adjusti ng screw bracket, l i ne pressure
adjusti ng screw, pressure regul ator val ve spri ng and
swi tch val ve spri ng (Fi g. 293). Do not remove throttl e
pressure adjusti ng screw from bracket and do not
di sturb setti ng of ei ther adjusti ng screw duri ng
removal .
(19) Turn upper housi ng over and remove swi tch
val ve, regul ator val ve and spri ng, and manual val ve
(Fi g. 294).
(20) Remove ki ckdown detent, ki ckdown val ve, and
throttl e val ve and spri ng (Fi g. 294).
(21) Loosen l eft-si de 3-4 accumul ator housi ng
attachi ng screw about 2-3 threads. Then remove cen-
ter and ri ght-si de housi ng attachi ng screws (Fi g.
295).
(22) Careful l y rotate 3-4 accumul ator housi ng
upward and remove 3-4 shi ft val ve spri ng and con-
verter cl utch val ve pl ug and spri ng (Fi g. 296).
(23) Remove l eft-si de screw and remove 3-4 accu-
mul ator housi ng from val ve body (Fi g. 297).
(24) Bend back tabs on boost val ve tube brace (Fi g.
298).
Fig. 291 Detent Ball And Spring
1 - DETENT HOUSING
2 - DETENT SPRING
3 - DETENT BALL
4 - PENCIL MAGNET
Fig. 292 Adjusting Screw Bracket Fastener
1 - T25 TORX BIT
2 - REMOVE THESE SCREWS FIRST
3 - BRACKET
4 - BRACKET
5 - REMOVE THIS SCREW LAST
Fig. 293 Adjusting Screw Bracket And Spring
1 - SWITCH VALVE SPRING
2 - LINE PRESSURE SCREW
3 - THROTTLE PRESSURE ADJUSTING SCREW
4 - ADJUSTING SCREW BRACKET
5 - PRESSURE REGULATOR VALVE SPRING
Fig. 295 Accumulator Housing Screw Locations
1 - LOOSEN THIS SCREW
2 - REMOVE THESE SCREWS
Fig. 296 3-4 Shift And Converter Clutch Valve
Springs And Plug
1 - ACCUMULATOR HOUSING
2 - CONVERTER CLUTCH VALVE SPRING
3 - CLUTCH VALVE PLUG
4 - 3-4 SHIFT VALVE SPRING
(25) Remove boost val ve connecti ng tube (Fi g.
299). Di sengage tube from upper housi ng port fi rst.
Then rock opposi te end of tube back and forth to
work i t out of l ower housi ng.
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
(26) Turn val ve body over so l ower housi ng i s fac-
i ng upward (Fi g. 300). I n thi s posi ti on, the two check
bal l s i n upper housi ng wi l l remai n i n pl ace and not
fal l out when l ower housi ng and separator pl ate are
removed.
(27) Remove screws attachi ng val ve body l ower
housi ng to upper housi ng and transfer pl ate (Fi g.
300). Note posi ti on of boost val ve tube brace for
assembl y reference.
(28) Remove l ower housi ng and overdri ve separa-
tor pl ate from transfer pl ate (Fi g. 300).
(29) Remove the ECE check bal l from the transfer
pl ate (Fi g. 301). The ECE check bal l i s approxi matel y
4.8 mm (3/16 i n.) i n di ameter.
(30) Remove transfer pl ate from upper housi ng
(Fi g. 302).
(31) Turn transfer pl ate over so upper housi ng sep-
arator pl ate i s faci ng upward.
(32) Remove upper housi ng separator pl ate from
transfer pl ate (Fi g. 303). Note posi ti on of fi l ter i n
separator pl ate for assembl y reference.
(33) Remove rear cl utch and rear servo check bal l s
from transfer pl ate. Note check bal l l ocati on for
assembl y reference (Fi g. 304).
Fig. 297 Accumulator Housing, Valve Springs And
Plug
2 - CONVERTER CLUTCH VALVE SPRING AND PLUG
Fig. 298 Boost Valve Tube Brace
2 - TUBE BRACE (DOUBLE TAB)
Fig. 299 Boost Valve Tube
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 300 Lower Housing
1 - LOWER HOUSING
2 - OVERDRIVE SEPARATOR PLATE
3 - TRANSFER PLATE AND UPPER HOUSING
Fig. 301 ECE Check Ball
1 - ECE CHECK BALL (3/16)
Fig. 302 Transfer Plate
1 - UPPER HOUSING
2 - TRANSFER PLATE
Fig. 303 Upper Housing Separator Plate
1 - TRANSFER PLATE
2 - UPPER HOUSING SEPARATOR PLATE
3 - FILTER SCREEN
4 - BRACE
Fig. 304 Rear Clutch And Rear Servo Check Ball
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
VALVE BODY UPPER HOUSING
(1) Note l ocati on of check bal l s i n val ve body upper
housi ng (Fi g. 305). Then remove the one l arge di am-
eter and the si x smal l er di ameter check bal l s.
(2) Remove governor pl ug and shuttl e val ve covers
(Fi g. 307).
(3) Remove E-cl i p that secures shuttl e val ve sec-
ondary spri ng on val ve stem (Fi g. 306).
(4) Remove throttl e pl ug, pri mary spri ng, shuttl e
val ve, secondary spri ng, and spri ng gui des (Fi g. 307).
(5) Remove boost val ve retai ner, spri ng and val ve
i f not previ ousl y removed.
(6) Remove throttl e pl ug and 1-2 and 2-3 governor
pl ugs (Fi g. 294).
(7) Turn upper housi ng around and remove l i mi t
val ve and shi ft val ve covers (Fi g. 308).
(8) Remove l i mi t val ve housi ng. Then remove
retai ner, spri ng, l i mi t val ve, and 2-3 throttl e pl ug
from l i mi t val ve housi ng (Fi g. 308).
(9) Remove 1-2 shi ft control val ve and spri ng (Fi g.
308).
(10) Remove 1-2 shi ft val ve and spri ng (Fi g. 308).
(11) Remove 2-3 shi ft val ve and spri ng from val ve
body (Fi g. 308).
(12) Remove pressure pl ug cover (Fi g. 308).
(13) Remove l i ne pressure pl ug, sl eeve, throttl e
pressure pl ug and spri ng (Fi g. 308).
Fig. 305 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (6)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 306 Shuttle Valve E-Clip And Secondary Spring
Location
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
Fig. 307 Shuttle And Boost Valve Components
Fig. 308 Upper Housing Shift Valve And Pressure Plug Locations
VALVE BODY LOWER HOUSING
(1) Remove ti mi ng val ve cover.
(2) Remove 3-4 ti mi ng val ve and spri ng.
(3) Remove 3-4 qui ck fi l l val ve, spri ng and pl ug.
(4) Remove 3-4 shi ft val ve and spri ng.
(5) Remove converter cl utch val ve, spri ng and pl ug
(Fi g. 309).
(6) Remove converter cl utch ti mi ng val ve, retai ner
and val ve spri ng.
3-4 ACCUMULATOR HOUSING
(1) Remove end pl ate from housi ng.
(2) Remove pi ston spri ng.
(3) Remove pi ston. Remove and di scard pi ston
seal s (Fi g. 310).
CLEANING
Cl ean the val ve housi ngs, val ves, pl ugs, spri ngs,
and separator pl ates wi th a standard parts cl eani ng
sol uti on onl y. Do not use gasol i ne, kerosene, or any
type of causti c sol uti on.
Do not i mmerse any of the el ectri cal components i n
cl eani ng sol uti on. Cl ean the governor sol enoi d and
sensor and the dual sol enoi d and harness assembl y
by wi pi ng them off wi th dry shop towel s onl y.
Dry al l except the el ectri cal parts wi th compressed
ai r. Make sure al l passages are cl ean and free from
obstructi ons. Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Fig. 309 Lower Housing Shift Valves and Springs
1 - 3-4 ACCUMULATOR HOUSING 11 - TIMING VALVE COVER
2 - 3-4 SHIFT VALVE AND SPRING 12 - PLUG
3 - PLUG 13 - 3-4 TIMING VALVE AND SPRING
4 - SPRING RETAINER 14 - LOWER HOUSING
5 - CONVERTER CLUTCH VALVE AND SPRING 15 - ACCUMULATOR END PLATE
6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 16 - 3-4 ACCUMULATOR PISTON AND SPRING
7 - OVERDRIVE SEPARATOR PLATE 17 - E-CLIP
8 - CASE CONNECTOR 18 - 3-4 QUICK FILL SPRING AND VALVE
9 - CONVERTER CLUTCH SOLENOID 19 - SOLENOID GASKET
10 - OVERDRIVE SOLENOID 20 - HARNESS
Wi pe the governor pressure sensor and sol enoi d
val ve wi th dry, l i nt free shop towel s onl y. The O-ri ngs
on the sensor and sol enoi d val ve are the onl y servi ce-
abl e components. Be sure the vent ports i n the sol e-
noi d val ve are open and not bl ocked by di rt or debri s.
Repl ace the val ve and/or sensor onl y when DRB scan
tool di agnosi s i ndi cates thi s i s necessary. Or, i f ei ther
part has sustai ned physi cal damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of
the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
INSPECTION
I nspect the throttl e and manual val ve l evers and
shafts. Do not attempt to strai ghten a bent shaft or
correct a l oose l ever. Repl ace these components i f
worn, bent, l oose or damaged i n any way.
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th a
sheet of crocus cl oth. Posi ti on the crocus cl oth on a
surface pl ate, sheet of pl ate gl ass or equal l y fl at sur-
face. I f di storti on i s severe or any surfaces are
heavi l y scored, the val ve body wi l l have to be
repl aced.
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the
dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Mi nor surface scratches on steel
val ves and pl ugs can be removed wi th crocus cl oth
but do not round off the edges of the valve or
plug lands.Mai ntai ni ng sharpness of these edges i s
vi tal l y i mportant. The edges prevent forei gn matter
from l odgi ng between the val ves and pl ugs and the
bore.
I nspect al l the val ve and pl ug bores i n the val ve
body. Use a penl i ght to vi ew the bore i nteri ors.
Repl ace the val ve body i f any bores are di storted or
scored. I nspect al l of the val ve body spri ngs. The
spri ngs must be free of di storti on, warpage or broken
coi l s.
Check the two separator pl ates for di storti on or
damage of any ki nd. I nspect the upper housi ng,
l ower housi ng, 3-4 accumul ator housi ng, and transfer
pl ate careful l y. Be sure al l fl ui d passages are cl ean
and cl ear. Check condi ti on of the upper housi ng and
transfer pl ate check bal l s as wel l . The check bal l s
and bal l seats must not be worn or damaged.
Tri al fi t each val ve and pl ug i n i ts bore to check
freedom of operati on. When cl ean and dry, the val ves
and pl ugs shoul d drop freel y i nto the bores.
Val ve body bores do not change di mensi onal l y wi th
use. I f the val ve body functi oned correctl y when new,
i t wi l l conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
The onl y servi ceabl e val ve body components are
l i sted bel ow. The remai ni ng val ve body components
are servi ced onl y as part of a compl ete val ve body
assembl y. Servi ceabl e parts are:
dual sol enoi d and harness assembl y
sol enoi d gasket
sol enoi d case connector O-ri ngs and shoul der
bol t
swi tch val ve and spri ng
Fig. 310 Accumulator Housing Components
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
pressure adjusti ng screw and bracket assembl y
throttl e l ever
manual l ever and shaft seal
throttl e l ever shaft seal , washer, and E-cl i p
fl ui d fi l ter and screws
detent bal l and spri ng
val ve body screws
governor pressure sol enoi d
governor pressure sensor and retai ni ng cl i p
park l ock rod and E-cl i p
ASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
LOWER HOUSING
(1) Lubri cate val ves, spri ngs, and the housi ng
val ve and pl ug bores wi th cl ean transmi ssi on fl ui d
(Fi g. 309).
(2) I nstal l 3-4 ti mi ng val ve spri ng and val ve i n
l ower housi ng.
(3) I nstal l 3-4 qui ck fi l l val ve i n l ower housi ng.
(4) I nstal l 3-4 qui ck fi l l val ve spri ng and pl ug i n
housi ng.
(5) I nstal l ti mi ng val ve end pl ate. Ti ghten end
pl ate screws to 4 Nm (35 i n. l bs.) torque.
3-4 ACCUMULATOR
(1) Lubri cate accumul ator pi ston, seal s and hous-
i ng pi ston bore wi th cl ean transmi ssi on fl ui d (Fi g.
310).
(2) I nstal l new seal ri ngs on accumul ator pi ston.
(3) I nstal l pi ston and spri ng i n housi ng.
(4) I nstal l end pl ate on housi ng.
TRANSFER PLATE
(1) I nstal l rear cl utch and rear servo check bal l s i n
transfer pl ate (Fi g. 311).
(2) I nstal l fi l ter screen i n upper housi ng separator
pl ate (Fi g. 312).
(3) Al i gn and posi ti on upper housi ng separator
pl ate on transfer pl ate (Fi g. 313).
(4) I nstal l brace pl ate (Fi g. 313). Ti ghten brace
attachi ng screws to 4 Nm (35 i n. l bs.) torque.
(5) I nstal l remai ni ng separator pl ate attachi ng
screws. Ti ghten screws to 4 Nm (35 i n. l bs.) torque.
UPPER AND LOWER HOUSING
(1) Posi ti on upper housi ng so i nternal passages
and check bal l seats are faci ng upward. Then i nstal l
check bal l s i n housi ng (Fi g. 314). Ei ght check bal l s
are used. The si ngl e l arge check bal l i s approxi -
matel y 8.7 mm (11/32 i n.) di ameter. The si ngl e smal l
check bal l i s approxi matel y 4.8 mm (3/16 i n.) i n
di ameter. The remai ni ng 6 check bal l s are approxi -
matel y 6.3 mm (1/4 i n.) i n di ameter.
(2) Posi ti on assembl ed transfer pl ate and upper
housi ng separator pl ate on upper housi ng (Fi g. 315).
Be sure fi l ter screen i s seated i n proper housi ng
recess.
Fig. 311 Rear Clutch And Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
Fig. 312 Separator Plate Filter Screen Installation
1 - UPPER HOUSING SEPARATOR PLATE
2 - FILTER SCREEN
(3) I nstal l the ECE check bal l i nto the transfer
pl ate (Fi g. 301). The ECE check bal l i s approxi matel y
4.8 mm (3/16 i n.) i n di ameter.
(4) Posi ti on l ower housi ng separator pl ate on
transfer pl ate (Fi g. 316).
(5) I nstal l l ower housi ng on assembl ed transfer
pl ate and upper housi ng (Fi g. 317).
(6) I nstal l and start al l val ve body screws by hand
except for the screws to hol d the boost val ve tube
brace. Save those screws for l ater i nstal l ati on. Then
ti ghten screws evenl y to 4 Nm (35 i n. l bs.) torque.
Start at center and work out to si des when ti ghten-
i ng screws (Fi g. 317).
Fig. 313 Brace Plate
1 - BRACE
2 - TRANSFER PLATE
3 - SEPARATOR PLATE
Fig. 314 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (6)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 315 Installing Transfer Plate On Upper Housing
1 - FILTER SCREEN
2 - TRANSFER PLATE/SEPARATOR PLATE ASSEMBLY
3 - UPPER HOUSING
Fig. 316 Lower Housing Separator Plate
1 - BE SURE TO ALIGN BORES
2 - TRANSFER PLATE
3 - LOWER HOUSING (OVERDRIVE) SEPARATOR PLATE
UPPER HOUSING VALVE AND PLUG
Refer to (Fi g. 318), (Fi g. 319) and (Fi g. 320) to per-
form the fol l owi ng steps.
(1) Lubri cate val ves, pl ugs, spri ngs wi th cl ean
(2) Assembl e regul ator val ve l i ne pressure pl ug,
sl eeve, throttl e pl ug and spri ng. I nsert assembl y i n
upper housi ng and i nstal l cover pl ate. Ti ghten cover
(3) I nstal l 1-2 and 2-3 shi ft val ves and spri ngs.
(4) I nstal l 1-2 shi ft control val ve and spri ng.
(5) I nstal l retai ner, spri ng, l i mi t val ve, and 2-3
throttl e pl ug from l i mi t val ve housi ng.
Fig. 318 Shuttle And Boost Valve Components
Fig. 317 Installing Lower Housing On Transfer Plate
And Upper Housing
1 - VALVE BODY SCREWS (13)
2 - LOWER HOUSING
3 - UPPER HOUSING
4 - TRANSFER PLATE
(6) I nstal l l i mi t val ve housi ng and cover pl ate.
Ti ghten screws to 4 Nm (35 i n. l bs.).
(7) I nstal l shuttl e val ve as fol l ows:
(a) I nsert pl asti c gui des i n shuttl e val ve second-
ary spri ng and i nstal l spri ng on end of val ve.
(b) I nstal l shuttl e val ve i nto housi ng.
(c) Hol d shuttl e val ve i n pl ace.
(d) Compress secondary spri ng and i nstal l E-cl i p
i n groove at end of shuttl e val ve.
(e) Veri fy that spri ng and E-cl i p are properl y
seated before proceedi ng.
(8) I nstal l shuttl e val ve cover pl ate. Ti ghten cover
(9) I nstal l 1-2 and 2-3 val ve governor pl ugs i n
val ve body.
(10) I nstal l shuttl e val ve pri mary spri ng and
throttl e pl ug.
(11) Al i gn and i nstal l governor pl ug cover. Ti ghten
cover screws to 4 Nm (35 i n. l bs.) torque.
Fig. 320 Upper Housing Shift Valve And Pressure Plug Locations
BOOST VALVE TUBE AND BRACE
(1) Posi ti on val ve body assembl y so l ower housi ng
i s faci ng upward (Fi g. 321).
(2) Lubri cate tube ends and housi ng ports wi th
transmi ssi on fl ui d or petrol eum jel l y.
(3) Start tube i n l ower housi ng port fi rst. Then
swi ng tube downward and work opposi te end of tube
i nto upper housi ng port (Fi g. 321).
(4) I nsert and seat each end of tube i n housi ngs.
(5) Sl i de tube brace under tube and i nto al i gnment
wi th val ve body screw hol es (Fi g. 322).
(6) I nstal l and fi nger ti ghten three screws that
secure tube brace to val ve body housi ngs (Fi g. 322).
(7) Bend tube brace tabs up and agai nst tube to
hol d i t i n posi ti on (Fi g. 323).
(8) Ti ghten al l val ve body housi ng screws to 4 Nm
(35 i n. l bs.) torque after tube and brace are i nstal l ed.
Ti ghten screws i n di agonal pattern starti ng at center
and worki ng outward.
Fig. 321 Boost Valve Tube
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 322 Boost Valve Tube And Brace
2 - TUBE BRACE
Fig. 323 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
3-4 ACCUMULATOR
(1) Posi ti on converter cl utch val ve and 3-4 shi ft
val ve spri ngs i n housi ng (Fi g. 324).
(2) Loosel y attach accumul ator housi ng wi th ri ght-
si de screw (Fi g. 324). I nstal l onl y one screw at thi s
ti me as accumul ator must be free to pi vot upward for
ease of i nstal l ati on.
(3) I nstal l 3-4 shi ft val ve and spri ng.
(4) I nstal l converter cl utch ti mi ng val ve and
spri ng.
(5) Posi ti on pl ug on end of converter cl utch val ve
spri ng. Then compress and hol d spri ngs and pl ug i n
pl ace wi th fi ngers of one hand.
(6) Swi ng accumul ator housi ng upward over val ve
spri ngs and pl ug.
(7) Hol d accumul ator housi ng fi rml y i n pl ace and
i nstal l remai ni ng two attachi ng screws. Be sure
spri ngs and cl utch val ve pl ug are properl y seated
(Fi g. 325). Ti ghten screws to 4 Nm (35 i n. l bs.).
VALVE BODY FINAL
(1) I nstal l boost val ve, val ve spri ng, retai ner and
cover pl ate. Ti ghten cover pl ate screws to 4 Nm (35
i n. l bs.) torque.
(2) I nsert manual l ever detent spri ng i n upper
housi ng.
(3) Posi ti on detent bal l on end of spri ng. Then hol d
detent bal l and spri ng i n detent housi ng wi th
Retai ner Tool 6583 (Fi g. 326).
(4) I nstal l throttl e l ever i n upper housi ng. Then
i nstal l manual l ever over throttl e l ever and start
manual l ever i nto housi ng.
(5) Al i gn manual l ever wi th detent bal l and man-
ual val ve. Hol d throttl e l ever upward. Then press
down on manual l ever unti l ful l y seated. Remove
detent bal l retai ner tool after l ever i s seated.
(6) Then i nstal l manual l ever seal , washer and
E-cl i p.
(7) Veri fy that throttl e l ever i s al i gned wi th end of
ki ckdown val ve stem and that manual l ever arm i s
engaged i n manual val ve (Fi g. 327).
(8) Posi ti on l i ne pressure adjusti ng screw i n
adjusti ng screw bracket.
(9) I nstal l spri ng on end of l i ne pressure regul ator
val ve.
(10) I nstal l swi tch val ve spri ng on tang at end of
adjusti ng screw bracket.
(11) I nstal l manual val ve.
(12) I nstal l throttl e val ve and spri ng.
(13) I nstal l ki ckdown val ve and detent.
(14) I nstal l pressure regul ator val ve.
(15) I nstal l swi tch val ve.
(16) Posi ti on adjusti ng screw bracket on val ve
body. Al i gn val ve spri ngs and press bracket i nto
pl ace. I nstal l short, upper bracket screws fi rst and
l ong bottom screw l ast. Veri fy that val ve spri ngs and
bracket are properl y al i gned. Then ti ghten al l three
bracket screws to 4 Nm (35 i n. l bs.) torque.
(17) Perform Li ne Pressure and Throttl e Pressure
adjustments. (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C/VALVE BODY - ADJUST-
MENTS)
(18) Lubri cate sol enoi d case connector O-ri ngs and
shaft of manual l ever wi th l i ght coat of petrol eum
jel l y.
Fig. 324 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
4 - CONVERTER CLUTCH VALVE SPRING
Fig. 325 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
(19) Attach sol enoi d case connector to 3-4 accumu-
l ator wi th shoul der-type screw. Connector has smal l
l ocati ng tang that fi ts i n di mpl e at top of accumul a-
tor housi ng (Fi g. 328). Seat tang i n di mpl e before
ti ghteni ng connector screw.
(20) I nstal l sol enoi d assembl y and gasket. Ti ghten
sol enoi d attachi ng screws to 8 Nm (72 i n. l bs.)
torque.
(21) Veri fy that sol enoi d wi re harness i s properl y
routed (Fi g. 329). Sol enoi d harness must be cl ear of
manual l ever and park rod and not be pi nched
between accumul ator housi ng and cover.
Fig. 326 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 327 Manual And Throttle Lever Alignment
1 - THROTTLE LEVER
2 - MANUAL LEVER VALVE ARM
3 - MANUAL VALVE
4 - KICKDOWN VALVE
Fig. 328 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
Fig. 329 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn val ve body assembl y over so accumul ator
si de of transfer pl ate i s faci ng down.
(2) I nstal l new O-ri ngs on governor pressure sol e-
noi d and sensor.
(3) Lubri cate sol enoi d and sensor O-ri ngs wi th
cl ean transmi ssi on fl ui d.
(4) I nstal l governor pressure sensor i n governor
body.
(5) I nstal l governor pressure sol enoi d i n governor
body. Push sol enoi d i n unti l i t snaps i nto pl ace i n
body.
(6) Posi ti on governor body gasket on transfer
pl ate.
(7) I nstal l retai ner pl ate on governor body and
around sol enoi d. Be sure sol enoi d connector i s posi -
ti oned i n retai ner cutout.
(8) Al i gn screw hol es i n governor body and trans-
fer pl ate. Then i nstal l and ti ghten governor body
screws to 4 Nm (35 i n. l bs.) torque.
(9) Connect harness wi res to governor pressure
sol enoi d and governor pressure sensor.
(10) I nstal l fl ui d fi l ter and pan.
(12) Fi l l transmi ssi on wi th recommended fl ui d and
road test vehi cl e to veri fy repai r.
INSTALLATION
(1) Check condi ti on of O-ri ng seal s on val ve body
harness connector (Fi g. 330). Repl ace seal s on con-
nector body i f cut or worn.
(2) Check condi ti on of manual l ever shaft seal i n
transmi ssi on case. Repl ace seal i f l i p i s cut or worn.
I nstal l new seal wi th 15/16 deep wel l socket (Fi g.
331).
(3) Check condi ti on of seal s on accumul ator pi ston
(Fi g. 332). I nstal l new pi ston seal s, i f necessary.
(4) Pl ace val ve body manual l ever i n l ow (1 posi -
ti on) so bal l on park l ock rod wi l l be easi er to i nstal l
i n sprag.
(5) Lubri cate shaft of manual l ever wi th petrol eum
jel l y. Thi s wi l l ease i nserti ng shaft through seal i n
case.
(6) Lubri cate seal ri ngs on val ve body harness con-
nector wi th petrol eum jel l y.
(7) Posi ti on val ve body i n case and work end of
park l ock rod i nto and through pawl sprag. Turn pro-
pel l er shaft to al i gn sprag and park l ock teeth i f nec-
essary. The rod wi l l cl i ck as i t enters pawl . Move rod
to check engagement.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into this cavity.
(8) I nstal l accumul ator spri ngs and pi ston i nto
case. Then swi ng val ve body over pi ston and outer
spri ng to hol d i t i n pl ace.
(9) Al i gn accumul ator pi ston and outer spri ng,
manual l ever shaft and el ectri cal connector i n case.
(10) Then seat val ve body i n case and i nstal l one
or two bol ts to hol d val ve body i n pl ace.
(11) Ti ghten val ve body bol ts al ternatel y and
evenl y to 11 Nm (100 i n. l bs.) torque.
(12) I nstal l new fl ui d fi l ter on val ve body. Ti ghten
fi l ter screws to 4 Nm (35 i n. l bs.) torque.
(13) I nstal l throttl e and gearshi ft l evers on val ve
body manual l ever shaft.
(14) Check and adjust front and rear bands i f nec-
essary.
(15) Connect sol enoi d case connector wi res.
(16) I nstal l oi l pan and new gasket. Ti ghten pan
bol ts to 13.6 Nm (125 i n. l bs.) torque.
(17) Lower vehi cl e and fi l l transmi ssi on wi th
(18) Check and adjust gearshi ft and throttl e val ve
cabl es, i f necessary.
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
val ve body;
Li ne Pressure
Throttl e Pressure
Li ne and throttl e pressures are i nterdependent
because each affects shi ft qual i ty and ti mi ng. As a
resul t, both adjustments must be performed properl y
and i n the correct sequence. Adjust l i ne pressure fi rst
and throttl e pressure l ast.
Fig. 330 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
LINE PRESSURE ADJUSTMENT
Measure di stance from the val ve body to the i nner
edge of the adjusti ng screw wi th an accurate steel
scal e (Fi g. 333).
Di stance shoul d be 33.4 mm (1-5/16 i n.).
I f adjustment i s requi red, turn the adjusti ng screw
i n, or out, to obtai n requi red di stance setti ng.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One compl ete turn of the adjusti ng screw changes
l i ne pressure approxi matel y 1-2/3 psi (9 kPa).
Turni ng the adjusti ng screw countercl ockwi se
i ncreases pressure whi l e turni ng the screw cl ockwi se
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
I nsert Gauge Tool C-3763 between the throttl e
l ever cam and the ki ckdown val ve stem (Fi g. 334).
Push the gauge tool i nward to compress the ki ck-
down val ve agai nst the spri ng and bottom the throt-
tl e val ve.
Mai ntai n pressure agai nst ki ckdown val ve spri ng.
Turn throttl e l ever stop screw unti l the screw head
touches throttl e l ever tang and the throttl e l ever cam
touches gauge tool .
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Fig. 331 Manual Lever Shaft Seal
1 - 15/16 SOCKET
2 - SEAL
Fig. 332 Accumulator Piston Components
1 - INNER SPRING
3 - OUTER SPRING
4 - SEAL RINGS
Fig. 333 Line Pressure Adjustment
1 - WRENCH
2 - 15/16 INCH
Fig. 334 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
AUTOMATIC TRANSMISSION - 545RFE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 545RFE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 178
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 179
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 179
DIAGNOSIS AND TESTING - PRELIMINARY . 180
DIAGNOSIS AND TESTING - ROAD
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . 181
TRANSMISSION CLUTCH OPERATION . . . . 182
HOUSING FLUID LEAK . . . . . . . . . . . . . . . . 182
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . 183
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 185
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 190
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 197
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . 199
SPECIFICATIONS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 220
SPECIAL TOOLS
RFE TRANSMISSION . . . . . . . . . . . . . . . . . 221
4C RETAINER/BULKHEAD
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 224
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
ADAPTER HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 225
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 226
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 226
TRANSMISSION SHIFT INTERLOCK . . . . . . 226
SHIFT INTERLOCK . . . . . . . . . . . . . . . . . . . 227
FLUID AND FILTER
INCORRECT FLUID LEVEL . . . . . . . . . . . . . 228
BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . 228
CONTAMINATION . . . . . . . . . . . . . . . . . . . . 228
STANDARD PROCEDURE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT . . . . . . . . . . . . . . . 230
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
GEARSHIFT CABLE
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 231
ADJUSTMENTS - GEARSHIFT CABLE . . . . . . 232
HOLDING CLUTCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 233
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 234
INPUT CLUTCH ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 235
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 235
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 237
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
INPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 244
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 244
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 244
LINE PRESSURE (LP) SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 245
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 245
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 245
LOW/REVERSE CLUTCH
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 246
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 247
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 248
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 248
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK . . . . . . . . . . . . . . . . . . . . . 249
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 250
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 252
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
OIL PUMP FRONT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
WJ AUTOMATIC TRANSMISSION - 545RFE 21 - 177
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 253
OUTPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 254
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 254
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 254
OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 254
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 254
PARK LOCK CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 255
PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 256
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 256
PLANETARY GEARTRAIN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 258
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 260
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 260
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 260
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 261
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 261
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 263
SOLENOID SWITCH VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 263
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 263
SOLENOIDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 263
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 264
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 264
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 268
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 269
TRANSMISSION CONTROL RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 270
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 270
TRANSMISSION RANGE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 270
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 270
TRANSMISSION SOLENOID/TRS ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 271
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 271
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 272
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 272
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 272
VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 273
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 273
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 275
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 277
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 279
AUTOMATIC TRANSMISSION -
545RFE
DESCRIPTION
The 545RFE automati c transmi ssi on i s a sophi sti -
cated, mul ti -range, el ectroni cal l y control l ed transmi s-
si on whi ch combi nes opti mi zed gear rati os for
responsi ve performance, state of the art effi ci ency
features and l ow NVH. Other features i ncl ude dri ver
adapti ve shi fti ng and three pl anetary gear sets to
provi de wi de rati o capabi l i ty wi th preci se rati o steps
for opti mum dri veabi l i ty. The three pl anetary gear
sets al so make avai l abl e a uni que al ternate second
gear rati o. The pri mary 2nd gear rati o fi ts between
1st and 3rd gears for normal through-gear accel era-
ti ons. The al ternate second gear rati o (2pri me) al l ows
smoother 4-2 ki ckdowns at hi gh speeds to provi de
2nd gear passi ng performance over a wi der hi ghway
crui si ng range. An addi ti onal overdri ve rati o (0.67:1)
i s al so provi ded for greater fuel economy and l ess
NVH at hi ghway speeds.
The hydraul i c porti on of the transmi ssi on consi sts
of the transmi ssi on fl ui d, fl ui d passages, hydraul i c
val ves, and vari ous l i ne pressure control components.
The pri mary mechani cal components of the trans-
mi ssi on consi st of the fol l owi ng:
Three mul ti pl e di sc i nput cl utches
Three mul ti pl e di sc hol di ng cl utches
Fi ve hydraul i c accumul ators
Three pl anetary gear sets
Dual Stage Hydraul i c oi l pump
Val ve body
Sol enoi d pack
The TCM i s the heart or brai n of the el ectroni c
control system and rel i es on i nformati on from vari -
ous di rect and i ndi rect i nputs (sensors, swi tches, etc.)
to determi ne dri ver demand and vehi cl e operati ng
condi ti ons. Wi th thi s i nformati on, the TCM can cal -
cul ate and perform ti mel y and qual i ty shi fts through
vari ous output or control devi ces (sol enoi d pack,
transmi ssi on control rel ay, etc.).
21 - 178 AUTOMATIC TRANSMISSION - 545RFE WJ
TRANSMISSION IDENTIFICATION
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan
seal i ng surface (Fi g. 1). Refer to thi s i nformati on
when orderi ng repl acement parts. A l abel i s attached
to the transmi ssi on case above the stamped numbers.
The l abel gi ves addi ti onal i nformati on whi ch may
al so be necessary for i denti fi cati on purposes.
GEAR RATIOS The 545RFE gear ratios are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:1
2nd Pri me . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.67:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
OPERATION
The 545RFE offers ful l el ectroni c control of al l auto-
mati c up and downshi fts, and features real -ti me adap-
ti ve cl osed-l oop shi ft and pressure control . El ectroni c
shi ft and torque converter cl utch control s hel p protect
the transmi ssi on from damage due to hi gh tempera-
tures, whi ch can occur under severe operati ng condi -
ti ons. By al teri ng shi ft schedul es, l i ne pressure, and
converter cl utch control , these control s reduce heat gen-
erati on and i ncrease transmi ssi on cool i ng.
To hel p reduce effi ci ency-robbi ng parasi ti c l osses,
the transmi ssi on i ncl udes a dual -stage transmi ssi on
fl ui d pump wi th el ectroni c output pressure control .
Under most dri vi ng condi ti ons, pump output pres-
sure greatl y exceeds that whi ch i s needed to keep the
cl utches appl i ed. The 545RFE pump-pressure control
system moni tors i nput torque and adjusts the pump
pressure accordi ngl y. The pri mary stage of the pump
works conti nuousl y; the second stage i s bypassed
when demand i s l ow. The control system al so moni -
tors i nput and output speed and, i f i nci pi ent cl utch
sl i p i s observed, the pressure control sol enoi d duty
cycl e i s vari ed, i ncreasi ng pressure i n proporti on to
demand.
A hi gh-travel torque converter damper assembl y
al l ows earl i er torque converter cl utch engagement to
reduce sl i ppage. Needl e-type thrust beari ngs reduce
i nternal fri cti on. The 545RFE i s packaged i n a one-
pi ece di e-cast al umi num case. To reduce NVH, the
case has hi gh l ateral , verti cal and torsi onal sti ffness.
I t i s al so desi gned to maxi mi ze the benefi t of the
structural dust cover that connects the bottom of the
bel l housi ng to the engi ne bedpl ate, enhanci ng over-
al l power trai n sti ffness. Dual fi l ters protect the
pump and other components. A pump return fi l ter i s
added to the customary mai n sump fi l ter. I ndepen-
dent l ubri cati on and cool er ci rcui ts assure ampl e
pressure for normal transmi ssi on operati on even i f
the cool er i s obstructed or the fl ui d cannot fl ow due
to extremel y l ow temperatures.
The hydraul i c control system desi gn (wi thout el ec-
troni c assi st) provi des the transmi ssi on wi th PARK,
REVERSE, NEUTRAL, SECOND, and THI RD gears,
based sol el y on dri ver shi ft l ever sel ecti on. Thi s
desi gn al l ows the vehi cl e to be dri ven (i n l i mp-i n
mode) i n the event of a el ectroni c control system fai l -
ure, or a si tuati on that the Transmi ssi on Control
Modul e (TCM) recogni zes as potenti al l y damagi ng to
the transmi ssi on.
The TCM al so performs certai n sel f-di agnosti c
functi ons and provi des comprehensi ve i nformati on
(sensor data, DTCs, etc.) whi ch i s hel pful i n proper
di agnosi s and repai r. Thi s i nformati on can be vi ewed
wi th the DRB scan tool .
TRANSMISSION
CAUTION: Before attempting any repair on a
545RFE automatic transmission, check for Diagnos-
tic Trouble Codes with the DRB scan tool.
Transmi ssi on mal functi ons may be caused by these
general condi ti ons:
Poor engi ne performance
I mproper adjustments
Hydraul i c mal functi ons
Mechani cal mal functi ons
El ectroni c mal functi ons
Fig. 1 Transmission Part And Serial Number
Location
AUTOMATIC TRANSMISSION - 545RFE (Continued)
Di agnosi s of these probl ems shoul d al ways begi n
by checki ng the easi l y accessi bl e vari abl es: fl ui d l evel
and condi ti on, gearshi ft cabl e adjustment. Then per-
form a road test to determi ne i f the probl em has been
corrected or i f more di agnosi s i s necessary. I f the
probl em persi sts after the prel i mi nary tests and cor-
recti ons are compl eted, hydraul i c pressure checks
shoul d be performed.
DIAGNOSIS AND TESTING - PRELIMINARY
Two basi c procedures are requi red. One procedure for
vehi cl es that are dri vabl e and an al ternate procedure for
di sabl ed vehi cl es (wi l l not back up or move forward).
VEHICLE IS DRIVABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(3) Adjust gearshi ft cabl e i f compl ai nt was based
on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform stal l test i f compl ai nt i s based on sl ug-
gi sh accel erati on. Or, i f abnormal throttl e openi ng i s
needed to mai ntai n normal speeds wi th a properl y
tuned engi ne.
(6) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(7) Perform ai r-pressure test to check cl utch operati on.
VEHICLE IS DISABLED
(2) Check for broken or di sconnected gearshi ft cabl e.
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri vepl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that al l di agnosti c trou-
bl e codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, overrunni ng cl utch, or l i ne presure probl ems.
A sl i ppi ng cl utch can often be determi ned by com-
pari ng whi ch i nternal uni ts are appl i ed i n the vari -
ous gear ranges. The Cl utch Appl i cati on chart
provi des a basi s for anal yzi ng road test resul ts.
CLUTCH APPLICATION CHART
SLP UD OD R 2C 4C L/R OVERRUNNING
PPARK ON
RREVERSE ON ON
N-NEUTRAL ON
DOVERDRIVE
FIRST
ON ON* ON
SECOND ON ON
SECOND PRIME ON ON
THIRD ON ON
FOURTH ON ON
FIFTH ON ON
LIMP-IN ON ON
2FIRST ON ON* ON
SECOND ON ON
LIMP-IN ON ON
1LOW ON ON ON
*L/R clutch is on only with the output shaft speed below 150 rpm.
PRESSURE TEST
An accurate tachometer and pressure test gauges
are requi red. Test Gauge C-3293-SP has a 300 psi
range and i s used at al l l ocati ons where pressures
exceed 100 psi .
Pressure Test Port Locations
Onl y two pressure ports are suppl i ed on the trans-
mi ssi on case. The torque converter cl utch appl y and
rel ease ports are l ocated on the ri ght si de of the
transmi ssi on case (Fi g. 2).
To determi ne the l i ne pressure, there are two avai l -
abl e methods. The DRB scan tool can be used to
read l i ne pressure from the l i ne pressure sensor. The
second method i s to i nstal l Li ne Pressure Adapter
8259 (Fi g. 4) i nto the transmi ssi on case and then
i nstal l the pressure gauge and the ori gi nal sensor
i nto the adapter. Thi s wi l l al l ow a compari son of the
DRB readi ngs and the gauge readi ng to determe the
accuracy of the l i ne pressure sensor. The DRB l i ne
pressure readi ng shoul d match the gauge readi ng
wi thi n 10 psi .
I n order to access any other pressure tap l ocati ons,
the transmi ssi on oi l pan must be removed, the pres-
sure port pl ugs removed and Val ve Body Pressure
Tap Adapter 8258-A (Fi g. 5) i nstal l ed. The extensi ons
suppl i ed wi th Adapter 8258-A wi l l al l ow the i nstal l a-
ti on of pressure gauges to the val ve body. Refer to
(Fi g. 3) for correct pressure tap l ocati on i denti fi ca-
ti on.
TEST PROCEDURE
Al l pressure readi ngs shoul d be taken wi th the
transmi ssi on fl ui d l evel ful l , transmi ssi on oi l at the
normal operati ng temperature, and the engi ne at
1500 rpm. Check the transmi ssi on for proper opera-
ti on i n each gear posi ti on that i s i n questi on or i f a
speci fi c el ement i s i n questi on, check the pressure
readi ngs i n at l east two gear posi ti ons that empl oy
that el ement. Refer to the Hydraul i c Schemati cs at
the rear of thi s secti on to determi ne the correct pres-
sures for each el ement i n a gi ven gear posi ti on.
Fig. 2 Torque Converter Pressure Locations
1 - TCC RELEASE
2 - TO COOLER
3 - TCC APPLY
4 - FROM COOLER
5 - LINE PRESSURE SENSOR
Fig. 3 Pressure Tap Locations
Fig. 4 Line Pressure Adapter 8259
1 - LINE PRESSURE SENSOR PORT
3 - TOOL 8259
4 - PRESSURE TAP
NOTE: The 545RFE utilizes closed loop control of
pump line pressure. The pressure readings may
therefore vary greatly but should always follow line
pressure.
Some common pressures that can be measured to
eval uate pump and cl utch performance are the
upshi ft/downshi ft pressures and the garage shi ft
pressures. The upshi ft/downshi ft pressure for al l
shi fts except the 4-5 shi ft i s 120 psi . The upshi ft
pressure for the 4-5 shi ft i s 130 psi . The garage shi ft
pressure when performi ng a N-R shi ft i s 220 psi . The
garage shi ft pressure for the R-N and N-1 shi fts i s
120 psi .
TRANSMISSION CLUTCH OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on cl utch operati on. The test can be conducted wi th
the transmi ssi on ei ther i n the vehi cl e or on the work
bench, as a fi nal check.
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
cl utch appl y passages are shown (Fi g. 6).
NOTE: The air supply which is used must be free of
moisture and dirt. Use a pressure of 30 psi to test
clutch operation.
Appl y ai r pressure at each port. I f the cl utch i s
functi oni ng, a soft thump wi l l be heard as the cl utch
i s appl i ed. The cl utch appl i cati on can al so be fel t by
touchi ng the appropri ate el ement whi l e appl yi ng ai r
pressure. As the ai r pressure i s rel eased, the cl utch
shoul d al so rel ease.
HOUSING FLUID LEAK
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Torque converter seal l eaks tend to move
al ong the dri ve hub and onto the rear of the con-
verter. Pump cover seal tend to run down the cover
and the i nsi de surface of the bel l housi ng.
Some l eaks, or suspected l eaks, may be parti cu-
l arl y di ffi cul t to l ocate. I f necessary, a Mopar
approved dye may be used to l ocate a l eak.
Fig. 5 Valve Body Pressure Tap Adapter 8258-A
1 - 545RFE TRANSMISSION
2 - TOOL 8258-A
Fig. 6 Air Pressure Test Passages
1 - LOW REVERSE CLUTCH
2 - 4TH CLUTCH
3 - 2ND CLUTCH
4 - OVERDRIVE CLUTCH
5 - UNDERDRIVE CLUTCH
6 - REVERSE CLUTCH
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
(1) Leaks at the wel d joi nt around the outsi de
di ameter wel d (Fi g. 7).
(2) Leaks at the converter hub wel d (Fi g. 7).
THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s , or equi val ent. Thi s repai r con-
si sts of dri l l i ng out the worn-out damaged threads.
Then tap the hol e wi th a speci al Hel i -Coi l tap, or
equi val ent, and i nstal l i ng a Hel i -Coi l i nsert, or
equi val ent, i nto the hol e. Thi s bri ngs the hol e back to
i ts ori gi nal thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
REMOVAL
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, converter
hub o-ring, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal. Be sure to remove the transmission and
converter as an assembly.
(2) Rai se and support the vehi cl e
(3) Mark propel l er shaft and axl e yokes for assem-
bl y al i gnment.
(4) Remove the rear propel l er shaft
(5) Remove the front propel l er shaft.
(6) Remove the engi ne to transmi ssi on col l ar (Fi g.
8).
(7) Remove the exhaust support bracket from the
rear of the transmi ssi on.
(8) Di sconnect and l ower or remove any necessary
exhaust components.
(9) Remove the starter motor.
(10) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(11) Di sconnect wi res from sol enoi d and pressure
swi tch assembl y, i nput and output speed sensors, and
l i ne pressure sensor.
1 - TURBINE ASSEMBLY
2 - STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
Fig. 8 Transmission Collar
1 - ENGINE
2 - ENGINE TO TRANSMISSION COLLAR
3 - TRANSMISSION
(12) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever (Fi g. 9).
(13) Di sconnect transfer case shi ft cabl e from the
(14) Remove the cl i p securi ng the transfer case
shi ft cabl e i nto the cabl e support bracket.
(15) Di sconnect transmi ssi on fl ui d cool er l i nes at
transmi ssi on fi tti ngs and cl i ps.
(16) Di sconnect the transmi ssi on vent hose from
the transmi ssi on.
(17) Support rear of engi ne wi th safety stand or
jack.
(18) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(19) Remove bol ts securi ng rear support and cush-
i on to transmi ssi on and crossmember (Fi g. 11).
(20) Remove bol ts attachi ng crossmember to frame
and remove crossmember.
(21) Remove transfer case (Fi g. 12) and (Fi g. 13).
(22) Remove al l remai ni ng converter housi ng bol ts.
(23) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(24) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(25) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
Fig. 11 Rear Transmission Crossmember
1 - CROSSMEMBER
(26) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
DISASSEMBLY
(1) Drai n fl ui d from transmi ssi on.
(2) Cl ean exteri or of transmi ssi on wi th sui tabl e
sol vent or pressure washer.
(3) Remove the torque converter from the trans-
mi ssi on.
(4) Remove the manual shi ft l ever from the trans-
mi ssi on.
(5) Remove the i nput, output, and l i ne pressure
sensors from the transmi ssi on case (Fi g. 14).
(6) I nspect the ends of the sensors for debri s,
whi ch may i ndi cate the nature of the transmi ssi on
fai l ure.
(7) I nstal l Support Stand 8257 onto the transmi s-
(8) Usi ng Adapter 8266-1 from End-Pl ay Tool Set
8266 and Di al I ndi cator C-3339, measure and record
the i nput shaft end-pl ay (Fi g. 16).
Fig. 14 Remove Input, Output, and Line Pressure
Sensors
Fig. 15 Install Support Stand - Tool 8257
1 - TOOL 8257
Fig. 16 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
NOTE: When measuring the input shaft end-play,
two stops will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first stop felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
(9) Remove the bol ts hol di ng the transmi ssi on
extensi on/adapter housi ng to the transmi ssi on case.
(10) Remove the extensi on/adapter housi ng from
the transmi ssi on case.
(11) Usi ng Al i gnment Pl ate 8261, Adapter 8266-17
from End-Pl ay Tool Set 8266 and Di al I ndi cator
C-3339, measure and record the output shaft end-
pl ay (Fi g. 17).
(12) Remove the bol ts hol di ng the transmi ssi on oi l
pan to the transmi ssi on case.
(13) Remove the transmi ssi on oi l pan from the
transmi ssi on case.
(14) Remove the pri mary oi l fi l ter and the oi l
cool er return fi l ter (Fi g. 18).
(15) Remove the cool er return fi l ter bypass val ve.
(16) Remove the bol ts hol di ng the val ve body to
the transmi ssi on case (Fi g. 19).
(17) Remove the val ve body from the transmi ssi on
case.
(18) Remove the outer snap-ri ng securi ng the
transmi ssi on front cover i nto the transmi ssi on case
(Fi g. 20).
Fig. 17 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 18 Remove Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 19 Remove Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
(19) Remove the i nner snap-ri ng securi ng the
transmi ssi on front cover to the oi l pump (Fi g. 20).
(20) Reachi ng through a case openi ng i n the val ve
body area wi th a l ong bl unted tool , remove the trans-
mi ssi on front cover from the transmi ssi on case.
(21) Remove the bol ts hol di ng the oi l pump i nto
(22) Remove the oi l pump. Hol d i nward on the
i nput shaft to prevent pul l i ng the i nput cl utch
assembl y wi th the oi l pump (Fi g. 21).
(23) Remove the number 1 beari ng from the i nput
cl utch assembl y (Fi g. 22).
(24) Remove the i nput cl utch assembl y from the
(25) Remove the number 5 beari ng and sel ecti ve
thrust pl ate from the i nput cl utch assembl y (Fi g. 22),
or the 4C cl utch retai ner/bul khead.
(26) Remove the 4C cl utch retai ner/bul khead tapered
snap-ri ng from the transmi ssi on case (Fi g. 23).
(27) Remove the 4C cl utch retai ner/bul khead from
Fig. 20 Remove Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 21 Remove Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 22 Remove Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
Fig. 23 Remove 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
(28) Remove the front 2C cl utch pack snap-ri ng
from the transmi ssi on case (Fi g. 24).
(29) Remove the 2C cl utch pack from the transmi s-
(30) Remove the rear sel ecti ve pl ate and number 6
beari ng from the reacti on annul us (Fi g. 25).
(31) Remove the reacti on annul us from the reac-
ti on pl anetary carri er (Fi g. 25).
(32) Remove the number 7 beari ng (Fi g. 25).
(33) Remove the reacti on sun gear (Fi g. 25).
(34) Remove the number 8 beari ng from the reac-
ti on pl anetary carri er (Fi g. 25).
(35) Remove the reacti on pl anetary carri er (Fi g.
25). Note that thi s pl anetary gear set has three pi n-
i on gears.
(36) Remove the number 9 beari ng from the
reverse pl anetary gear set (Fi g. 25).
Fig. 24 Remove 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 25 Remove Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
(37) Remove the snap-ri ng hol di ng the park sprag
gear onto the output shaft (Fi g. 26).
(38) Remove the park sprag gear from the output
shaft (Fi g. 27).
(39) Remove the i nput/reverse pl anetary assembl y
(Fi g. 28).
(40) Remove the number 12 beari ng from the
i nput/reverse pl anetary assembl y (Fi g. 28).
(41) Remove the snap-ri ng hol di ng the l ow/reverse
cl utch retai ner i nto the transmi ssi on case (Fi g. 29).
(42) Remove the l ow/reverse cl utch retai ner from
(43) Remove the park pawl rod and e-cl i p (Fi g. 30).
(44) Remove the park pawl rod gui de snap-ri ng
(Fi g. 30).
(45) Remove the park pawl rod gui de (Fi g. 30).
(46) Remove the park pawl pi vot shaft, park pawl ,
and spri ng (Fi g. 30).
(47) Remove the manual sel ector shaft (Fi g. 30).
Fig. 26 Remove Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 27 Remove Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 28 Remove Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
Fig. 29 Remove Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
(48) Remove the manual sel ector shaft seal .
(49) Remove the di psti ck tube seal .
CLEANING
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on
shafts, or val ves, use extreme care to avoi d roundi ng
off sharp edges. Sharp edges are vi tal as they pre-
vent forei gn matter from getti ng between the val ve
and val ve bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or
O-ri ngs duri ng overhaul . Repl ace these parts as a
matter of course. Al so do not reuse snap ri ngs or
E-cl i ps that are bent or di storted. Repl ace these parts
as wel l .
Lubri cate transmi ssi on parts wi th Mopar ATF +4,
Type 9602, transmi ssi on fl ui d duri ng overhaul and
assembl y. Use petrol eum jel l y, Mopar Door Ease, or
Ru-Gl yde to prel ubri cate seal s, O-ri ngs, and thrust
washers. Petrol eum jel l y can al so be used to hol d
parts i n pl ace duri ng reassembl y.
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
I nspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repai red wi th Hel i coi l thread i nserts. However, the
case wi l l have to be repl aced i f i t exhi bi ts any type of
damage or wear.
ASSEMBLY
(1) Cl ean and i nspect al l components. Repl ace any
components whi ch show evi dence of excessi ve wear
or scori ng.
(2) I nstal l the cool er fi l ter bypass val ve.
(3) Torque the bypass val ve to speci fi cati on. The
val ve uses a tapered pi pe thread and excessi ve
torque can damage the transmi ssi on case. Ti ghten
the cool er fi l ter bypass val ve to 4.5 Nm (40 i n.l bs.).
(4) I nstal l a new sel ector shaft seal usi ng Seal
I nstal l er 8253 (Fi g. 31).
Fig. 30 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 31 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
(5) I nstal l the manual sel ector shaft and retai ni ng
screw. Ti ghten the manual sel ector shaft retai ni ng
screw to 28 Nm (250 i n.l bs.).
(6) I nstal l the park pawl , spri ng, and shaft (Fi g.
32).
(7) I nstal l the park rod and e-cl i p (Fi g. 32).
(8) I nstal l the park rod gui de and snap-ri ng (Fi g.
32).
(9) I nstal l a new di psti ck tube seal usi ng Seal
NOTE: Before final assembly of transmission cen-
terline, the 2C/4C clutch components should be
installed into position and measured as follows:
(10) I nstal l the 2C reacti on pl ate i nto the trans-
mi ssi on case (Fi g. 34). The reacti on pl ate i s di rec-
ti onal . The pl ate must be i nstal l ed wi th the fl at si de
toward the front of the transmi ssi on.
(11) I nstal l the 2C cl utch pack i nto the transmi s-
(12) I nstal l the fl at 2C cl utch snap-ri ng i nto the
(13) I nstal l the 4C retai ner/bul khead i nto the
transmi ssi on case. Make sure that the oi l feed hol es
are poi nti ng toward the val ve body area.
(14) I nstal l the 4C retai ner/bul khead tapered
snap-ri ng i nto the transmi ssi on case. Make sure that
the open ends of the snap-ri ng are l ocated i n the case
openi ng toward the val ve body area.
Fig. 32 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 33 Install Dipstick Tube Seal Using Tool 8254
1 - TOOL 8254
2 - SEAL
Fig. 34 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
(15) Usi ng a feel er gauge through the openi ng i n
the rear of the transmi ssi on case, measure the 2C
cl utch pack cl earance between the 2C reacti on pl ate
and the transmi ssi on case at four di fferent poi nts.
The average of these measurements i s the 2C cl utch
pack cl earance. The correct cl utch cl earance i s 0.455-
1.335 mm (0.018-0.053 i n.). The reacti on pl ate i s not
sel ecti ve. I f the cl utch pack cl earance i s not wi thi n
speci fi cati on, the reacti on pl ate, al l the fri cti on di scs,
and steel s must be repl aced.
(16) Remove the 4C retai ner/bul khead and al l of
the 2C cl utch components from the transmi ssi on
case.
(17) I nstal l the l ow/reverse cl utch assembl y (Fi g.
35). Make sure that the oi l feed hol e poi nts toward
the val ve body area and that the bl eed ori fi ce i s
al i gned wi th the notch i n the rear of the transmi s-
si on case.
(18) I nstal l the snap-ri ng to hol d the l ow/reverse
cl utch retai ner i nto the transmi ssi on case (Fi g. 35).
The snap-ri ng i s tapered and must be i nstal l ed wi th
the tapered si de forward. Once i nstal l ed, veri fy that
the snap-ri ng i s ful l y seated i n the snap-ri ng groove.
(19) Ai r check the l ow/reverse cl utch and veri fy
correct overrunni ng cl utch operati on.
(20) I nstal l the number 12 beari ng over the output
shaft and agai nst the rear pl anetary gear set. The
fl at si de of the beari ng goes toward the pl anetary
gearset and the rai sed tabs on the i nner race shoul d
face the rear of the transmi ssi on.
(21) I nstal l the reverse/i nput pl anetary assembl y
through the l ow/reverse cl utch assembl y (Fi g. 36).
(22) I nstal l the park sprag onto the output shaft
(Fi g. 37).
(23) I nstal l the snap-ri ng to hol d the park sprag
onto the output shaft (Fi g. 38).
Fig. 35 Install Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
Fig. 36 Install Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
Fig. 37 Install Park Sprag Gear
1 - PARK SPRAG GEAR
(24) I nstal l the 2C reacti on pl ate i nto the trans-
mi ssi on case (Fi g. 39). The reacti on pl ate i s di rec-
ti onal . The pl ate must be i nstal l ed wi th the fl at si de
toward the front of the transmi ssi on.
(25) I nstal l the 2C cl utch pack i nto the transmi s-
(26) I nstal l the number 8 beari ng i nsi de the reac-
ti on carri er wi th the outer race agai nst the reacti on
pl anetary carri er.
(27) I nstal l the reacti on pl anetary gear set and the
number 9 beari ng, wi th the i nner race agai nst the
reacti on pl anetary carri er, i nto the transmi ssi on case
(Fi g. 40).
(28) I nstal l the fl at 2C cl utch snap-ri ng i nto the
(29) I nstal l the reacti on sun gear i nto the reacti on
pl anetary gear set. Make sure the smal l shoul der i s
faci ng the front of the transmi ssi on (Fi g. 40).
(30) I nstal l the number 7 beari ng onto the reacti on
sun gear wi th the i nner race agai nst the sun gear
(Fi g. 40).
(31) I nstal l the output shaft sel ecti ve thrust pl ate
onto the reacti on annul us wi th the oi l grooves faci ng
the annul us gear and the tabs and notches al i gned as
shown i n (Fi g. 41).
(32) I nstal l the number 6 beari ng agai nst the out-
put shaft sel ecti ve thrust pl ate wi th the fl at si de
agai nst the thrust pl ate (Fi g. 40) and the rai sed tabs
on the i nner race faci ng the front of the transmi s-
si on.
(33) I nstal l the reacti on annul us i nto the reacti on
pl anetary gear set (Fi g. 40).
(34) I nstal l the 4C retai ner/bul khead i nto the
transmi ssi on case. Make sure that the oi l feed hol es
are poi nti ng toward the val ve body area. Rotate the
reacti on annul us duri ng the i nstal l ati on of the 4C
retai ner/bul khead to ease i nstal l ati on.
(35) I nstal l the 4C retai ner/bul khead tapered
snap-ri ng i nto the transmi ssi on case (Fi g. 42) wi th
the taper toward the front of the case. Make sure
that the open ends of the snap-ri ng are l ocated i n the
case openi ng toward the val ve body area.
(36) Ai r check the 2C and 4C cl utch operati on.
Fig. 38 Install Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 39 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 40 Install Reaction Annulus and Carrier
Fig. 41 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
Fig. 42 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
(37) Usi ng Al i gnment Pl ate 8261, Adapter 8266-17
from End-Pl ay Tool Set 8266 and Di al I ndi cator
C-3339, measure and record the output shaft end-
pl ay (Fi g. 43). The correct output shaft end-pl ay i s
0.22-0.55 mm (0.009-0.021 i n.). Adjust as necessary.
I nstal l the chosen output shaft sel ecti ve thrust pl ate
and re-measure end-pl ay to veri fy sel ecti on.
(38) Appl y a bead of RTV si l i cone and i nstal l the
extensi on/adapter housi ng onto the transmi ssi on
case.
(39) I nstal l and torque the bol ts to hol d the exten-
si on/adapter housi ng onto the transmi ssi on case. The
correct torque i s 54 Nm (40 ft.l bs.).
(40) I nstal l the number 5 beari ng and sel ecti ve
thrust pl ate onto the 4C retai ner/bul khead (Fi g. 44).
Be sure that the outer race of the beari ng i s agai nst
the thrust pl ate.
(41) I nstal l the i nput cl utch assembl y i nto the
transmi ssi on case (Fi g. 44). Make sure that the i nput
cl utch assembl y i s ful l y i nstal l ed by performi ng a
vi sual i nspecti on through the i nput speed sensor
hol e. I f the tone wheel teeth on the i nput cl utch
assembl y are centered i n the hol e, the assembl y i s
ful l y i nstal l ed.
(42) I nstal l the number 1 beari ng wi th the outer
race up i n the pocket of the i nput cl utch assembl y
(Fi g. 44).
(43) I nstal l the oi l pump i nto the transmi ssi on
case (Fi g. 45).
(44) I nstal l the bol ts to hol d the oi l pump i nto the
transmi ssi on case. Ti ghten the oi l pump bol ts to 28
Nm (250 i n.l bs.).
Fig. 43 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 44 Install Input Clutch Assembly
2 - THRUST PLATE (SELECT)
Fig. 45 Install Oil Pump
2 - OIL PUMP
(45) Usi ng Adapter 8266-1 from End-Pl ay Tool Set
8266 and Di al I ndi cator C-3339, measure and record
the i nput shaft end-pl ay (Fi g. 46). The correct end-
pl ay i s 0.46-0.89 mm (0.018-0.035 i n.). Adjust as nec-
essary. I nstal l the chosen thrust pl ate on the number
5 beari ng and re-measure end-pl ay to veri fy sel ec-
ti on.
NOTE: When measuring the input shaft end-play,
two stops will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first stop felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
(46) I nstal l the transmi ssi on front cover i nto the
(47) I nstal l the outer snap-ri ng to hol d the trans-
mi ssi on front cover i nto the transmi ssi on case (Fi g.
47).
(48) Parti al l y i nstal l the i nner transmi ssi on front
cover snap-ri ng onto the oi l pump (Fi g. 47).
(49) Usi ng I nstal l er 8255, i nstal l the i nner trans-
mi ssi on front cover snap-ri ng the remai nder of the
way onto the oi l pump (Fi g. 48).
(50) I nstal l the val ve body (Fi g. 49). Veri fy that
the pi n on the manual l ever has properl y engaged
the TRS sel ector pl ate. Ti ghten the val ve body to
transmi ssi on case bol ts to 12 Nm (105 i n.l bs.).
Fig. 46 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
Fig. 47 Install the Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 48 Seat Snap-Ring Using Tool 8255
1 - TOOL 8255
2 - SNAP-RING
(51) I nstal l a new pri mary oi l fi l ter seal i n the oi l
pump i nl et bore. Seat the seal i n the bore wi th the
butt end of a hammer, or other sui tabl e tool .
CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(52) I nstal l the pri mary oi l fi l ter and the oi l cool er
return fi l ter (Fi g. 50). Ti ghten the screw to hol d the
pri mary oi l fi l ter to the val ve body to 4.5 Nm (40
i n.l bs.). Usi ng Oi l Fi l ter Wrench 8321, ti ghten the
cool er return oi l fi l ter to the transmi ssi on case to 14
Nm (125 i n.l bs.).
(53) Appl y RTV si l i cone to the oi l pan and i nstal l
the transmi ssi on oi l pan. Ti ghten the bol ts to 12 Nm
(105 i n.l bs.).
(54) I nstal l the i nput, output, and l i ne pressure
sensors (Fi g. 51). Ti ghten the bol ts to 12 Nm (105
i n.l bs.).
(55) I nstal l the manual shi ft l ever from the trans-
mi ssi on. Torque the retai ni ng cross-bol t to 16 Nm
(140 i n.l bs.).
INSTALLATION
(1) Check torque converter hub and hub dri ve fl ats
for sharp edges burrs, scratches, or ni cks. Pol i sh the
hub and fl ats wi th 320/400 gri t paper and crocus
cl oth i f necessary. Veri fy that the converter hub
o-ri ng i s properl y i nstal l ed and i s free of any debri s.
The hub must be smooth to avoi d damagi ng pump
seal at i nstal l ati on.
(2) I f a repl acement transmi ssi on i s bei ng
i nstal l ed, transfer any components necessary, such as
the manual shi ft l ever and shi ft cabl e bracket, from
the ori gi nal transmi ssi on onto the repl acement trans-
mi ssi on.
fl ui d.
(4) Al i gn converter and oi l pump.
Fig. 49 Install Valve Body Assembly
Fig. 50 Install Primary Oil and Cooler Filters
4 - VALVE BODY
Fig. 51 Install Input, Output, and Line Pressure
Sensors
(5) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(6) Check converter seati ng wi th steel scal e and
shoul d be at l east 13 mm (1/2 i n.) to rear of strai ght-
edge when converter i s ful l y seated.
(7) Temporari l y secure converter wi th C-cl amp.
(8) Posi ti on transmi ssi on on jack and secure i t
wi th chai ns.
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Appl y a l i ght coati ng of Mopar Hi gh Temp
Grease to the torque converter hub pocket i n the rear
pocket of the engi nes crankshaft.
(11) Rai se transmi ssi on and al i gn the torque con-
verter wi th the dri ve pl ate and the transmi ssi on con-
verter housi ng wi th the engi ne bl ock.
(12) Move transmi ssi on forward. Then rai se, l ower,
or ti l t transmi ssi on to al i gn the converter housi ng
wi th the engi ne bl ock dowel s.
(13) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft. Veri fy that no wi res, or the transmi ssi on
vent hose, have become trapped between the engi ne
bl ock and the transmi ssi on.
(14) I nstal l two bol ts to attach the transmi ssi on to
the engi ne.
(15) I nstal l remai ni ng torque converter housi ng to
engi ne bol ts. Ti ghten to 68 Nm (50 ft.l bs.).
(16) I nstal l rear transmi ssi on crossmember.
Ti ghten crossmember to frame bol ts to 68 Nm (50
ft.l bs.).
(17) I nstal l rear support to transmi ssi on. Ti ghten
bol ts to 47 Nm (35 ft.l bs.).
(18) Lower transmi ssi on onto crossmember and
i nstal l bol ts attachi ng transmi ssi on mount to cross-
member. Ti ghten cl evi s bracket to crossmember bol ts
to 47 Nm (35 ft.l bs.). Ti ghten the cl evi s bracket to
rear support bol t to 68 Nm (50 ft.l bs.).
(19) Remove engi ne support fi xture.
(20) I nstal l new pl asti c retai ner grommet on any
shi ft cabl e that was di sconnected. Grommets shoul d
not be reused. Use pry tool to remove rod from grom-
met and cut away ol d grommet. Use pl i ers to snap
new grommet i nto cabl e and to snap grommet onto
l ever.
(21) Connect gearshi ft cabl e to transmi ssi on.
(22) Connect wi res to sol enoi d and pressure swi tch
assembl y connector, i nput and output speed sensors,
and l i ne pressure sensor. Be sure transmi ssi on har-
nesses are properl y routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(23) I nstal l al l torque converter-to-dri vepl ate bol ts
by hand.
(24) Veri fy that the torque converter i s pul l ed
fl ush to the dri vepl ate. Ti ghten bol ts to 31 Nm (270
i n. l bs.).
(25) I nstal l starter motor and cool er l i ne bracket.
(26) Connect cool er l i nes to transmi ssi on.
(27) I nstal l transmi ssi on fi l l tube.
(28) I nstal l exhaust components.
(29) I nstal l transfer case. Ti ghten transfer case
nuts to 35 Nm (26 ft.l bs.).
cabl e support bracket and the transfer case shi ft
l ever.
(31) I nstal l the transmi ssi on col l ar onto the trans-
mi ssi on and the engi ne. Ti ghten the bol ts to 54 Nm
(40 ft.l bs.).
(32) Al i gn and connect propel l er shaft(s).
(33) Adjust gearshi ft cabl e i f necessary.
(35) Fi l l transmi ssi on wi th Mopar ATF +4, type
9602, Automati c Transmi ssi on fl ui d.
Fig. 52 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
HYDRAULIC SCHEMATICS
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SPECIFICATIONS
TRANSMISSION
GENERAL
Output Shaft End Play 0.22-0.55
mm
0.009-0.021
in.
Input Shaft End Play 0.46-0.89
mm
0.018-0.035
in.
2C Clutch Pack
Clearance
0.455-1.335
mm
0.018-0.053
in.
4C Clutch Pack
Clearance
0.770-1.390
mm
0.030-0.055
in.
L/R Clutch Pack
Clearance
1.00-1.74
mm
0.039-0.069
in.
OD Clutch Pack
Clearance
1.103-1.856
mm
0.043-0.073
in.
UD Clutch Pack
Clearance
0.84-1.54
mm
0.033-0.061
in.
Reverse Clutch Pack
Clearance
0.81-1.24
mm
0.032-0.049
in.
Recommended fluid Mopar ATF +4, type 9602
GEAR RATIOS
1ST 3.00:1
2ND 1.67:1
2ND Prime 1.50:1
3RD 1.0:1
4TH 0.75:1
5TH 0.67:1
REVERSE 3.00:1
Fitting, cooler line at trans 17.5 - 155
Bolt, torque convertor 31 23 -
Bolt/nut, crossmember 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Bolt, oil pan 11.8 - 105
Screw, primary fluid filter 4.5 - 40
Bolt, oil pump 28.2 - 250
Bolt, oil pump body to cover 4.5 - 40
Screw, plate to oil pump body 4.5 - 40
Bolt, valve body to case 11.8 - 105
Plug, pressure test port 5.1 - 45
Bolt, reaction shaft support 11.8 - 105
Screw, valve body to transfer plate 5.6 - 50
Screw, solenoid module to transfer plate 5.7 - 50
Screw, accumulator cover 4.5 - 40
Screw, detent spring 4.5 - 40
Bolt, input speed sensor 11.8 - 105
Bolt, output speed sensor 11.8 - 105
Bolt, line pressure sensor 11.8 - 105
Bolt, extension housing 54 40 -
Valve, cooler return filter bypass 4.5 - 40
Screw, manual valve cam retaining 4.5 - 40
Bolt, manual lever 28.2 - 250
SPECIAL TOOLS
RFE TRANSMISSION
Gauge, Oil Pressure - C-3292
Gauge, Oil Pressure - C-3293SP
Dial Indicator - C-3339
Flusher, Oil Cooler - 6906-C
Compressor, Spring - 8249
Installer, Seal - 8253
Installer, Snap-ring - 8255
Stand, Support - 8257
Adapter, Pressure Tap - 8258-A
Adapter, Line Pressure - 8259
Fixture, Input Clutch Pressure - 8260
Plate, Alignment - 8261
End Play Set - 8266
Installer, Bearing - 8320
Wrench, Filter - 8321
4C RETAINER/BULKHEAD
DISASSEMBLY
(1) Remove the 2C pi ston bel l evi l l e spri ng snap-
ri ng from the 4C retai ner /bul khead (Fi g. 53).
(2) Remove the 2C pi ston Bel l evi l l e spri ng from
the retai ner/bul khead (Fi g. 53).
(3) Remove the 2C pi ston from the retai ner/bul k-
head. Use 20 psi of ai r pressure to remove the pi ston
i f necessary.
(4) Remove the 4C cl utch snap-ri ng from the
retai ner/bul khead (Fi g. 53).
(5) Remove the 4C cl utch pack from the retai ner/
bul khead (Fi g. 53).
(6) Usi ng Spri ng Compressor 8250 and a sui tabl e
shop press, compress the 4C pi ston return spri ng and
remove the snap-ri ng (Fi g. 53).
(7) Remove the 4C pi ston return spri ng and pi ston
from the retai ner/bul khead (Fi g. 53). Use 20 psi of
ai r pressure to remove the pi ston i f necessary.
ASSEMBLY
or scori ng.
(2) I nstal l new seal s on the 2C and 4C pi stons
(Fi g. 53).
(3) Lubri cate al l seal s wi th Mopar ATF +4, type
9602 pri or to i nstal l ati on.
(4) I nstal l the 4C pi ston i nto the 4C retai ner/bul k-
head (Fi g. 53).
(5) Posi ti on the 4C pi ston return spri ng onto the
4C pi ston.
Fig. 53 4C Retainer/Bulkhead Components
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
shop press, compress the 4C pi ston return spri ng and
i nstal l the snap-ri ng (Fi g. 54).
(7) Assembl e and i nstal l the 4C cl utch pack i nto
the retai ner/bul khead (Fi g. 53) wi th the steel separa-
tor pl ate agai nst the pi ston.
(8) I nstal l the 4C reacti on pl ate and snap-ri ng i nto
the retai ner/bul khead (Fi g. 53). The 4C reacti on pl ate
i s non-di recti onal .
(9) Measure the 4C cl utch cl earance. The correct
cl utch cl earance i s 0.77-1.39 mm (0.030-0.055 i n.).
The snap-ri ng i s sel ectabl e. I nstal l the chosen snap-
ri ng and re-measure to veri fy the sel ecti on.
(10) I nstal l the 2C pi ston i nto the retai ner/bul k-
head (Fi g. 53).
(11) Posi ti on the 2C Bel l evi l l e spri ng onto the 2C
pi ston.
(12) Posi ti on the 2C Bel l evi l l e spri ng snap-ri ng
onto the 2C Bel l evi l l e spri ng (Fi g. 53).
shop press (Fi g. 55), compress the bel l evi l l e spri ng
unti l the snap-ri ng i s engaged wi th the snap-ri ng
groove i n the retai ner/bul khead.
ADAPTER HOUSING SEAL
REMOVAL
(1) Remove the transfer case from the transmi s-
si on.
(2) Usi ng a screw mounted on a sl i de hammer,
remove the adapter housi ng seal .
INSTALLATION
(1) Cl ean the adapter seal bore i n the adapter
housi ng of any resi due or parti cl es remai ni ng from
the ori gi nal seal .
(2) I nstal l new oi l seal i n the adapter housi ng
usi ng Seal I nstal l er C-3860-A (Fi g. 56). A properl y
i nstal l ed seal i s fl ush to the face of the seal bore.
(3) I nstal l the transfer case onto the transmi ssi on.
Fig. 54 Compress 4C Piston Return Spring Using
Tool 8250
1 - PRESS
2 - TOOL 8250
Fig. 55 Compress 2C Belleville Spring Using Tool
8249
1 - PRESS
2 - TOOL 8249
Fig. 56 Adapter Housing Seal Installation
1 - TOOL C-3860-A
4C RETAINER/BULKHEAD (Continued)
BRAKE TRANSMISSION SHIFT
INTERLOCK MECHANISM
DESCRIPTION
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 57).
OPERATION
The system l ocks the shi fter i nto the PARK posi -
ti on. The i nterl ock system i s engaged whenever the
i gni ti on swi tch i s i n the LOCK or ACCESSORY posi -
ti on. An addi ti onal el ectri cal l y acti vated feature wi l l
prevent shi fti ng out of the PARK posi ti on unl ess the
brake pedal i s depressed approxi matel y one-hal f an
i nch. A magneti c hol di ng devi ce i n the shi fter assem-
bl y i s energi zed when the i gni ti on i s i n the RUN
posi ti on. When the key i s i n the RUN posi ti on and
the brake pedal i s depressed, the shi fter i s unl ocked
and wi l l move i nto any posi ti on. The i nterl ock system
al so prevents the i gni ti on swi tch from bei ng turned
to the LOCK or ACCESSORY posi ti on, unl ess the
shi fter i s ful l y l ocked i nto the PARK posi ti on.
TRANSMISSION SHIFT INTERLOCK
(1) Veri fy that the key can onl y be removed i n the
PARK posi ti on
(2) When the shi ft l ever i s i n PARK And the shi ft
handl e pushbutton i s i n the OUT posi ti on, the i gni -
ti on key cyl i nder shoul d rotate freel y from OFF to
LOCK. When the shi fter i s i n any other gear or neu-
tral posi ti on, the i gni ti on key cyl i nder shoul d not
rotate to the LOCK posi ti on.
when the i gni ti on key cyl i nder i s i n the OFF posi -
ti on.
whi l e appl yi ng normal pushbutton force and i gni ti on
key cyl i nder i s i n the RUN or START posi ti ons
when the i gni ti on key cyl i nder i s i n the ACCESSORY
or LOCK posi ti ons.
(6) Shi fti ng between any gears, NEUTRAL or i nto
PARK may be done wi thout depressi ng foot brake
pedal wi th i gni ti on swi tch i n RUN or START posi -
ti ons.
Fig. 57 Ignition Interlock Cable
3 - ADJUSTMENT CLIP
SHIFT INTERLOCK
The park i nterl ock cabl e i s part of the brake/shi ft
l ever i nterl ock system. Correct cabl e adjustment i s
i mportant to proper i nterl ock operati on. The gear
shi ft and park l ock cabl es must both be correctl y
adjusted i n order to shi ft out of PARK.
the brake transmi ssi on shi ft i nterl ock cabl e. (Refer to
REMOVAL)
(2) Shi ft the transmi ssi on i nto the PARK posi ti on.
(3) Turn i gni ti on swi tch to LOCK posi ti on. Be
sure ignition key cylinder is in the LOCK posi-
tion. Cable will not adjust correctly in any
other position.
(4) Pul l cabl e l ock button up to rel ease cabl e (Fi g.
58).
(5) Ensure that the cabl e i s free to sel f-adjust by
pushi ng cabl e rearward and rel easi ng.
(6) Push l ock button down unti l i t snaps i n pl ace.
BTSI FUNCTION CHECK
(1) Veri fy removal of i gni ti on key al l owed i n PARK
posi ti on onl y.
(2) When the shi ft l ever i s i n PARK, and the shi ft
handl e push-button i s i n the out posi ti on, the i gni -
ti on key cyl i nder shoul d rotate freel y from off to l ock.
When the shi fter i s i n any other posi ti on, the i gni ti on
key shoul d not rotate from off to l ock.
(3) Shi fti ng out of PARK shoul d be possi bl e when
the i gni ti on key cyl i nder i s i n the off posi ti on.
whi l e appl yi ng normal push-button force, and i gni -
ti on key cyl i nder i s i n the run or start posi ti ons,
when the i gni ti on key cyl i nder i s i n the accessory or
l ock posi ti on.
(6) Shi fti ng between any gear and NEUTRAL, or
PARK, may be done wi thout depressi ng foot brake
wi th i gni ti on swi tch i n run or start posi ti ons.
shoul d be i n al i gnment wi th al l transmi ssi on detent
posi ti ons.
Fig. 58 Brake Transmission Shift Interlock Cable
3 - ADJUSTMENT CLIP
(8) Engi ne starts must be possi bl e wi th shi fter
Engi ne starts must not be possi bl e i n any other gate
posi ti ons other than PARK or NEUTRAL.
(9) Wi th shi fter l ever handl e push-button not
depressed and l ever detent i n:
PARK posi ti on- appl y forward force on center of
handl e and remove pressure. Engi ne start must be
possi bl e.
PARK posi ti on- appl y rearward force on center
of handl e and remove pressure. Engi ne start must be
possi bl e.
NEUTRAL posi ti on- engi ne start must be possi -
bl e.
NEUTRAL posi ti on, engi ne runni ng and brakes
appl i ed- Appl y forward force on center of shi ft han-
dl e. Transmi ssi on shoul d not be abl e to shi ft i nto
REVERSE detent.
FLUID AND FILTER
INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve and cl utch operati on. Foami ng al so causes fl ui d
expansi on whi ch can resul t i n fl ui d overfl ow from the
transmi ssi on vent or fi l l tube. Fl ui d overfl ow can eas-
i l y be mi staken for a l eak i f i nspecti on i s not careful .
BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has three pri mary causes.
(1) I nternal cl utch sl i ppage, usual l y caused by l ow
l i ne pressure, i nadequate cl utch appl y pressure, or
cl utch seal fai l ure.
(2) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(3) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to reverse fl ush cool er and l i nes after
repai r
fai l ure to repl ace contami nated converter after
repai r
The use of non-recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on, an overhaul i s necessary.
The transmi ssi on cool er and l i nes shoul d be
reverse fl ushed whenever a mal functi on generates
sl udge and/or debri s. The torque converter shoul d
al so be repl aced at the same ti me.
Fai l ure to fl ush the cool er and l i nes wi l l resul t i n
recontami nati on. Fl ushi ng appl i es to auxi l i ary cool -
ers as wel l . The torque converter shoul d al so be
repl aced whenever a fai l ure generates sl udge and
debri s. Thi s i s necessary because normal converter
fl ushi ng procedures wi l l not remove al l contami -
nants.
STANDARD PROCEDURE
CHECK
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th
the fl ui d. As i n any hydraul i c system, ai r bubbl es
make the fl ui d spongy, therefore, pressures wi l l be
l ow and bui l d up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transmssi on has too much fl ui d, the
geartrai n churns up foam and cause the same condi -
ti ons whi ch occur wi th a l ow fl ui d l evel .
I n ei ther case, ai r bubbl es can cause overheati ng
and/or fl ui d oxi dati on, and varni shi ng. Thi s can i nter-
fere wi th normal val ve, cl utch, and accumul ator opera-
ti on. Foami ng can al so resul t i n fl ui d escapi ng from the
transmi ssi on vent where i t may be mi staken for a l eak.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
The transmi ssi on has a di psti ck to check oi l l evel .
I t i s l ocated on the ri ght si de of the engi ne. Be sure
to wi pe al l di rt from di psti ck handl e before removi ng.
The torque converter fi l l s i n both the P (PARK)
and N (NEUTRAL) posi ti ons. Pl ace the sel ector l ever
i n P (PARK) to be sure that the fl ui d l evel check i s
accurate. The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground. At normal operati ng temperature
(approxi matel y 82 C. or 180 F.), the fl ui d l evel i s cor-
rect i f i t i s i n the HOT regi on (cross-hatched area) on
the oi l l evel i ndi cator. The fl ui d l evel wi l l be approx-
i matel y at the upper COLD hol e of the di psti ck at
70 F fl ui d temperature.
NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.
(1) Start engi ne and appl y parki ng brake.
(2) Shi ft the transmi ssi on i nto DRI VE for approxi -
matel y 2 seconds.
(3) Shi ft the transmi ssi on i nto REVERSE for
approxi matel y 2 seconds.
(4) Shi ft the transmi ssi on i nto PARK.
(5) Hook up DRB scan tool and sel ect transmi ssi on.
(6) Sel ect sensors.
(7) Read the transmi ssi on temperature val ue.
(8) Compare the fl ui d temperature val ue wi th the
chart. (Fi g. 59)
(9) Adjust transmi ssi on fl ui d l evel shown on the
di psti ck accordi ng to the chart.
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmi ssi on for l eaks.
Fig. 59 Transmission Fluid Temperature Chart
STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper servi ce i nterval s (Refer to LUBRI CA-
TI ON & MAI NTENANCE/MAI NTENANCE SCHED-
ULES - DESCRI PTI ON).
REMOVAL
(2) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(3) Remove bol ts hol di ng front and si des of pan to
transmi ssi on.
(4) Loosen bol ts hol di ng rear of pan to transmi ssi on.
(5) Sl owl y separate front of pan away from trans-
mi ssi on al l owi ng the fl ui d to drai n i nto drai n pan.
(6) Hol d up pan and remove remai ni ng bol ts hol d-
i ng pan to transmi ssi on.
(7) Whi l e hol di ng pan l evel , l ower pan away from
transmi ssi on.
(8) Pour remai ni ng fl ui d i n pan i nto drai n pan.
(9) Remove screw hol di ng fi l ter to val ve body (Fi g. 60).
(10) Separate fi l ter from val ve body and oi l pump
and pour fl ui d i n fi l ter i nto drai n pan.
(11) Remove and di scard the oi l fi l ter seal from the
bottom of the oi l pump.
(12) I f repl aci ng the cool er return fi l ter, use Oi l
Fi l ter Wrench 8321 to remove the fi l ter from the
transmi ssi on.
(13) Di spose of used trans fl ui d and fi l ter(s) prop-
erl y.
INSPECTION
I nspect bottom of pan and magnet for excessi ve
amounts of metal . A l i ght coati ng of cl utch materi al
on the bottom of the pan does not i ndi cate a probl em
unl ess accompani ed by a sl i ppi ng condi ti on or shi ft
l ag. I f fl ui d and pan are contami nated wi th excessi ve
amounts of debri s, refer to the di agnosi s secti on of
thi s group.
CLEANING
(1) Usi ng a sui tabl e sol vent, cl ean pan and mag-
net.
(2) Usi ng a sui tabl e gasket scraper, cl ean ori gi nal
seal i ng materi al from surface of transmi ssi on case
and the transmi ssi on pan.
INSTALLATION
(2) Pl ace repl acement fi l ter i n posi ti on on val ve
body and i nto the oi l pump.
(3) I nstal l screw to hol d fi l ter to val ve body (Fi g.
60). Ti ghten screw to 4.5 Nm (40 i n. l bs.) torque.
(4) I nstal l new cool er return fi l ter onto the trans-
mi ssi on, i f necessary. Torque the fi l ter to 14.12 Nm
(125 i n.l bs.).
(5) Pl ace bead of Mopar RTV seal ant onto the
transmi ssi on case seal i ng surface.
(6) Pl ace pan i n posi ti on on transmi ssi on.
(7) I nstal l bol ts to hol d pan to transmi ssi on.
Ti ghten bol ts to 11.8 Nm (105 i n. l bs.) torque.
Mopar ATF +4, type 9602 fl ui d.
FILL
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar ATF
+4 to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 10
pints (5 quarts) of ATF +4 to transmi ssi on.
(b) I f transmi ssi on was compl etel y overhaul ed,
torque converter was repl aced or drai ned, and
cool er was fl ushed, add 24 pints (12 quarts) of
ATF +4 to transmi ssi on.
(3) Check the transmi ssi on fl ui d (Refer to 21 -
TRANSMI SSI ON/TRANSAXLE/AUTOMATI C -
45RFE/FLUI D - STANDARD PROCEDURE) and
adjust as requi red.
Fig. 60 Transmission Filters - 4X4 Shown
4 - VALVE BODY
GEARSHIFT CABLE
CABLE
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti on - Appl y forward force on cen-
must be possi bl e.
(b) PARK posi ti on - Appl y rearward force on cen-
must be possi bl e.
(c) NEUTRAL posi ti on - Normal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti on - Engi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from NEUTRAL to REVERSE.
REMOVAL
(3) Remove the shi ft cabl e eyel et from the trans-
mi ssi on manual shi ft l ever (Fi g. 61).
bracket.
(6) Remove necessary consol e parts for access to
BODY/I NTERI OR/FLOOR CONSOLE - REMOVAL)
(10) Remove shi ft cabl e from vehi cl e.
INSTALLATION
Fig. 61 Remove Shift Cable From Transmission
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
Fig. 62 Transmission Shift Cable at Shifter
1 - SHIFT LEVER PIN
3 - SHIFT CABLE
1 - SEAL PLATES
(3) I nstal l nuts to hol d seal pl ate to fl oor pan.
Ti ghten nuts to 7 Nm (65 i n.l bs.).
bracket.
(10) Shi ft the transmi ssi on i nto PARK. PARK i s
the rearmost detent posi ti on on the transmi ssi on
(11) Snap the shi ft cabl e onto the transmi ssi on
ti on.
i n.l bs.).
(15) Veri fy correct shi fter operati on.
TI ON)
ADJUSTMENTS - GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n PARK
and NEUTRAL. Adjustment i s CORRECT i f the
engi ne starts onl y i n these posi ti ons. Adjustment i s
I NCORRECT i f the engi ne starts i n one but not both
posi ti ons. I f the engi ne starts i n any posi ti on other
than PARK or NEUTRAL, or i f the engi ne wi l l not
start at al l , the park/neutral posi ti on swi tch or TRS
may be faul ty.
the shi ft cabl e adjustment. (Refer to 23 - BODY/I N-
TERI OR/FLOOR CONSOLE - REMOVAL)
(3) Loosen the shi ft cabl e adjustment screw (Fi g.
64).
(5) Unsnap cabl e eyel et from transmi ssi on shi ft
l ever (Fi g. 65).
(6) Veri fy transmi ssi on shi ft l ever i s i n PARK
detent by movi ng l ever ful l y rearward. Last rearward
detent i s PARK posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Snap cabl e eyel et onto transmi ssi on shi ft l ever.
(9) Lower vehi cl e
(10) Ti ghten the shi ft cabl e adjustment screw to 7
Nm (65 i n.l bs.).
(11) Veri fy correct operati on.
(12) I nstal l any fl oor consol e components removed
for access. (Refer to 23 - BODY/I NTERI OR/FLOOR
CONSOLE - I NSTALLATI ON)
Fig. 64 Shift Cable at the Shifter
1 - SHIFT LEVER PIN
3 - SHIFT CABLE
Fig. 65 Shift Cable at Transmission
BOLT(S)
HOLDING CLUTCHES
DESCRIPTION
Three hydraul i cal l y appl i ed mul ti -di sc cl utches are
used to hol d some pl anetary geartrai n components
stati onary whi l e the i nput cl utches dri ve others. The
2C, 4C, and Low/Reverse cl utches are consi dered
hol di ng cl utches. The 2C and 4C cl utches are l ocated
i n the 4C retai ner/bul khead (Fi g. 66), whi l e the Low/
Reverse cl utch i s l ocated at the rear of the transmi s-
Fig. 66 2C and 4C Clutches
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
OPERATION
2C CLUTCH
The 2C cl utch i s hydraul i cal l y appl i ed i n second
and fi fth gear by pressuri zed fl ui d agai nst the 2C
pi ston. When the 2C cl utch i s appl i ed, the reverse
sun gear assembl y i s hel d or grounded to the trans-
mi ssi on case by hol di ng the reacti on pl anetary car-
ri er.
4C CLUTCH
The 4C cl utch i s hydraul i cal l y appl i ed i n second
pri me and fourth gear by pressuri zed fl ui d agai nst
the 4C cl utch pi ston. When the 4C cl utch i s appl i ed,
the reacti on annul us gear i s hel d or grounded to the
LOW/REVERSE CLUTCH
The Low/Reverse cl utch i s hydraul i cal l y appl i ed i n
park, reverse, neutral , and fi rst gear, onl y at l ow
speeds, by pressuri zed fl ui d agai nst the Low/Reverse
cl utch pi ston. When the Low/Reverse cl utch i s
appl i ed, the i nput annul us assembl y i s hel d or
grounded to the transmi ssi on case.
Fig. 67 Low/Reverse Clutch
1 - SNAP-RING (SELECT) 8 - SEAL
2 - REACTION PLATE 9 - BELLEVILLE SPRING
3 - DISC 10 - RETAINER
4 - PLATE 11 - SNAP-RING
5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH
6 - SEAL 13 - SNAP-RING
7 - PISTON
HOLDING CLUTCHES (Continued)
INPUT CLUTCH ASSEMBLY
DESCRIPTION
Three hydraul i cal l y appl i ed i nput cl utches are used
to dri ve pl anetary components. The underdri ve, over-
dri ve, and reverse cl utches are consi dered i nput
cl utches and are contai ned wi thi n the i nput cl utch
assembl y (Fi g. 68) and (Fi g. 69). The i nput cl utch
assembl y al so contai ns:
I nput shaft
I nput hub
Cl utch retai ner
Underdri ve pi ston
Overdri ve/reverse pi ston
Overdri ve hub
Underdri ve hub
OPERATION
The three i nput cl utches are responsi bl e for dri vi ng
di fferent components of the pl anetary geartrai n.
UNDERDRIVE CLUTCH
The underdri ve cl utch i s hydraul i cal l y appl i ed i n
fi rst, second, second pri me, and thi rd (di rect) gears
by pressuri zed fl ui d agai nst the underdri ve pi ston.
Fig. 68 Input Clutch Assembly - Part 1
1 - INPUT CLUTCH HUB 11 - UD CLUTCH
2 - O-RING SEALS 12 - PLATE
3 - SEAL 13 - CLUTCH RETAINER
4 - SNAP-RING 14 - SEAL
5 - SNAP-RING 15 - OD/REV PISTON
6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING
7 - SNAP-RING 17 - SNAP-RING
8 - UD PISTON 18 - SEAL RINGS
9 - SPRING 19 - INPUT SHAFT
10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING
When the underdri ve cl utch i s appl i ed, the under-
dri ve hub dri ves the i nput sun gear.
OVERDRIVE CLUTCH
The overdri ve cl utch i s hydraul i cal l y appl i ed i n
thi rd (di rect), fourth, and fi fth gears by pressuri zed
fl ui d agai nst the overdri ve/reverse pi ston. When the
overdri ve cl utch i s appl i ed, the overdri ve hub dri ves
the reverse carri er/i nput annul us assembl y.
REVERSE CLUTCH
The reverse cl utch i s hydraul i cal l y appl i ed i n
reverse gear by pressuri zed fl ui d agai nst the over-
dri ve/reverse pi ston. When the reverse cl utch i s
appl i ed, the reacti on annul us gear i s dri ven.
1 - BEARING NUMBER 3 10 - SNAP-RING (SELECT)
2 - OD HUB/SHAFT 11 - PLATE
3 - SNAP-RING (WAVE) 12 - DISC
4 - REV/OD REACTION PLATE 13 - OD CLUTCH
5 - BEARING NUMBER 4 14 - SNAP-RING (TAPERED)
6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE
7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)
8 - REVERSE CLUTCH 17 - UD HUB/SHAFT
9 - REVERSE REACTION PLATE 18 - BEARING NUMBER 2
INPUT CLUTCH ASSEMBLY (Continued)
DISASSEMBLY
(1) Remove the reverse reacti on pl ate sel ecti ve
snap-ri ng from the i nput cl utch retai ner (Fi g. 70).
(2) Remove the reverse reacti on pl ate from the
i nput cl utch retai ner.
(3) Remove the reverse hub and reverse cl utch
pack from the i nput cl utch retai ner.
(4) Remove the number 4 beari ng from the over-
dri ve hub.
(5) Remove the overdri ve hub from the i nput
cl utch retai ner (Fi g. 70).
(6) Remove the number 3 beari ng from the under-
dri ve hub.
(7) Remove the OD/reverse reacti on pl ate snap-
ri ng from the i nput cl utch retai ner.
(8) Remove the underdri ve hub, overdri ve cl utch,
and overdri ve reacti on pl ate from the i nput cl utch
retai ner (Fi g. 70).
NOTE: The overdrive friction discs and steel discs
are thicker than the matching components in the
underdrive and reverse clutches.
cl utch hub.
(10) Remove the overdri ve cl utch wave snap-ri ng
from the i nput cl utch retai ner.
(11) Remove the UD/OD reacti on pl ate tapered
snap-ri ng from the i nput cl utch retai ner.
(12) Remove the UD/OD reacti on pl ate from the
(13) Remove the UD/OD reacti on pl ate fl at snap-
ri ng from the i nput cl utch retai ner (Fi g. 70).
(14) Remove the underdri ve cl utch pack from the
i nput cl utch retai ner (Fi g. 72).
(15) Usi ng Spri ng Compressor 8251, compress the
UD/OD bal ance pi ston and remove the snap-ri ng
from the i nput cl utch hub (Fi g. 71).
(16) Remove the UD/OD bal ance pi ston and pi ston
return spri ng from the i nput cl utch retai ner (Fi g. 72).
(17) Remove the underdri ve pi ston from the i nput
NOTE: Both the UD/OD balance piston and the
underdrive piston have seals molded onto them. If
the seal is damaged, do not attempt to install a new
seal onto the piston. The piston/seal must be
replaced as an assembly.
(18) Remove the i nput cl utch retai ner tapered
snap-ri ng.
(19) Separate i nput cl utch retai ner from i nput
cl utch hub.
(20) Separate OD/reverse pi ston from i nput cl utch
hub retai ner (Fi g. 72).
(21) Remove al l seal s and o-ri ngs from the i nput
shaft and i nput hub. The o-ri ngs on the i nput hub
are col or coded. Be sure to make note of whi ch o-ri ng
bel ongs i n whi ch l ocati on.
ASSEMBLY
(1) I nstal l al l new seal s and o-ri ngs onto the i nput
shaft and i nput hub. The o-ri ngs on the i nput hub
are col or coded. Be sure to i nstal l the correct o-ri ng
i n the correct l ocati on.
(2) Check the transmi ssi on l ubri cati on check val ve
l ocated i n the i nput shaft usi ng shop ai r. The val ve
shoul d onl y al l ow ai r fl ow i n one di recti on. I f the
val ve al l ows no ai r fl ow, or ai r fl ow i n both di rec-
ti ons, the val ve wi l l need to be repl aced.
(3) Lubri cate al l seal s wi th Mopar ATF +4, type
9602, pri or to i nstal l ati on.
(4) Assembl e the OD/reverse pi ston onto the i nput
cl utch hub (Fi g. 73).
(5) Assembl e the i nput cl utch retai ner onto the
i nput cl utch hub.
(6) I nstal l the i nput cl utch retai ner tapered snap-
ri ng wi th tapered si de up onto the i nput cl utch hub.
Fig. 71 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
Fig. 73 Input Clutch Assembly - Part I
(7) I nstal l Pi ston Gui des 8504 i nto the i nput cl utch
retai ner (Fi g. 74) and onto the i nput cl utch hub to
gui de the i nner and outer underdri ve pi ston seal s
i nto posi ti on.
(8) I nstal l the underdri ve pi ston i nto the i nput
cl utch retai ner and over the i nput cl utch hub (Fi g.
73).
(9) I nstal l the UD/OD bal ance pi ston return spri ng
pack i nto the i nput cl utch retai ner.
(10) I nstal l Pi ston Gui de 8252 i nto the i nput
cl utch retai ner (Fi g. 75) to gui de the UD/OD bal ance
pi ston seal i nto posi ti on i nsi de the underdri ve pi ston.
(11) I nstal l the UD/OD bal ance pi ston i nto the
i nput cl utch retai ner and the underdri ve pi ston.
(12) Usi ng Spri ng Compressor 8251, compress the
UD/OD return spri ng pack and secure the pi ston i n
pl ace wi th the snap-ri ng (Fi g. 76).
Fig. 74 Install Underdrive Piston Using Tool 8504
1 - TOOL 8504
Fig. 75 Install Balance Piston Using Tool 8252
1 - TOOL 8252
Fig. 76 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
(13) I nstal l the underdri ve cl utch pack i nto the
i nput cl utch retai ner (Fi g. 73).
(14) I nstal l the UD/OD reacti on pl ate l ower fl at
snap-ri ng (Fi g. 77). The correct snap-ri ng can be
i denti fi ed by the two tabbed ears.
Fig. 77 Input Clutch Assembly - Part II
(15) I nstal l the UD/OD reacti on pl ate i nto the
i nput cl utch retai ner. The reacti on pl ate i s to be
i nstal l ed wi th the bi g step down.
(16) I nstal l the UD/OD reacti on pl ate upper
tapered snap-ri ng wi th tapered si de up.
(17) I nstal l the i nput cl utch assembl y i nto I nput
Cl utch Pressure Fi xture 8260 (Fi g. 78). Mount a di al
i ndi cator to the assembl y, push down on the cl utch
di scs and zero the i ndi cator agai nst the underdri ve
cl utch di scs (Fi g. 79). Appl y 20 psi of ai r pressure to
the underdri ve cl utch and record the di al i ndi cator
readi ng. Measure and record UD cl utch pack mea-
surement i n four (4) pl aces, 90 apart. Take average
of four measurements and compare wi th UD cl utch
pack cl earance speci fi cati on. The correct cl utch cl ear-
ance i s 0.84-1.54 mm (0.033-0.061 i n.). The reacti on
pl ate i s not sel ecti ve. I f the cl utch cl earance i s not
wi thi n speci fi cati on, repl ace the reacti on pl ate al ong
wi th al l the fri cti on and steel di scs.
(18) I nstal l the overdri ve cl utch pack i nto the
i nput cl utch retai ner (Fi g. 77). The overdri ve steel
separator pl ates can be i denti fi ed by the l ack of the
hal f-moon cuts i n the l ocati ng tabs.
(19) I nstal l the overdri ve cl utch wavy snap-ri ng
wi th the two tabbed ears i nto the i nput cl utch
retai ner.
(20) I nstal l the OD/reverse reacti on pl ate i nto the
i nput cl utch retai ner. The reacti on pl ate i s non-di rec-
ti onal (Fi g. 77).
(21) I nstal l the OD/reverse reacti on pl ate fl at
snap-ri ng i nto the i nput cl utch retai ner.
(22) Mount a di al i ndi cator to the assembl y and
zero the i ndi cator agai nst the OD/reverse reacti on
pl ate (Fi g. 80). Appl y 20 psi of ai r pressure to the
overdri ve cl utch and record the di al i ndi cator read-
i ng. Measure and record OD cl utch pack measure-
ment i n four (4) pl aces, 90 apart. Take average of
four measurements and compare wi th OD cl utch
pack cl earance speci fi cati on.Veri fy that the cl utch
cl earance i s 1.103-1.856 mm (0.043-0.073 i n.). The
reacti on pl ate i s not sel ecti ve. I f the cl utch cl earance
i s not wi thi n speci fi cati on, repl ace the reacti on pl ate
al ong wi th al l the fri cti on and steel di scs.
Fig. 78 Input Clutch Assembly Mounted on Tool
8260
2 - TOOL 8260
Fig. 79 Measuring UD Clutch Clearance
1 - TOOL C-3339
2 - UNDERDRIVE CLUTCH PACK
Fig. 80 Measuring OD Clutch Clearance
1 - TOOL C-3339
2 - OD/REV REACTION PLATE
(23) I nstal l the reverse cl utch pack i nto the i nput
(24) I nstal l the reverse reacti on pl ate i nto the
(25) I nstal l the reverse reacti on pl ate sel ecti ve
snap-ri ng i nto the i nput cl utch retai ner.
(26) Mount a di al i ndi cator to the assembl y, push
down on the cl utch di scs, pul l up on the reacti on
pl ate to ensure the pl ate i s properl y seated and zero
the i ndi cator agai nst the reverse cl utch di scs (Fi g.
81). Appl y 20 psi of ai r pressure to the reverse cl utch
and record the di al i ndi cator readi ng. Measure and
record Reverse cl utch pack measurement i n four (4)
pl aces, 90 apart. Take average of four measurements
and compare wi th Reverse cl utch pack cl earance
speci fi cati on. The correct cl utch cl earance i s 0.58-1.47
mm (0.023-0.058 i n.). Adjust as necessary. I nstal l the
chosen snap-ri ng and re-measure to veri fy sel ecti on.
(27) Remove the reverse cl utch pack from the
(28) I nstal l the number 2 beari ng onto the under-
dri ve hub wi th outer race agai nst the hub wi th petro-
l eum jel l y.
(29) I nstal l the underdri ve hub i nto the i nput
cl utch retai ner.
(30) I nstal l the number 3 beari ng i nto the over-
dri ve hub wi th the outer race agai nst the hub wi th
petrol eum jel l y.
(31) I nstal l the overdri ve hub i nto the i nput cl utch
retai ner.
(32) I nstal l the number 4 beari ng i nto the reverse
hub wi th outer race agai nst the hub wi th petrol eum
jel l y.
(33) I nstal l the reverse hub i nto the i nput cl utch
retai ner.
(34) I nstal l the compl ete reverse cl utch pack.
(35) I nstal l the reverse reacti on pl ate and snap-
ri ng.
(36) Push up on reacti on pl ate to al l ow reverse
cl utch to move freel y.
INPUT SPEED SENSOR
DESCRIPTION
The I nput and Output Speed Sensors are two-wi re
magneti c pi ckup devi ces that generate AC si gnal s as
rotati on occurs. They are mounted i n the l eft si de of
the transmi ssi on case and are consi dered pri mary
i nputs to the Transmi ssi on Control Modul e (TCM).
OPERATION
The I nput Speed Sensor provi des i nformati on on
how fast the i nput shaft i s rotati ng. As the teeth of
the i nput cl utch hub pass by the sensor coi l , an AC
vol tage i s generated and sent to the TCM. The TCM
i nterprets thi s i nformati on as i nput shaft rpm.
The Output Speed Sensor generates an AC si gnal
i n a si mi l ar fashi on, though i ts coi l i s exci ted by rota-
ti on of the rear pl anetary carri er l ugs. The TCM
i nterprets thi s i nformati on as output shaft rpm.
The TCM compares the i nput and output speed
si gnal s to determi ne the fol l owi ng:
Transmi ssi on gear rati o
Speed rati o error detecti on
CVI cal cul ati on
The TCM al so compares the i nput speed si gnal and
the engi ne speed si gnal to determi ne the fol l owi ng:
Torque converter cl utch sl i ppage
Torque converter el ement speed rati o
REMOVAL
(2) Pl ace a sui tabl e fl ui d catch pan under the
transmi ssi on.
(3) Remove the wi ri ng connector from the i nput
speed sensor (Fi g. 82).
(4) Remove the bol t hol di ng the i nput speed sensor
to the transmi ssi on case.
(5) Remove the i nput speed sensor from the trans-
mi ssi on case.
INSTALLATION
(1) I nstal l the i nput speed sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the i nput speed sensor
i nto the transmi ssi on case. Ti ghten the bol t to 11.9
Nm (105 i n.l bs.).
Fig. 81 Measuring Reverse Clutch Clearance
1 - TOOL C-3339
2 - REVERSE CLUTCH PACK
(3) I nstal l the wi ri ng connector onto the i nput
speed sensor
(4) Veri fy the transmi ssi on fl ui d l evel . Add fl ui d as
necessary.
LINE PRESSURE (LP) SENSOR
DESCRIPTION
The TCM uti l i zes a cl osed-l oop system to control
transmi ssi on l i ne pressure. The system contai ns a
vari abl e force styl e sol enoi d, the Pressure Control
Sol enoi d, mounted on the si de of the sol enoi d and
pressure swi tch assembl y. The sol enoi d i s duty cycl e
control l ed by the TCM to vent the unnecessary l i ne
pressure suppl i ed by the oi l pump back to the sump.
The system al so contai ns a vari abl e pressure styl e
sensor, the Li ne Pressure Sensor, whi ch i s a di rect
i nput to the TCM. The l i ne pressure sol enoi d moni -
tors the transmi ssi on l i ne pressure and compl etes the
feedback l oop to the TCM. The TCM uses thi s i nfor-
mati on to adjust i ts control of the pressure control
sol enoi d to achi eve the desi red l i ne pressure.
OPERATION
The TCM cal cul ates the desi red l i ne pressure
based upon i nputs from the transmi ssi on and engi ne.
The TCM cal cul ates the torque i nput to the trans-
mi ssi on and uses that i nformati on as the pri mary
i nput to the cal cul ati on. The l i ne pressure i s set to a
predetermi ned val ue duri ng shi fts and when the
transmi ssi on i s i n the PARK and NEUTRAL posi -
ti ons. Thi s i s done to ensure consi stent shi ft qual i ty.
Duri ng al l other operati on, the actual l i ne pressure i s
compared to the desi red l i ne pressure and adjust-
ments are made to the pressure control sol enoi d duty
cycl e.
REMOVAL
transmi ssi on.
(3) Remove the wi ri ng connector from the l i ne
pressure sensor (Fi g. 83).
(4) Remove the bol t hol di ng the l i ne pressure sen-
sor to the transmi ssi on case.
(5) Remove the l i ne pressure sensor from the
INSTALLATION
(1) I nstal l the l i ne pressure sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the l i ne pressure sensor
Nm (105 i n.l bs.).
(3) I nstal l the wi ri ng connector onto the l i ne pres-
sure sensor
necessary.
Fig. 82 Input Speed Sensor
Fig. 83 Line Pressure Sensor
INPUT SPEED SENSOR (Continued)
LOW/REVERSE CLUTCH
DISASSEMBLY
(1) Remove the i nner overrunni ng cl utch snap-ri ng
from the l ow/reverse cl utch retai ner (Fi g. 84).
(2) Remove the outer l ow/reverse reacti on pl ate
fl at snap-ri ng (Fi g. 84).
(3) Remove the l ow/reverse cl utch and the over-
runni ng cl utch from the l ow/reverse cl utch retai ner
as an assembl y (Fi g. 84).
(4) Separate the l ow/reverse cl utch from the over-
runni ng cl utch.
(5) Remove the overrunni ng cl utch snap-ri ng (Fi g.
85).
(6) Remove the spacer from the overrunni ng cl utch
(Fi g. 85).
(7) Separate the i nner and outer races of the over-
runni ng cl utch (Fi g. 85).
(8) Remove the overrunni ng cl utch l ower snap-ri ng
(Fi g. 85).
shop press (Fi g. 86), compress the l ow/reverse pi ston
Bel l evi l l e spri ng and remove the spl i t retai ni ng ri ng
Fig. 84 Low/Reverse Clutch Assembly
1 - SNAP-RING (SELECT) 8 - SEAL
2 - REACTION PLATE 9 - BELLEVILLE SPRING
3 - DISC 10 - RETAINER
4 - PLATE 11 - SNAP-RING
5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH
6 - SEAL 13 - SNAP-RING
7 - PISTON
hol di ng the Bel l evi l l e spri ng i nto the l ow/reverse
cl utch retai ner.
(10) Remove the l ow/reverse cl utch Bel l evi l l e
spri ng and pi ston from the l ow/reverse cl utch
retai ner. Use 20 psi of ai r pressure to remove the pi s-
ton i f necessary.
CLEANING
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
and l ow-reverse cl utch retai ner. Dry them wi th com-
pressed ai r after cl eani ng.
INSPECTION
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse cl utch retai ner i f the
cl utch race, rol l er surface or i nsi de di ameter i s
scored, worn or damaged.
ASSEMBLY
(1) Check the bl eed ori fi ce to ensure that i t i s not
pl ugged or restri cted.
(2) I nstal l a new seal on the l ow/reverse pi ston.
Lubri cate the seal wi th Mopar ATF +4, type 9602,
pri or to i nstal l ati on.
(3) I nstal l the l ow/reverse pi ston i nto the l ow/re-
verse cl utch retai ner.
(4) Posi ti on the l ow/reverse pi ston Bel l evi l l e spri ng
on the l ow/reverse pi ston.
shop press (Fi g. 86), compress the l ow/reverse pi ston
Bel l evi l l e spri ng and i nstal l the spl i t retai ni ng ri ng
to hol d the Bel l evi l l e spri ng i nto the l ow/reverse
cl utch retai ner.
(6) I nstal l the l ower overrunni ng cl utch snap-ri ng
(Fi g. 85).
(7) Assembl e the i nner and outer races of the over-
runni ng cl utch (Fi g. 85).
(8) Posi ti on the overrunni ng cl utch spacer on the
overrunni ng cl utch.
(9) I nstal l the upper overrunni ng cl utch snap-ri ng
(Fi g. 85).
(10) Assembl e and i nstal l the l ow/reverse cl utch
pack i nto the l ow/reverse cl utch retai ner (Fi g. 84).
(11) I nstal l the l ow/reverse reacti on pl ate i nto the
l ow/reverse cl utch retai ner (Fi g. 84). The reacti on
pl ate i s di recti onal and must be i nstal l ed wi th the
fl at si de down.
(12) I nstal l the l ow/reverse cl utch pack snap-ri ng
(Fi g. 84). The snap-ri ng i s sel ectabl e and shoul d be
chosen to gi ve the correct cl utch pack cl earance.
(13) Measure the l ow/reverse cl utch pack cl earance
and adjust as necessary. The correct cl utch cl earance
i s 1.00-1.74 mm (0.039-0.075 i n.).
(14) I nstal l the overrunni ng cl utch i nto the l ow/re-
verse cl utch retai ner maki ng sure that the i ndex
spl i nes are al i gned wi th the retai ner.
(15) I nstal l the overrunni ng cl utch i nner snap-
ri ng.
1 - SNAP-RING
2 - OUTER RACE
4 - SPACER
Fig. 86 Compress Low/Reverse Belleville Spring
Using Tool 8285
1 - PRESS
2 - TOOL 8285
3 - BELLEVILLE SPRING
LOW/REVERSE CLUTCH (Continued)
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 87) i s l ocated at the front of the
transmi ssi on i nsi de the bel l housi ng and behi nd the
transmi ssi on front cover. The oi l pump consi sts of
two i ndependent pumps (Fi g. 88), a number of val ves
(Fi g. 89), a front seal (Fi g. 90), and a bol t on reacti on
shaft. The converter cl utch swi tch and regul ator
val ves, pressure regul ator val ve, and converter pres-
sure l i mi t val ve are al l l ocated i n the oi l pump val ve
body.
OPERATION
As the torque converter rotates, the converter hub
rotates the oi l pump dri ve gear. As the dri ve gear
rotates both dri ven gears, a vacuum i s created when
the gear teeth come out of mesh. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
gear teeth come back i nto mesh, pressuri zed fl ui d i s
forced i nto the pump outl et and to the oi l pump
val ves.
At l ow speeds, both si des of the pump suppl y fl ui d
to the transmi ssi on. As the speed of the torque con-
verter i ncreases, the fl ow from both si des i ncreases
unti l the fl ow from the pri mary si de al one i s suffi -
ci ent to meet system demands. At thi s poi nt, the
check val ve l ocated between the two pumps cl oses.
The secondary si de i s shut down and the pri mary
si de suppl i es al l the fl ui d to the transmi ssi on.
CONVERTER CLUTCH SWITCH VALVE
The converter cl utch swi tch val ve i s used to control
the hydraul i c pressure suppl i ed to the front (OFF)
si de of the torque converter cl utch.
CONVERTER CLUTCH REGULATOR VALVE
The converter cl utch regul ator val ve i s used to con-
trol the hydraul i c pressure suppl i ed to the back (ON)
si de of the torque converter cl utch.
TORQUE CONVERTER LIMIT VALVE
The torque converter l i mi t val ve serves to l i mi t the
avai l abl e l i ne pressure to the torque converter cl utch
to approxi matel y 120 psi .
Fig. 87 Oil Pump
2 - OIL PUMP
Fig. 88 Oil Pump Gears
1 - PUMP HOUSING
2 - DRIVE GEAR
3 - DRIVEN GEARS
Fig. 89 Oil Pump Valves
1 - TORQUE CONVERTER CLUTCH ACCUMULATOR VALVE
2 - TORQUE CONVERTER CLUTCH CONTROL VALVE
3 - TORQUE CONVERTER CLUTCH SWITCH VALVE
4 - PUMP VALVE BODY
5 - PRESSURE REGULATOR VALVE
6 - TORQUE CONVERTER CLUTCH LIMIT VALVE
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuri ng the oi l pump output vol ume wi l l deter-
mi ne i f suffi ci ent oi l fl ow to the transmi ssi on oi l
cool er exi sts, and whether or not an i nternal trans-
mi ssi on fai l ure i s present.
Veri fy that the transmi ssi on fl ui d i s at the proper
l evel . Refer to the Fl ui d Level Check procedure i n
thi s secti on. I f necessary, fi l l the transmi ssi on to the
proper l evel wi th Mopar ATF +4, type 9602, Auto-
mati c Transmi ssi on Fl ui d.
(1) Di sconnect the To cooler l i ne at the cool er
i nl et and pl ace a col l ecti ng contai ner under the di s-
connected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at 1800 rpm, wi th the shi ft
sel ector i n neutral . Veri fy that the transmi ssi on fl ui d
temperature i s bel ow 104.5 C (220 F) for thi s test.
(3) I f one quart of transmi ssi on fl ui d i s col l ected i n
the contai ner i n 30 seconds or l ess, oi l pump fl ow vol -
ume i s wi thi n acceptabl e l i mi ts. I f fl ui d fl ow i s i nter-
mi ttent, or i t takes more than 30 seconds to col l ect
one quart of fl ui d, refer to the Hydraul i c Pressure
tests i n thi s secti on for further di agnosi s.
(4) Re-connect the To cooler l i ne to the transmi s-
si on cool er i nl et.
Fig. 90 Oil Pump Reaction Shaft
1 - PUMP HOUSING 4 - SEAL RING (5)
2 - SEAL 5 - REACTION SHAFT SUPPORT
3 - OIL FILTER SEAL 6 - PUMP VALVE BODY
(5) Refi l l the transmi ssi on to proper l evel .
DISASSEMBLY
(1) Remove the bol ts hol di ng the reacti on shaft
support to the oi l pump (Fi g. 91).
(2) Remove the reacti on shaft support from the oi l
pump (Fi g. 91).
(3) Remove al l bol ts hol di ng the oi l pump hal ves
together (Fi g. 91).
(4) Usi ng sui tabl e pryi ng tool s, separate the oi l
pump secti ons by i nserti ng the tool s i n the suppl i ed
areas and pryi ng the hal ves apart.
NOTE: The oil pump halves are aligned to each
other through the use of two dowels. Be sure to pry
upward evenly to prevent damage to the oil pump
components.
Fig. 91 Oil Pump Assembly
1 - PUMP HOUSING 4 - SEAL RING (5)
2 - SEAL 5 - REACTION SHAFT SUPPORT
3 - OIL FILTER SEAL 6 - PUMP VALVE BODY
(5) Remove the screws hol di ng the separator pl ate
onto the oi l pump body (Fi g. 92).
(6) Remove the separator pl ate from the oi l pump
body (Fi g. 92).
(7) Mark al l gears for l ocati on. The gears are
sel ect fi t and i f the oi l pump i s to be reused, the
gears must be returned to thei r ori gi nal l ocati ons.
(8) Remove the oi l pump gears from the oi l pump
case (Fi g. 92).
Fig. 92 Oil Pump Housing and Gears
1 - SEPARATOR PLATE 5 - DOWEL (2)
2 - DRIVEN GEAR (2) 6 - DRIVE GEAR
3 - CHECK VALVE 7 - SCREW
4 - PUMP HOUSING
(9) Remove the oi l pump val ve retai ners and asso-
ci ated val ve and spri ng one at a ti me (Fi g. 93) (Fi g.
94). Mark the combi nati on of components as a group
and tag them as to the l ocati on from whi ch they were
removed.
CLEANING
Cl ean pump and support components wi th sol vent
and dry them wi th compressed ai r.
INSPECTION
Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
I nspect the pump and support components. Repl ace
the pump or support i f the seal ri ng grooves or
machi ned surfaces are worn, scored, pi tted, or dam-
aged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
I nspect the pump reacti on shaft support bushi ngs.
Repl ace ei ther bushi ng onl y i f heavi l y worn, scored or
damaged. I t i s not necessary to repl ace the bushi ngs
unl ess they are actual l y damaged.
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Mi nor surface scratches on steel
val ves and pl ugs can be removed wi th crocus cl oth
but do not round off the edges of the valve or
plug lands. Mai ntai ni ng sharpness of these edges i s
vi tal l y i mportant. The edges prevent forei gn matter
from l odgi ng between the val ves and pl ugs and the
bore.
I nspect al l the val ve and pl ug bores i n the oi l
pump cover. Use a penl i ght to vi ew the bore i nteri -
ors. Repl ace the oi l pump i f any bores are di storted
or scored. I nspect al l of the val ve spri ngs. The
coi l s.
Fig. 93 Oil Pump Valve Body
1 - T/C REGULATOR VALVE
2 - T/C LIMIT VALVE
3 - REGULATOR VALVE
4 - OIL PUMP VALVE BODY
Fig. 94 T/C Switch Valve
1 - RETAINER
2 - T/C SWITCH VALVE
3 - OIL PUMP VALVE BODY
ASSEMBLY
(1) Cl ean and i nspect al l components. Make sure
that al l passages are thoroughl y cl eaned and are free
from di rt or debri s. Make sure that al l val ves move
freel y i n thei r proper bore. Make sure that al l gear
pockets and bushi ngs are free from excessi ve wear
and scori ng. Repl ace the oi l pump i f any excessi ve
wear or scori ng i s found.
(2) Coat the gears wi th Mopar ATF +4, type 9602,
and i nstal l i nto thei r ori gi nal l ocati ons.
(3) Lubri cate the oi l pump val ves wi th Mopar
ATF +4, type 9602, and i nstal l the val ve, spri ng and
retai ner i nto the appropri ate oi l pump val ve body
bore (Fi g. 93) (Fi g. 94).
(4) Pl ace the separator pl ate onto the oi l pump
body (Fi g. 92).
(5) I nstal l the screws to hol d the separator pl ate
onto the oi l pump body (Fi g. 92). Ti ghten the screws
to 4.5 Nm (40 i n.l bs.).
(6) Posi ti on the oi l pump cover onto the l ocati ng
dowel s (Fi g. 91).
(7) Seat the two oi l pump hal ves together and
i nstal l al l bol ts fi nger ti ght.
(8) Torque al l bol ts down sl owl y starti ng i n the
center and worki ng outward. The correct torque i s
4.5 Nm (40 i n.l bs.).
(9) Veri fy that the oi l pump gears rotate freel y and
smoothl y.
(10) Posi ti on the reacti on shaft support i nto the oi l
pump (Fi g. 91).
(11) I nstal l and torque the bol ts to hol d the reac-
ti on shaft support to the oi l pump (Fi g. 91). The cor-
rect torque i s 12 Nm (105 i n.l bs.).
OIL PUMP FRONT SEAL
REMOVAL
(1) Remove transmi ssi on from the vehi cl e.
(2) Remove the torque converter from the trans-
mi ssi on.
(3) Usi ng a screw mounted i n a sl i de hammer,
remove the oi l pump front seal .
INSTALLATION
(1) Cl ean seal bore of the oi l pump of any resi due
or parti cl es from the ori gi nal seal .
(2) I nstal l new oi l seal i n the oi l pump housi ng
usi ng Seal I nstal l er C-3860-A (Fi g. 95).
Fig. 95 Install Oil Pump Front Seal
1 - TOOL C-3860-A
OUTPUT SPEED SENSOR
DESCRIPTION
The I nput and Output Speed Sensors are two-wi re
magneti c pi ckup devi ces that generate AC si gnal s as
rotati on occurs. They are mounted i n the l eft si de of
the transmi ssi on case and are consi dered pri mary
i nputs to the Transmi ssi on Control Modul e (TCM).
OPERATION
The I nput Speed Sensor provi des i nformati on on
how fast the i nput shaft i s rotati ng. As the teeth of
the i nput cl utch hub pass by the sensor coi l , an AC
vol tage i s generated and sent to the TCM. The TCM
i nterprets thi s i nformati on as i nput shaft rpm.
The Output Speed Sensor generates an AC si gnal
i n a si mi l ar fashi on, though i ts coi l i s exci ted by rota-
ti on of the rear pl anetary carri er l ugs. The TCM
i nterprets thi s i nformati on as output shaft rpm.
The TCM compares the i nput and output speed
si gnal s to determi ne the fol l owi ng:
Transmi ssi on gear rati o
Speed rati o error detecti on
CVI cal cul ati on
The TCM al so compares the i nput speed si gnal and
the engi ne speed si gnal to determi ne the fol l owi ng:
Torque converter cl utch sl i ppage
Torque converter el ement speed rati o
REMOVAL
transmi ssi on.
(3) Remove the wi ri ng connector from the output
speed sensor (Fi g. 96).
(4) Remove the bol t hol di ng the output speed sen-
sor to the transmi ssi on case.
(5) Remove the output speed sensor from the
INSTALLATION
(1) I nstal l the output speed sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the output speed sensor
Nm (105 i n.l bs.).
(3) I nstal l the wi ri ng connector onto the output
speed sensor
necessary.
OVERDRIVE SWITCH
DESCRIPTION
The overdri ve OFF (control ) swi tch i s l ocated i n
the shi fter handl e. The swi tch i s a momentary con-
tact devi ce that si gnal s the PCM to toggl e current
status of the overdri ve functi on.
OPERATION
At key-on, fourth and fi fth gear operati on i s
al l owed. Pressi ng the swi tch once causes the over-
dri ve OFF mode to be entered and the overdri ve OFF
swi tch l amp to be i l l umi nated. Pressi ng the swi tch a
second ti me causes normal overdri ve operati on to be
restored and the overdri ve l amp to be turned off. The
overdri ve OFF mode defaul ts to ON after the i gni ti on
swi tch i s cycl ed OFF and ON. The normal posi ti on
for the control swi tch i s the ON posi ti on. The swi tch
must be i n thi s posi ti on to energi ze the sol enoi ds and
al l ow upshi fts to fourth and fi fth gears. The control
swi tch i ndi cator l i ght i l l umi nates onl y when the over-
dri ve swi tch i s turned to the OFF posi ti on, or when
i l l umi nated by the transmi ssi on control modul e.
Fig. 96 Output Speed Sensor
PARK LOCK CABLE
REMOVAL
(1) Pl ace the shi fter i n the PARK posi ti on.
(2) Lower the steeri ng col umn cover.
(3) Wi th the i gni ti on swi tch i n the RUN posi ti on
depress the park l ock cabl e l ocki ng tab, l ocated on
top of the cabl e connector at the steeri ng col umn and
pul l the park l ock cabl e strai ght out.
(4) Remove the park l ock cabl e from steeri ng col -
umn (Fi g. 97).
(5) Remove the fl oor consol e and rel ated tri m.
REMOVAL)
(6) Di sconnect the park l ock cabl e from the shi ft
BTSI l ever and remove the cabl e from the shi fter
assembl y bracket.
(7) Rel ease the park l ock cabl e from any remai ni ng
cl i ps.
(8) Remove park l ock cabl e from the vehi cl e.
INSTALLATION
NOTE: The gearshift cable must be secured into
position and properly adjusted before the installa-
tion of the Park Lock Cable.
(1) Veri fy that the shi fter i s i n the PARK posi ti on.
(2) Push the park l ock cabl e strai ght i nto the
square mounti ng hol e i n the steeri ng col umn unti l
cabl e snaps i n pl ace.
(3) Route park l ock cabl e to the shi fter mecha-
ni sm.
(4) I nstal l the park l ock cabl e end fi tti ng i nto
shi fter BTSI l ever.
(5) Pul l rearward on the cabl e housi ng to snap
park l ock cabl e adjuster ears i nto fl oor shi fter
bracket.
(6) Pl ace the i gni ti on key cyl i nder i n the ACCES-
SORY posi ti on.
(7) Push the cabl e adjuster l ock cl amp downward
to l ock i t.
(8) Test the park l ock cabl e operati on.
(9) I nstal l the fl oor consol e and rel ated tri m.
I NSTALLATI ON)
Fig. 97 Brake Transmission Shift Interlock
3 - ADJUSTMENT CLIP
PISTONS
DESCRIPTION
There are several si zes and types of pi stons used i n
an automati c transmi ssi on. Some pi stons are used to
appl y cl utches. They al l have i n common the fact
that they are round or ci rcul ar i n shape, l ocated
wi thi n a smooth wal l ed cyl i nder, whi ch i s cl osed at
one end and converts fl ui d pressure i nto mechani cal
movement. The fl ui d pressure exerted on the pi ston
i s contai ned wi thi n the system through the use of
pi ston ri ngs or seal s.
OPERATION
The pri nci pal whi ch makes thi s operati on possi bl e
i s known as Pascal s Law. Pascal s Law can be stated
as: Pressure on a confi ned fl ui d i s transmi tted
equal l y i n al l di recti ons and acts wi th equal force on
equal areas.
PRESSURE
Pressure (Fi g. 98) i s nothi ng more than force (l bs.)
di vi ded by area (i n or ft.), or force per uni t area.
Gi ven a 100 l b. bl ock and an area of 100 sq. i n. on
the fl oor, the pressure exerted by the bl ock i s: 100
l bs. 100 i n or 1 pound per square i nch, or PSI as i t i s
commonl y referred to.
PRESSURE ON A CONFINED FLUID
Pressure i s exerted on a confi ned fl ui d (Fi g. 99) by
appl yi ng a force to some gi ven area i n contact wi th
the fl ui d. A good exampl e of thi s i s a cyl i nder fi l l ed
wi th fl ui d and equi pped wi th a pi ston that i s cl osel y
fi tted to the cyl i nder wal l . I f a force i s appl i ed to the
pi ston, pressure wi l l be devel oped i n the fl ui d. Of
course, no pressure wi l l be created i f the fl ui d i s not
confi ned. I t wi l l si mpl y l eak past the pi ston. There
must be a resi stance to fl ow i n order to create pres-
sure. Pi ston seal i ng i s extremel y i mportant i n
hydraul i c operati on. Several ki nds of seal s are used
to accompl i sh thi s wi thi n a transmi ssi on. These
i ncl ude but are not l i mi ted to O-ri ngs, D-ri ngs, l i p
seal s, seal i ng ri ngs, or extremel y cl ose tol erances
between the pi ston and the cyl i nder wal l . The force
exerted i s downward (gravi ty), however, the pri nci pl e
remai ns the same no matter whi ch di recti on i s taken.
The pressure created i n the fl ui d i s equal to the force
appl i ed, di vi ded by the pi ston area. I f the force i s 100
l bs., and the pi ston area i s 10 sq. i n., then the pres-
sure created equal s 10 PSI . Another i nterpretati on of
Pascal s Law i s that regardl ess of contai ner shape or
si ze, the pressure wi l l be mai ntai ned throughout, as
l ong as the fl ui d i s confi ned. I n other words, the
pressure i n the fl ui d i s the same everywhere wi thi n
the contai ner.
Fig. 98 Force and Pressure Relationship
Fig. 99 Pressure on a Confined Fluid
FORCE MULTIPLICATION
Usi ng the 10 PSI exampl e used i n the i l l ustrati on
(Fi g. 100), a force of 1000 l bs. can be moved wi th a
force of onl y 100 l bs. The secret of force mul ti pl i ca-
ti on i n hydraul i c systems i s the total fl ui d contact
area empl oyed. The i l l ustrati on, (Fi g. 100), shows an
area that i s ten ti mes l arger than the ori gi nal area.
The pressure created wi th the smal l er 100 l b. i nput
i s 10 PSI . The concept pressure i s the same every-
where means that the pressure underneath the
l arger pi ston i s al so 10 PSI . Pressure i s equal to the
force appl i ed di vi ded by the contact area. Therefore,
by means of si mpl e al gebra, the output force may be
found. Thi s concept i s extremel y i mportant, as i t i s
al so used i n the desi gn and operati on of al l shi ft
val ves and l i mi ti ng val ves i n the val ve body, as wel l
as the pi stons, of the transmi ssi on, whi ch acti vate
the cl utches and bands. I t i s nothi ng more than
usi ng a di fference of area to create a di fference i n
pressure to move an object.
PISTON TRAVEL
The rel ati onshi p between hydraul i c l ever and a
mechani cal l ever i s the same. Wi th a mechani cal
l ever i ts a wei ght-to-di stance output rather than a
pressure-to-area output. Usi ng the same forces and
areas as i n the previ ous exampl e, the smal l er pi ston
(Fi g. 101) has to move ten ti mes the di stance
requi red to move the l arger pi ston one i nch. There-
fore, for every i nch the l arger pi ston moves, the
smal l er pi ston moves ten i nches. Thi s pri nci pl e i s
true i n other i nstances al so. A common garage fl oor
jack i s a good exampl e. To rai se a car wei ghi ng 2000
l bs., an effort of onl y 100 l bs. may be requi red. For
every i nch the car moves upward, the i nput pi ston at
the jack handl e must move 20 i nches downward.
Fig. 100 Force Multiplication
Fig. 101 Piston Travel
PISTONS (Continued)
PLANETARY GEARTRAIN
DESCRIPTION
The pl anetary geartrai n i s l ocated behi nd the 4C
retai ner/bul khead, toward the rear of the transmi s-
si on. The pl anetary geartrai n consi sts of three pri -
mary assembl i es:
Reacti on (Fi g. 102).
Reverse (Fi g. 103).
I nput (Fi g. 103).
Fig. 102 Reaction Planetary Geartrain
Fig. 103 Reverse/Input Planetary Geartrain
1 - SNAP-RING 5 - INPUT PLANETARY CARRIER
2 - BEARING NUMBER 10 6 - INPUT SUN GEAR
3 - BEARING NUMBER 11 7 - REVERSE PLANETARY CARRIER
4 - INPUT ANNULUS
PLANETARY GEARTRAIN (Continued)
OPERATION
REACTION PLANETARY GEARTRAIN
The reacti on pl anetary carri er and reverse sun
gear of the reacti on pl anetary geartrai n are a si ngl e
component whi ch i s hel d by the 2C cl utch when
requi red. The reacti on annul us gear i s a stand al one
component that can be dri ven by the reverse cl utch
or hel d by the 4C cl utch. The reacti on sun gear i s
dri ven by the overdri ve cl utch.
REVERSE PLANETARY GEARTRAIN
The reverse pl anetary geartrai n i s the mi ddl e of
the three pl anetary sets. The reverse pl anetary car-
ri er can be dri ven by the overdri ve cl utch as
requi red. The reverse pl anetary carri er i s al so
spl i ned to the i nput annul us gear, whi ch can be hel d
by the l ow/reverse cl utch. The reverse pl anetary
annul us, i nput pl anetary carri er, and output shaft
are al l one pi ece.
INPUT PLANETARY GEARTRAIN
The i nput sun gear of the i nput pl anetary
geartrai n i s dri ven by the underdri ve cl utch.
DISASSEMBLY
(1) Remove the snap-ri ng hol di ng the i nput annu-
l us i nto the i nput carri er (Fi g. 104).
(2) Remove the i nput annul us from the i nput car-
ri er (Fi g. 104).
(3) Remove the number 9 beari ng from the reverse
pl anetary carri er. Note that thi s pl anetary carri er
has four pi ni on gears.
(4) Remove the reverse pl anetary gear carri er (Fi g.
104).
sun gear (Fi g. 104).
(6) Remove the i nput sun gear from the i nput car-
ri er (Fi g. 104).
carri er (Fi g. 104).
CLEANING
Cl ean the pl anetary components i n sol vent and dry
them wi th compressed ai r.
INSPECTION
Check sun gear and dri vi ng shel l condi ti on.
Repl ace the gear i f damaged or i f the bushi ngs are
scored or worn. The bushi ngs are not servi ceabl e.
Fig. 104 Reverse/Input Planetary Carrier Assembly
1 - SNAP-RING 5 - INPUT PLANETARY CARRIER
2 - BEARING NUMBER 10 6 - INPUT SUN GEAR
3 - BEARING NUMBER 11 7 - REVERSE PLANETARY CARRIER
4 - INPUT ANNULUS
Repl ace the dri vi ng shel l i f worn, cracked or dam-
aged.
Repl ace pl anetary gear sets i f gears, pi ni on pi ns, or
carri er are damaged i n any way. Repl ace the annul us
gears and supports i f ei ther component i s worn or
damaged.
Repl ace the output shaft i f the machi ned surfaces
are scored, pi tted, or damaged i n any way. Al so
repl ace the shaft i f the spl i nes are damaged, or
exhi bi ts cracks at any l ocati on.
ASSEMBLY
or scori ng.
(2) I nstal l the number 11 beari ng i nto the i nput
pl anetary carri er so that the i nner race wi l l be
toward the front of the transmi ssi on (Fi g. 104).
(3) I nstal l the i nput sun gear i nto the i nput carri er
(Fi g. 104).
(4) I nstal l the number 10 beari ng onto the rear of
the reverse pl anetary carri er wi th the i nner race
toward the carri er (Fi g. 104).
(5) I nstal l the number 9 beari ng onto the front of
the reverse pl anetary carri er wi th the outer race
toward the carri er and the i nner race faci ng upward
(Fi g. 104).
(6) I nstal l the reverse pl anetary gear carri er i nto
the i nput carri er (Fi g. 104).
(7) I nstal l the i nput annul us gear i nto the i nput
carri er (Fi g. 104).
(8) I nstal l the snap-ri ng to hol d the i nput annul us
gear i nto the i nput carri er (Fi g. 104).
SHIFT MECHANISM
DESCRIPTION
The gear shi ft mechani sm provi des si x shi ft posi -
ti ons whi ch are:
Park (P)
Reverse (R)
Neutral (N)
Dri ve (D)
Manual second (2)
Manual l ow (1)
OPERATION
MANUAL LOW (1) range provi des FI RST gear
onl y. Overrun braki ng i s al so provi ded i n thi s range.
MANUAL SECOND (2) range provi des FI RST and
SECOND gear onl y.
DRI VE range provi des FI RST, SECOND, THI RD
and OVERDRI VE FOURTH and FI FTH gear ranges.
The shi ft i nto OVERDRI VE FOURTH and FI FTH
gear range occurs onl y after the transmi ssi on has
compl eted the shi ft i nto D THI RD gear range. No
further movement of the shi ft mechani sm i s requi red
to compl ete the 3-4 or 4-5 shi fts.
The FOURTH and FI FTH gear upshi fts occurs
automati cal l y when the overdri ve sel ector swi tch i s
i n the ON posi ti on. An upshi ft to FOURTH and
FI FTH gears may not occur or may be del ayed i n
some of the possi bl e shi ft schedul es. (Refer to 8 -
ULES/TRANSMI SSI ON CONTROL MODULE -
OPERATI ON)
REMOVAL
to shi ft l ever assembl y and shi fter cabl es. (Refer to
REMOVAL)
(3) Di sconnect the transmi ssi on shi ft cabl e at shi ft
l ever and shi fter assembl y bracket (Fi g. 105).
(4) Di sconnect the park l ock cabl e from the shi fter
BTSI l ever and the shi fter assembl y bracket. (Fi g.
106)
(5) Di sconnect the transfer case shi ft cabl e from
the transfer case shi ft l ever pi n (Fi g. 107), i f
equi pped.
(6) Remove the cl i p hol di ng the transfer case shi ft
cabl e to the shi fter assembl y bracket, i f equi pped.
(7) Remove the transfer case shi ft cabl e from the
shi fter assembl y bracket, i f equi pped.
(8) Di sengage al l wi ri ng connectors from the
shi fter assembl y.
(9) Remove al l nuts hol di ng the shi fter assembl y to
the fl oor pan (Fi g. 108).
1 - SHIFT LEVER PIN
3 - SHIFT CABLE
(10) Remove the shi fter assembl y from the vehi cl e.
Fig. 106 Brake Transmission Interlock Cable
3 - ADJUSTMENT CLIP
1 - CLIP
2 - SHIFTER
Fig. 108 Shifter Assembly
1 - FLOOR PAN
2 - SHIFTER ASSEMBLY
INSTALLATION
(3) Veri fy that the park l ock cabl e adjustment tab
i s pul l ed upward to the unl ocked posi ti on.
(4) I nstal l wi ri ng harness to the shi fter assembl y
bracket. Engage any wi re connectors removed from
the shi fter assembl y.
shi fter assembl y bracket. I nstal l cl i p to hol d cabl e to
the bracket.
(6) Snap the transfer case shi ft cabl e, i f equi pped,
onto the transfer case shi ft l ever pi n.
(7) I nstal l the park l ock cabl e i nto the shi fter
assembl y bracket and i nto the shi fter BTSI l ever.(Re-
fer to 21 - TRANSMI SSI ON/TRANSAXLE/AUTO-
MATI C/SHI FT I NTERLOCK MECHANI SM -
ADJUSTMENTS)
(9) I nstal l shi fter assembl y onto the shi fter assem-
bl y studs on the fl oor pan.
(10) I nstal l the nuts to hol d the shi fter assembl y
onto the fl oor pan. Ti ghten nuts to 28 Nm (250
i n.l bs.).
ti on.
i n.l bs.).
(14) Pl ace the key i n the accessory posi ti on.
(15) Push downward on the park l ock cabl e adjust-
ment tab to l ock the adjustment.
(16) Veri fy correct shi fter, park l ock, and BTSI
operati on.
shi ft l ever assembl y and shi ft cabl es. (Refer to 23 -
TI ON)
DESCRIPTION
The Sol enoi d Swi tch Val ve (SSV) i s l ocated i n the
val ve body and control s the di recti on of the transmi s-
si on fl ui d when the L/R-TCC sol enoi d i s energi zed.
OPERATION
The Sol enoi d Swi tch Val ve control s l i ne pressure
from the LR-TCC sol enoi d. I n 1st gear, the SSV wi l l
be i n the downshi fted posi ti on, thus di recti ng fl ui d to
the L/R cl utch ci rcui t. I n 2nd, 3rd, 4th,and 5th gears,
the sol enoi d swi tch val ve wi l l be i n the upshi fted
posi ti on and di rects the fl ui d i nto the torque con-
verter cl utch (TCC) ci rcui t.
When shi fti ng i nto 1st gear, a speci al hydraul i c
sequence i s performed to ensure SSV movement i nto
the downshi fted posi ti on. The L/R pressure swi tch i s
moni tored to confi rm SSV movement. I f the move-
ment i s not confi rmed (the L/R pressure swi tch does
not cl ose), 2nd gear i s substi tuted for 1st. A DTC wi l l
be set after three unsuccessful attempts are made to
get i nto 1st gear i n one gi ven key start.
SOLENOIDS
DESCRIPTION
The typi cal el ectri cal sol enoi d used i n automoti ve
appl i cati ons i s a l i near actuator. I t i s a devi ce that
produces moti on i n a strai ght l i ne. Thi s strai ght l i ne
moti on can be ei ther forward or backward i n di rec-
ti on, and short or l ong di stance.
A sol enoi d i s an el ectromechani cal devi ce that uses
a magneti c force to perform work. I t consi sts of a coi l
of wi re, wrapped around a magneti c core made from
steel or i ron, and a spri ng l oaded, movabl e pl unger,
whi ch performs the work, or strai ght l i ne moti on.
The sol enoi ds used i n transmi ssi on appl i cati ons
are attached to val ves whi ch can be cl assi fi ed as nor-
mally open or normally closed. The normally
open sol enoi d val ve i s defi ned as a val ve whi ch
al l ows hydraul i c fl ow when no current or vol tage i s
appl i ed to the sol enoi d. The normally closed sol e-
noi d val ve i s defi ned as a val ve whi ch does not al l ow
hydraul i c fl ow when no current or vol tage i s appl i ed
to the sol enoi d. These val ves perform hydraul i c con-
trol functi ons for the transmi ssi on and must there-
fore be durabl e and tol erant of di rt parti cl es. For
these reasons, the val ves have hardened steel pop-
pets and bal l val ves. The sol enoi ds operate the val ves
di rectl y, whi ch means that the sol enoi ds must have
very hi gh outputs to cl ose the val ves agai nst the si z-
abl e fl ow areas and l i ne pressures found i n current
transmi ssi ons. Fast response ti me i s al so necessary
to ensure accurate control of the transmi ssi on.
The strength of the magneti c fi el d i s the pri mary
force that determi nes the speed of operati on i n a par-
ti cul ar sol enoi d desi gn. A stronger magneti c fi el d wi l l
cause the pl unger to move at a greater speed than a
weaker one. There are basi cal l y two ways to i ncrease
the force of the magneti c fi el d:
1. I ncrease the amount of current appl i ed to the
coi l or
2. I ncrease the number of turns of wi re i n the coi l .
The most common practi ce i s to i ncrease the num-
ber of turns by usi ng thi n wi re that can compl etel y
fi l l the avai l abl e space wi thi n the sol enoi d housi ng.
The strength of the spri ng and the l ength of the
pl unger al so contri bute to the response speed possi -
bl e by a parti cul ar sol enoi d desi gn.
A sol enoi d can al so be descri bed by the method by
whi ch i t i s control l ed. Some of the possi bi l i ti es
i ncl ude vari abl e force, pul se-wi dth modul ated, con-
stant ON, or duty cycl e. The vari abl e force and pul se-
wi dth modul ated versi ons uti l i ze si mi l ar methods to
control the current fl ow through the sol enoi d to posi -
ti on the sol enoi d pl unger at a desi red posi ti on some-
where between ful l ON and ful l OFF. The constant
ON and duty cycl ed versi ons control the vol tage
across the sol enoi d to al l ow ei ther ful l fl ow or no fl ow
through the sol enoi ds val ve.
OPERATION
When an el ectri cal current i s appl i ed to the sol e-
noi d coi l , a magneti c fi el d i s created whi ch produces
an attracti on to the pl unger, causi ng the pl unger to
move and work agai nst the spri ng pressure and the
l oad appl i ed by the fl ui d the val ve i s control l i ng. The
pl unger i s normal l y di rectl y attached to the val ve
whi ch i t i s to operate. When the current i s removed
from the coi l , the attracti on i s removed and the
pl unger wi l l return to i ts ori gi nal posi ti on due to
spri ng pressure.
The pl unger i s made of a conducti ve materi al and
accompl i shes thi s movement by provi di ng a path for
the magneti c fi el d to fl ow. By keepi ng the ai r gap
between the pl unger and the coi l to the mi ni mum
necessary to al l ow free movement of the pl unger, the
magneti c fi el d i s maxi mi zed.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 109) i s a hydraul i c
devi ce that coupl es the engi ne crankshaft to the
transmi ssi on. The torque converter consi sts of an
outer shel l wi th an i nternal turbi ne, a stator, an
overrunni ng cl utch, an i mpel l er and an el ectroni cal l y
appl i ed converter cl utch. The converter cl utch pro-
vi des reduced engi ne speed and greater fuel economy
when engaged. Cl utch engagement al so provi des
reduced transmi ssi on fl ui d temperatures. The con-
verter cl utch engages i n thi rd gear. The torque con-
verter hub dri ves the transmi ssi on oi l (fl ui d) pump
and contai ns an o-ri ng seal to better control oi l fl ow.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.
1 - TURBINE ASSEMBLY
2 - STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
SOLENOIDS (Continued)
IMPELLER
The i mpel l er (Fi g. 110) i s an i ntegral part of the
converter housi ng. The i mpel l er consi sts of curved
bl ades pl aced radi al l y al ong the i nsi de of the housi ng
on the transmi ssi on si de of the converter. As the con-
verter housi ng i s rotated by the engi ne, so i s the
i mpel l er, because they are one and the same and are
the dri vi ng members of the system.
Fig. 110 Impeller
1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
5 - ENGINE ROTATION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
TURBINE
The turbi ne (Fi g. 111) i s the output, or dri ven,
member of the converter. The turbi ne i s mounted
wi thi n the housi ng opposi te the i mpel l er, but i s not
attached to the housi ng. The i nput shaft i s i nserted
through the center of the i mpel l er and spl i ned i nto
the turbi ne. The desi gn of the turbi ne i s si mi l ar to
the i mpel l er, except the bl ades of the turbi ne are
curved i n the opposi te di recti on.
Fig. 111 Turbine
1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
STATOR
The stator assembl y (Fi g. 112) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator i s l ocated between the i mpel l er and
turbi ne wi thi n the torque converter case (Fi g. 113).
The stator contai ns an over-runni ng cl utch, whi ch
al l ows the stator to rotate onl y i n a cl ockwi se di rec-
ti on. When the stator i s l ocked agai nst the over-run-
ni ng cl utch, the torque mul ti pl i cati on feature of the
torque converter i s operati onal .
The TCC (Fi g. 114) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shock-free power transfer, i t i s
natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel l er
and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston wi th fri cti on materi al was added to the tur-
bi ne assembl y to provi de thi s mechani cal l ock-up.
I n order to reduce heat bui l d-up i n the transmi ssi on
and buffer the powertrai n agai nst torsi onal vi brati ons,
the TCM can duty cycl e the L/R-CC Sol enoi d to achi eve
a smooth appl i cati on of the torque converter cl utch.
Thi s functi on, referred to as El ectroni cal l y Modul ated
Converter Cl utch (EMCC) can occur at vari ous ti mes
dependi ng on the fol l owi ng vari abl es:
Shi ft l ever posi ti on
Current gear range
Transmi ssi on fl ui d temperature
I nput speed
Throttl e angl e
Engi ne speed
Fig. 112 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 113 Stator Location
1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 114 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
OPERATION
The converter i mpel l er (Fi g. 115) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi nes bl ades i t con-
ti nues i n a hi nderi ng di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n such a
di recti on that i t woul d tend to sl ow i t down.
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
stators over-runni ng cl utch to i ts shaft (Fi g. 116).
Under stal l condi ti ons (the turbi ne i s stati onary), the
oi l l eavi ng the turbi ne bl ades stri kes the face of the
stator bl ades and tri es to rotate them i n a counter-
cl ockwi se di recti on. When thi s happens the over-run-
ni ng cl utch of the stator l ocks and hol ds the stator
from rotati ng. Wi th the stator l ocked, the oi l stri kes
the stator bl ades and i s redi rected i nto a hel pi ng
di recti on before i t enters the i mpel l er. Thi s ci rcul a-
ti on of oi l from i mpel l er to turbi ne, turbi ne to stator,
and stator to i mpel l er, can produce a maxi mum
torque mul ti pl i cati on of about 2.4:1. As the turbi ne
begi ns to match the speed of the i mpel l er, the fl ui d
that was hi tti ng the stator i n such as way as to
cause i t to l ock-up i s no l onger doi ng so. I n thi s con-
di ti on of operati on, the stator begi ns to free wheel
and the converter acts as a fl ui d coupl i ng.
I n a standard torque converter, the i mpel l er and
turbi ne are rotati ng at about the same speed and the
stator i s freewheel i ng, provi di ng no torque mul ti pl i -
cati on. By appl yi ng the turbi nes pi ston and fri cti on
materi al to the front cover, a total converter engage-
ment can be obtai ned. The resul t of thi s engagement
i s a di rect 1:1 mechani cal l i nk between the engi ne
and the transmi ssi on.
The cl utch can be engaged i n second, thi rd, fourth,
and fi fth gear ranges dependi ng on overdri ve control
swi tch posi ti on. I f the overdri ve control swi tch i s i n
the normal ON posi ti on, the cl utch wi l l engage after
the shi ft to fourth gear, and above approxi matel y 72
km/h (45 mph). I f the control swi tch i s i n the OFF
Fig. 115 Torque Converter Fluid Operation - Typical
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
posi ti on, the cl utch wi l l engage after the shi ft to
thi rd gear, at approxi matel y 56 km/h (35 mph) at
l i ght throttl e.
The TCM control s the torque converter by way of
i nternal l ogi c software. The programmi ng of the soft-
ware provi des the TCM wi th control over the L/R-CC
Sol enoi d. There are four output l ogi c states that can
be appl i ed as fol l ows:
No EMCC
Parti al EMCC
Ful l EMCC
Gradual -to-no EMCC
NO EMCC
Under No EMCC condi ti ons, the L/R Sol enoi d i s
OFF. There are several condi ti ons that can resul t i n
NO EMCC operati ons. No EMCC can be i ni ti ated
due to a faul t i n the transmi ssi on or because the
TCM does not see the need for EMCC under current
dri vi ng condi ti ons.
PARTIAL EMCC
Parti al EMCC operati on modul ates the L/R Sol e-
noi d (duty cycl e) to obtai n parti al torque converter
cl utch appl i cati on. Parti al EMCC operati on i s mai n-
tai ned unti l Ful l EMCC i s cal l ed for and actuated.
Duri ng Parti al EMCC some sl i p does occur. Parti al
EMCC wi l l usual l y occur at l ow speeds, l ow l oad and
l i ght throttl e si tuati ons.
FULL EMCC
Duri ng Ful l EMCC operati on, the TCM i ncreases
the L/R Sol enoi d duty cycl e to ful l ON after Parti al
EMCC control bri ngs the engi ne speed wi thi n the
desi red sl i p range of transmi ssi on i nput speed rel a-
ti ve to engi ne rpm.
GRADUAL-TO-NO EMCC
Thi s operati on i s to soften the change from Ful l or
Parti al EMCC to No EMCC. Thi s i s done at mi d-
throttl e by decreasi ng the L/R Sol enoi d duty cycl e.
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve fl ats for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
fl ats wi th 320/400 gri t paper or crocus cl oth i f neces-
sary. Veri fy that the converter hub o-ri ng i s properl y
i nstal l ed and i s free from debri s. The hub must be
smooth to avoi d damagi ng the pump seal at i nstal l a-
ti on.
fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or con-
verter hub o-ring while inserting torque converter
into the front of the transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
shoul d be at l east 13 mm (1/2 i n.) to rear of strai ght-
edge when converter i s ful l y seated.
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
Fig. 116 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
TRANSMISSION CONTROL
RELAY
DESCRIPTION
The rel ay i s suppl i ed fused B+ vol tage, energi zed
by the TCM, and i s used to suppl y power to the sol e-
noi d pack when the transmi ssi on i s i n normal oper-
ati ng mode.
OPERATION
When the rel ay i s off, no power i s suppl i ed to the
sol enoi d pack and the transmi ssi on i s i n l i mp-i n
mode. After a control l er reset, the TCM energi zes the
rel ay. Pri or to thi s, the TCM veri fi es that the con-
tacts are open by checki ng for no vol tage at the
swi tched battery termi nal s. After thi s i s veri fi ed, the
vol tage at the sol enoi d pack pressure swi tches i s
checked. After the rel ay i s energi zed, the TCM mon-
i tors the termi nal s to veri fy that the vol tage i s
greater than 3 vol ts.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmi ssi on Range Sensor (TRS) i s part of
the sol enoi d modul e, whi ch i s mounted to the top of
the val ve body i nsi de the transmi ssi on.
The Transmi ssi on Range Sensor (TRS) has fi ve
swi tch contact pi ns that:
Determi ne shi ft l ever posi ti on
Suppl y ground to the Starter Rel ay i n Park and
Neutral onl y.
Suppl y +12 V to the backup l amps i n Reverse
onl y.
The TRS al so has an i ntegrated temperature sen-
sor (thermi stor) that communi cates transmi ssi on
temperature to the TCM and PCM.
OPERATION
The Transmi ssi on Range Sensor (TRS) communi -
cates shi ft l ever posi ti on to the TCM as a combi na-
ti on of open and cl osed swi tches. Each shi ft l ever
posi ti on has an assi gned combi nati on of swi tch states
(open/cl osed) that the TCM recei ves from four sense
ci rcui ts. The TCM i nterprets thi s i nformati on and
determi nes the appropri ate transmi ssi on gear posi -
ti on and shi ft schedul e.
There are many possi bl e combi nati ons of open and
cl osed swi tches (codes). Seven of these possi bl e codes
are rel ated to gear posi ti on and fi ve are recogni zed
as between gear codes. Thi s resul ts i n many codes
whi ch shoul d never occur. These are cal l ed
i nval i d codes. An i nval i d code wi l l resul t i n a DTC,
and the TCM wi l l then determi ne the shi ft l ever
posi ti on based on pressure swi tch data. Thi s al l ows
reasonabl y normal transmi ssi on operati on wi th a
TRS fai l ure.
GEAR C5 C4 C3 C2 C1
Park CL OP OP CL CL
Temp 1 CL OP OP CL OP
Reverse OP OP OP CL OP
Temp 2 OP OP CL CL OP
Neutral 1 OP OP CL CL CL
Neutral 2 OP CL CL CL CL
Temp 3 OP CL CL CL OP
Drive OP CL CL OP OP
Temp 4 OP CL OP OP OP
Manual 2 CL CL OP OP OP
Temp 5 CL OP OP OP OP
Manual 1 CL OP CL OP OP
Fig. 117 Checking Torque Converter Seating-Typical
1 - SCALE
2 - STRAIGHTEDGE
TRANSMISSION SOLENOID/
TRS ASSEMBLY
DESCRIPTION
The transmi ssi on sol enoi d/TRS assembl y i s i nter-
nal to the transmi ssi on and mounted on the val ve
body assembl y (Fi g. 118). The assembl y consi sts of
si x sol enoi ds that control hydraul i c pressure to the
si x fri cti on el ements (transmi ssi on cl utches), and the
torque converter cl utch. The pressure control sol e-
noi d i s l ocated on the si de of the sol enoi d/TRS assem-
bl y. The sol enoi d/TRS assembl y al so contai ns fi ve
pressure swi tches that feed i nformati on to the TCM.
OPERATION
SOLENOIDS
Sol enoi ds are used to control the L/R, 2C, 4C, OD,
and UD fri cti on el ements. The reverse cl utch i s con-
trol l ed by l i ne pressure and the posi ti on of the man-
ual val ve i n the val ve body. Al l the sol enoi ds are
contai ned wi thi n the Sol enoi d and Pressure Swi tch
Assembl y. The sol enoi d and pressure swi tch assembl y
contai ns one addi ti onal sol enoi d, Mul ti -Sel ect (MS),
whi ch serves pri mari l y to provi de 2nd and 3rd gear
l i mp-i n operati on.
The sol enoi ds recei ve el ectri cal power from the
Transmi ssi on Control Rel ay through a si ngl e wi re.
The TCM energi zes or operates the sol enoi ds i ndi vi d-
ual l y by groundi ng the return wi re of the sol enoi d as
necessary. When a sol enoi d i s energi zed, the sol enoi d
val ve shi fts, and a fl ui d passage i s opened or cl osed
(vented or appl i ed), dependi ng on i ts defaul t operat-
i ng state. The resul t i s an appl y or rel ease of a fri c-
ti onal el ement.
The MS and UD sol enoi ds are normal l y appl i ed to
al l ow transmi ssi on l i mp-i n i n the event of an el ectri -
cal fai l ure.
The conti nui ty of the sol enoi ds and ci rcui ts are
peri odi cal l y tested. Each sol enoi d i s turned on or off
dependi ng on i ts current state. An i nducti ve spi ke
shoul d be detected by the TCM duri ng thi s test. I f no
spi ke i s detected, the ci rcui t i s tested agai n to veri fy
the fai l ure. I n addi ti on to the peri odi c testi ng, the
sol enoi d ci rcui ts are tested i f a speed rati o or pres-
sure swi tch error occurs.
PRESSURE SWITCHES
The TCM rel i es on fi ve pressure swi tches to moni -
tor fl ui d pressure i n the L/R, 2C, 4C, UD, and OD
hydraul i c ci rcui ts. The pri mary purpose of these
swi tches i s to hel p the TCM detect when cl utch ci r-
cui t hydraul i c fai l ures occur. The swi tches cl ose at 23
psi and open at 11 psi , and si mpl y i ndi cate whether
or not pressure exi sts. The swi tches are conti nuousl y
moni tored by the TCM for the correct states (open or
cl osed) i n each gear as shown i n the fol l owi ng chart:
GEAR L/R 2C 4C UD OD
R OP OP OP OP OP
P/N CL OP OP OP OP
1ST CL* OP OP CL OP
2ND OP CL OP CL OP
2ND
PRIME
OP OP CL CL OP
D OP OP OP CL CL
4TH OP OP CL OP CL
5TH OP CL OP OP CL
*L/R is closed if output speed is below 100 rpm in
Drive and Manual 2. L/R is open in Manual 1.
A Di agnosti c Troubl e Code (DTC) wi l l set i f the
TCM senses any swi tch open or cl osed at the wrong
ti me i n a gi ven gear.
Fig. 118 Transmission Solenoid/TRS Assembly
1 - PRESSURE CONTROL SOLENOID
2 - TRANSMISSION RANGE SELECTOR PLATE
3 - 23-WAY CONNECTOR
4 - SOLENOID PACK
5 - TRANSMISSION RANGE SENSOR
6 - VALVE BODY
REMOVAL
(1) Remove the val ve body from the transmi ssi on
(Fi g. 119).
(2) Remove the screws hol di ng the transmi ssi on
sol enoi d/TRS assembl y onto the val ve body (Fi g. 120).
(3) Separate the transmi ssi on sol enoi d/TRS assem-
bl y from the val ve body.
INSTALLATION
(1) Pl ace TRS sel ector pl ate i n the PARK posi ti on.
(2) Posi ti on the transmi ssi on sol enoi d/TRS assem-
bl y onto the val ve body. Be sure that both al i gnment
dowel s are ful l y seated i n the val ve body and that
the TRS swi tch contacts are properl y posi ti oned i n
the sel ector pl ate
(3) I nstal l the screws to hol d the transmi ssi on
sol enoi d/TRS assembl y onto the val ve body.
(4) Ti ghten the sol enoi d assembl y screws adjacent
to the arrows cast i nto the bottom of the val ve body
fi rst. Ti ghten the screws to 5.7 Nm (50 i n.l bs.).
(5) Ti ghten the remai nder of the sol enoi d assembl y
screws to 5.7 Nm (50 i n.l bs.).
(6) I nstal l the val ve body i nto the transmi ssi on.
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
The transmi ssi on temperature sensor i s a ther-
mi stor that i s i ntegral to the Transmi ssi on Range
Sensor (TRS).
OPERATION
The transmi ssi on temperature sensor i s used by
the TCM to sense the temperature of the fl ui d i n the
sump. Si nce fl ui d temperature can affect transmi s-
si on shi ft qual i ty and convertor l ock up, the TCM
requi res thi s i nformati on to determi ne whi ch shi ft
schedul e to operate i n.
Calculated Temperature
A fai l ure i n the temperature sensor or ci rcui t wi l l
resul t i n cal cul ated temperature bei ng substi tuted for
actual temperature. Cal cul ated temperature i s a pre-
di cted fl ui d temperature whi ch i s cal cul ated from a
combi nati on of i nputs:
Battery (ambi ent) temperature
I n-gear run ti me si nce start-up
Fig. 119 Valve Body Bolts
Fig. 120 Ttransmission Solenoid/TRS Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
TRANSMISSION SOLENOID/TRS ASSEMBLY (Continued)
VALVE BODY
DESCRIPTION
The val ve body consi sts of a cast al umi num val ve
body, a separator pl ate, and a transfer pl ate. The
val ve body contai ns val ves and check bal l s that con-
trol fl ui d del i very to the torque converter cl utch,
bands, and fri cti onal cl utches. The val ve body con-
tai ns the fol l owi ng components (Fi g. 121) and (Fi g.
122):
Sol enoi d swi tch val ve
Manual val ve
Low/reverse swi tch val ve
5 Accumul ators
7 check bal l s
OPERATION
NOTE: Refer to the Hydraulic Schematics for a
visual aid in determining valve location, operation
and design.
The Sol enoi d Swi tch Val ve (SSV) control s the di rec-
ti on of the transmi ssi on fl ui d when the L/R-TCC sol e-
noi d i s energi zed.
The Sol enoi d Swi tch Val ve control s l i ne pressure
from the LR-TCC sol enoi d. I n 1st gear, the SSV wi l l
Fig. 121 Valve Body Components
1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR
2 - LOW/REVERSE SWITCH VALVE 7 - UNDERDRIVE ACCUMULATOR
3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR
4 - MANUAL VALVE 9 - 2C ACCUMULATOR
5 - SOLENOID SWITCH VALVE
Fig. 122 Check Ball Locations
be i n the downshi fted posi ti on, thus di recti ng fl ui d to
the L/R cl utch ci rcui t. I n 2nd, 3rd, 4th, and fi fth
gears, the sol enoi d swi tch val ve wi l l be i n the
upshi fted posi ti on and di rects the fl ui d i nto the
torque converter cl utch (TCC) ci rcui t.
When shi fti ng i nto 1st gear, a speci al hydraul i c
sequence i s performed to ensure SSV movement i nto
the downshi fted posi ti on. The L/R pressure swi tch i s
moni tored to confi rm SSV movement. I f the move-
ment i s not confi rmed (the L/R pressure swi tch does
not cl ose), 2nd gear i s substi tuted for 1st. A DTC wi l l
be set after three unsuccessful attempts are made to
get i nto 1st gear i n one gi ven key start.
MANUAL VALVE
The manual val ve i s a rel ay val ve. The purpose of
the manual val ve i s to di rect fl ui d to the correct ci r-
cui t needed for a speci fi c gear or dri vi ng range. The
manual val ve, as the name i mpl i es, i s manual l y oper-
ated by the dri ver wi th a l ever l ocated on the top of
the val ve body. The val ve i s connected mechani cal l y
by a cabl e to the gearshi ft mechani sm. The val ve i s
hel d i n each of i ts posi ti ons by a rol l er detent spri ng
(Fi g. 123) that engages the roostercomb of the TRS
sel ector pl ate.
LOW/REVERSE SWITCH VALVE
The l ow/reverse swi tch val ve al l ows the l ow/reverse
cl utch to be operated by ei ther the LR/CC sol enoi d or
the MS sol enoi d.
REMOVAL
The val ve body can be removed for servi ce wi thout
havi ng to remove the transmi ssi on assembl y.
The val ve body can be di sassembl ed for cl eani ng
and i nspecti on of the i ndi vi dual components. (Refer
to 21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C
- 45RFE/VALVE BODY - DI SASSEMBLY)
(3) Di sconnect wi res at the sol enoi d and pressure
swi tch assembl y connector.
(4) Posi ti on drai n pan under transmi ssi on oi l pan.
(5) Remove transmi ssi on oi l pan.
(6) Remove the pri mary oi l fi l ter from val ve body.
(Fi g. 124)
Fig. 123 TRS Selector Plate and Detent Spring
1 - TRS SELECTOR PLATE
2 - DETENT SPRING
3 - CLUTCH PASSAGE SEALS
Fig. 124 Remove Primary Oil Filter
4 - VALVE BODY
(7) Remove bol ts attachi ng val ve body to transmi s-
(8) Lower the val ve body and work the el ectri cal
connector out of transmi ssi on case.
(9) Separate the val ve body from the transmi ssi on.
DISASSEMBLY
(1) Remove the screws hol di ng the sol enoi d and
pressure swi tch assembl y to the val ve body (Fi g.
126). Do not remove the screws on the top of the sol e-
noi d and pressure swi tch assembl y.
(2) Separate the sol enoi d and pressure swi tch
assembl y from the val ve body.
(3) Remove the screw hol di ng the detent spri ng
(Fi g. 127) onto the val ve body.
(4) Remove the detent spri ng from the val ve body.
(5) Remove the TRS sel ector pl ate from the val ve
body and the manual val ve.
(6) Remove the cl utch passage seal s from the val ve
body, i f necessary.
Fig. 125 Valve Body Bolts
Fig. 126 Solenoid and Pressure Switch Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
Fig. 127 Valve Body External Components
1 - TRS SELECTOR PLATE
2 - DETENT SPRING
3 - CLUTCH PASSAGE SEALS
(7) Remove the screws hol di ng the accumul ator
cover onto the val ve body (Fi g. 128).
(8) Remove the accumul ator spri ngs and pi stons
from the val ve body. Note whi ch accumul ator pi ston
and spri ng bel ong i n each l ocati on.
(9) Pl ace the val ve body on the bench wi th the
transfer pl ate upward.
NOTE: The valve body contains seven check balls.
The transfer plate must be placed upward to pre-
vent losing the check balls when the transfer plate
is removed from the valve body.
(10) Remove the screws hol di ng the val ve body to
the val ve body transfer pl ate.
(11) Remove the transfer pl ate from the val ve
body. Note the l ocati on of al l check bal l s (Fi g. 129).
(12) Remove the check bal l s from the val ve body.
(13) Remove the retai ners securi ng the sol enoi d
swi tch val ve, manual val ve, and the l ow/reverse
swi tch val ve i nto the val ve body and remove the
associ ated val ve and spri ng. Tag each val ve and
spri ng combi nati on wi th l ocati on i nformati on to ai d
i n assembl y. (Fi g. 130)
1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR
2 - LOW/REVERSE SWITCH VALVE 7 - UNDERDRIVE ACCUMULATOR
3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR
4 - MANUAL VALVE 9 - 2C ACCUMULATOR
Fig. 129 Check Ball Locations
CLEANING
Cl ean the val ve housi ngs, val ves, pl ugs, spri ngs,
and separator pl ates wi th a standard parts cl eani ng
sol uti on onl y. Do not use gasol i ne, kerosene, or any
type of causti c sol uti on. (Fi g. 131)
Do not i mmerse any of the el ectri cal components i n
cl eani ng sol uti on. Cl ean the el ectri cal components by
wi pi ng them off wi th dry shop towel s onl y.
Dry al l except the el ectri cal parts wi th compressed
ai r. Make sure al l passages are cl ean and free from
obstructi ons. Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
INSPECTION
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th a
sheet of crocus cl oth. Posi ti on the crocus cl oth on a
surface pl ate, sheet of pl ate gl ass or equal l y fl at sur-
face. I f di storti on i s severe or any surfaces are
heavi l y scored, the val ve body wi l l have to be
repl aced.
I nspect the val ves and pl ugs (Fi g. 132) for
scratches, burrs, ni cks, or scores. Mi nor surface
scratches on steel val ves and pl ugs can be removed
wi th crocus cl oth but do not round off the edges
of the valve or plug lands. Mai ntai ni ng sharpness
of these edges i s vi tal l y i mportant. The edges prevent
forei gn matter from l odgi ng between the val ves and
pl ugs and the bore.
2 - MANUAL VALVE
3 - LOW REVERSE SWITCH VALVE
4 - LOW REVERSE ACCUMULATOR
5 - 2ND CLUTCH ACCUMULATOR
6 - UNDERDRIVE ACCUMULATOR
7 - OVERDRIVE ACCUMULATOR
8 - 4TH CLUTCH ACCUMULATOR
9 - CHECK BALLS (7)
2 - MANUAL VALVE
9 - CHECK BALLS (7)
I nspect al l the val ve and pl ug bores i n the val ve
body. Use a penl i ght to vi ew the bore i nteri ors.
Repl ace the val ve body i f any bores are di storted or
scored. I nspect al l of the val ve body spri ngs. The
coi l s.
Val ve body bores do not change di mensi onal l y wi th
use. I f the val ve body functi oned correctl y when new,
i t wi l l conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
I nspect al l the accumul ator bores i n the val ve body.
Use a penl i ght to vi ew the bore i nteri ors. Repl ace the
val ve body i f any bores are di storted or scored.
I nspect al l of the accumul ator spri ngs. The spri ngs
must be free of di storti on, warpage or broken coi l s.
I nspect al l the fl ui d seal s on the val ve body (Fi g.
133). Repl ace any seal s that are cracked, di storted, or
damaged i n any way. These seal s pass fl ui d pressure
di rectl y to the cl utches. Any pressure l eak at these
poi nts, may cause transmi ssi on performance prob-
l ems.
ASSEMBLY
(1) Lubri cate val ves, spri ngs, and the housi ng
val ve bores wi th cl ean transmi ssi on fl ui d.
(2) I nstal l sol enoi d swi tch val ve, manual val ve,
and the l ow/reverse swi tch val ve i nto the val ve body.
(3) I nstal l the retai ners to hol d each val ve i nto the
val ve body.
(4) I nstal l the val ve body check bal l s i nto thei r
proper l ocati ons.
(5) Posi ti on the transfer pl ate onto the val ve body.
(6) I nstal l the screws to hol d the transfer pl ate to
the val ve body. Ti ghten the screws to 5.6 Nm (50 i n.
l bs.).
(7) I nstal l the accumul ator pi stons and spri ngs
i nto the val ve body i n the l ocati on from whi ch they
were removed. Note that al l accumul ators except the
overdri ve have two spri ngs. The overdri ve accumul a-
tor pi ston has onl y one spri ng.
2 - MANUAL VALVE
9 - CHECK BALLS (7)
Fig. 133 Valve Body Seals
1 - UNDERDRIVE ACCUMULATOR (2 SPRINGS)
2 - 4TH CLUTCH ACCUMULATOR (2 SPRINGS)
3 - 2ND CLUTCH ACCUMULATOR (2 SPRINGS)
4 - LOW REVERSE ACCUMULATOR (2 SPRINGS)
5 - LOW/REVERSE PASSAGE SEAL
6 - 2ND CLUTCH PASSAGE SEAL
7 - 4TH CLUTCH PASSAGE SEAL
8 - OVERDRIVE ACCUMULATOR (1 SPRING)
(8) Posi ti on the accumul ator cover onto the val ve
body.
(9) I nstal l the screws to hol d the accumul ator
cover onto the val ve body. Ti ghten the screws to 4.5
Nm (40 i n. l bs.).
(10) I nstal l the TRS sel ector pl ate onto the val ve
body and the manual val ve.
(11) I nstal l the sol enoi d and pressure swi tch
assembl y onto the val ve body.
(12) I nstal l the screws to hol d the sol enoi d and
pressure swi tch assembl y onto the val ve body.
Ti ghten the screws to 5.7 Nm (50 i n. l bs.). Ti ghten
the screws adjacent to the arrows cast i nto the bot-
tom of the transfer pl ate fi rst.
(13) Posi ti on the detent spri ng onto the val ve body.
(14) I nstal l the screw to hol d the detent spri ng
onto the val ve body. Ti ghten the screw to 4.5 Nm (40
i n. l bs.).
(15) I nstal l new cl utch passage seal s onto the
val ve body, i f necessary
INSTALLATION
(1) Check condi ti on of seal s on val ve body and the
sol enoi d and pressure swi tch assembl y. Repl ace seal s
i f cut or worn.
(2) Pl ace TRS sel ector pl ate i n the PARK posi ti on.
(3) Pl ace the transmi ssi on i n the PARK posi ti on.
(4) Lubri cate seal on the sol enoi d and pressure
swi tch assembl y connector wi th petrol eum jel l y.
(5) Posi ti on val ve body i n transmi ssi on and al i gn
the manual l ever on the val ve body to the pi n on the
transmi ssi on manual shi ft l ever.
(6) Seat val ve body i n case and i nstal l one or two
bol ts to hol d val ve body i n pl ace.
(7) Ti ghten val ve body bol ts al ternatel y and evenl y
(9) Pl ace repl acement fi l ter i n posi ti on on val ve
body and i nto the oi l pump.
(10) I nstal l screw to hol d fi l ter to val ve body.
Ti ghten screw to 4.5 Nm (40 i n. l bs.) torque.
(11) Connect the sol enoi d and pressure swi tch
assembl y connector.
(12) I nstal l oi l pan. Ti ghten pan bol ts to 12 Nm
(14) Check and adjust gearshi ft cabl e, i f necessary.
TRANSFER CASE - NV242
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 280
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 281
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV242 . . . . . . . . . . . . . . . . . . . . . . . 281
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 282
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 293
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 307
SPECIFICATIONS
TRANSFER CASE - NV242 . . . . . . . . . . . . . 308
SPECIAL TOOLS
TRANSFER CASE - NV242 . . . . . . . . . . . . . 308
FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
FRONT OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 310
POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 311
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 311
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 312
REAR RETAINER BUSHING AND SEAL -
NV242HD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 312
SHIFT CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 313
DESCRIPTION
The NV242 i s a ful l transfer case (Fi g. 1). I t pro-
vi des ful l ti me 2-wheel , or 4-wheel dri ve operati on.
A di fferenti al i n the transfer case i s used to control
torque transfer to the front and rear axl es. A l ow
range gear provi des i ncreased l ow speed torque capa-
bi l i ty for off road operati on. The l ow range provi des a
2.72:1 reducti on rati o.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
TRANSFER CASE IDENTIFICATION
Two versi ons of the NV242 are used i n the WJ
vehi cl es, NV242LD and NV242HD. The two transfer
cases can be di sti ngui shed from one another by the
rear output shaft retai ner. The NV242LD uses a rub-
ber boot to cover the rear output shaft, whi l e the
NV242HD uses a cast al umi num housi ng. Other than
thi s di fference, the two transfer cases are servi ced
the same.
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 2). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a l ever i n the
fl oor mounted shi fter assembl y. The shi ft l ever i s con-
nected to the transfer case range l ever by an adjust-
abl e cabl e. A strai ght l i ne shi ft pattern i s used.
Range posi ti ons are marked on the shi fter bezel .
Fig. 1 NV242 Transfer Case
21 - 280 TRANSFER CASE - NV242 WJ
OPERATION
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. I t dri ves the mai nshaft through the pl an-
etary gear and range hub. The front output shaft i s
operated by a dri ve chai n that connects the shaft to a
dri ve sprocket on the mai nshaft. The dri ve sprocket
i s engaged/di sengaged by the mode fork, whi ch oper-
ates the mode sl eeve and hub. The sl eeve and hub
are not equi pped wi th a synchro mechani sm for shi ft-
i ng.
OPERATING RANGES
NV242 operati ng ranges are 2WD (2-wheel dri ve),
4x4 part-ti me, 4x4 ful l ti me, and 4 Lo.
The 2WD and 4x4 ful l ti me ranges can be used at
any ti me and on any road surface.
The 4x4 part-ti me and 4 Lo ranges are for off road
use onl y. The onl y ti me these ranges can be used on
hard surface roads, i s when the surface i s covered
wi th snow and i ce.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV242
DIAGNOSIS CHART
Transfer case difficult to shift or will
not shift into desired range.
1) Transfer case shift linkage
binding.
1) Repair or replace linkage as
necessary.
2) Insufficient or incorrect lubricant. 2) Drain and refill transfer case with
the correct type and quantity of
lubricant.
3) Internal transfer case
components binding, worn, or
damaged.
3) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct type and quantity of
lubricant.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Transfer case will not shift through
4X4 part time range (light remains
on)
1) Incomplete shift due to drivetrain
torque load.
1) Momentarily release the
accelerator pedal to complete the
shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive Tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.
Fig. 2 Fill/Drain Plug And I.D. Tag Locations
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
WJ TRANSFER CASE - NV242 21 - 281
TRANSFER CASE - NV242 (Continued)
REMOVAL
(1) Shi ft transfer case i nto NEUTRAL.
(3) Remove transfer case drai n pl ug and drai n
transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember and ski d pl ate, i f
equi pped (Fi g. 3).
(7) Di sconnect front/rear propel l er shafts at trans-
fer case. (Refer to 3 - DI FFERENTI AL & DRI V-
ELI NE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(8) Di sconnect transfer case cabl e from range
l ever.
(9) Di sconnect transfer case vent hose (Fi g. 4) and
transfer case posi ti on sensor.
(10) Support transfer case wi th transmi ssi on jack.
(11) Secure transfer case to jack wi th chai ns.
(12) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(13) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(14) Remove transfer case from under vehi cl e.
DISASSEMBLY
REAR RETAINER - NV242LD
(1) Remove output shaft boot. Spread band cl amp
that secures boot on sl i nger wi th a sui tabl e awl .
Then sl i de boot off shaft (Fi g. 5).
Fig. 3 Crossmember Removal
1 - CROSSMEMBER
Fig. 4 Transfer Case Mounting
Fig. 5 Output Boot - Typical
1 - SLINGER
2 - BOOT
3 - AWL
4 - TRANSFER CASE
(2) Usi ng pul l er MD-998056-A, remove rear sl i nger
(Fi g. 6).
(3) Remove rear seal from retai ner (Fi g. 7). Use
pry tool , or col l apse seal wi th punch to remove i t.
(4) Remove rear output beari ng I .D. retai ni ng ri ng
(Fi g. 8).
(5) Remove rear retai ner bol ts.
(6) Remove rear retai ner. Tap retai ner wi th mal l et
and pry upward to break seal er bead. Then sl i de
retai ner off case and output shaft (Fi g. 9).
Fig. 6 Rear Slinger Removal
1 - TRANSFER CASE
2 - SPECIAL TOOL MD998056-A
3 - SLINGER
Fig. 7 Rear Retainer Seal
1 - REAR RETAINER
2 - OUTPUT SHAFT SEAL
Fig. 8 Output Shaft Rear Bearing Retaining Ring
2 - RETAINING RING
Fig. 9 Rear Retainer Removal
1 - MAINSHAFT
2 - REAR RETAINER
REAR RETAINER - NV242HD
(1) Remove extensi on housi ng bol ts.
(2) Tap extensi on housi ng wi th pl asti c or rawhi de
mal l et to l oosen seal er (Fi g. 10).
(3) Separate extensi on housi ng from rear retai ner.
(4) Remove rear beari ng snap-ri ng (Fi g. 11).
(5) Remove bol ts hol di ng rear retai ner to rear case
hal f.
(6) Loosen rear retai ner wi th pry tool to break
seal er bead. Pry onl y agai nst retai ner boss as shown
(Fi g. 12).
(7) Sl i de retai ner off case and output shaft (Fi g.
13).
OIL PUMP AND REAR CASE HALF
(1) Remove rear beari ng O.D. retai ni ng ri ng wi th
snap ri ng pl i ers. Then ti l t pump and sl i de i t off out-
put shaft (Fi g. 14)
(2) Remove pi ckup tube O-ri ng from pump (Fi g.
15) but do not di sassembl e pump; i t i s not a repai r-
abl e part.
(3) Remove seal from oi l pump wi th pry tool .
(4) Remove bol ts attachi ng rear case to front case
(Fi g. 16). Note posi ti on of the two bl ack fi ni sh bol ts
at each end of the case. These bol ts go through the
case dowel s and requi re a washer under the bol t
head.
Fig. 10 Remove Extension Housing
1 - EXTENSION HOUSING
2 - PLASTIC HAMMER
3 - REAR RETAINER
Fig. 11 Remove the Output Bearing Snap-ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
Fig. 12 Loosening Rear Retainer
1 - REAR RETAINER
2 - TAB (2)
3 - SCREWDRIVER
4 - TAB
1 - MAINSHAFT
2 - REAR RETAINER
(5) Remove rear case from front case (Fi g. 17).
I nsert screwdri vers i nto sl ots cast i nto each end of
case. Then pry upward to break seal er bead and
remove rear case.
CAUTION: Do not pry on the sealing surface of
either case half as the surfaces will become dam-
aged.
(6) Remove oi l pi ckup tube and screen from rear
case (Fi g. 18).
Fig. 14 Oil Pump Removal
1 - OIL PUMP
Fig. 15 Pickup Tube O-Ring Location
1 - OIL PUMP
2 - O-RING
Fig. 16 Spline And Dowel Bolt Locations
1 - DOWEL BOLT AND WASHER (2)
2 - CASE BOLTS
3 - SPLINE HEAD BOLT (1)
Fig. 17 Loosening/Removing Rear Case
1 - MAINSHAFT
2 - SCREWDRIVER
3 - FRONT CASE
4 - SCREWDRIVER
5 - REAR CASE
Fig. 18 Oil Pickup Screen, Hose And Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
COMPANION FLANGE AND RANGE LEVER
(1) Remove transfer case posi ti on sensor (Fi g. 19).
(2) I nstal l two bol ts (Fi g. 20) parti al l y i nto the pro-
pel l or shaft compani on fl ange, 180 from each other.
(3) I nstal l the rectangul ar end of the Fl ange
Hol der C-3281 over the bol ts to hol d the compani on
fl ange stati onary and remove the nut hol di ng the
compani on fl ange to the output shaft.
(4) Use Remover C-452 (Fi g. 21) to remove the
compani on fl ange.
(5) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(6) Remove the bol t (Fi g. 22) that attaches the
range l ever to sector shaft. Then move sector to neu-
tral posi ti on and remove range l ever from shaft.
NOTE: Be sure to note the orientation of the range
lever (lever up or down) so that it may be re-in-
stalled in the same direction.
Fig. 19 Remove Transfer Case Position Sensor
1 - TRANSFER CASE POSITION SENSOR
2 - TRANSFER CASE
Fig. 20 Hold Companion Flange - Typical
1 - HOLDER C-3281
2 - BOLTS
3 - COMPANION FLANGE
Fig. 21 Remove Companion Flange - Typical
1 - TRANSFER CASE
2 - COMPANION FLANGE
3 - REMOVER C-452
Fig. 22 Remove Shift Lever Bolt - Typical
1 - RANGE LEVER
2 - RANGE LEVER BOLT
3 - TRANSFER CASE
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove dri ve sprocket snap-ri ng (Fi g. 23).
(2) Remove dri ve sprocket and chai n (Fi g. 24).
(3) Remove front output shaft (Fi g. 25).
SHIFT FORKS AND MAINSHAFT
(1) Remove shi ft detent pl ug, spri ng and pi n (Fi g.
26).
Fig. 23 Drive Sprocket Snap-Ring Removal
1 - DRIVE SPROCKET
2 - DRIVE SPROCKET SNAP-RING
Fig. 24 Drive Sprocket And Chain Removal
1 - DRIVE SPROCKET
2 - DRIVE CHAIN
Fig. 25 Removing Front Output Shaft
1 - FRONT OUTPUT SHAFT
Fig. 26 Detent Component Removal
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
(2) Remove seal pl ug from l ow range fork l ockpi n
access hol e. Then move shi ft sector to al i gn l ow range
fork l ockpi n wi th access hol e.
(3) Remove range fork l ockpi n wi th si ze number
one easy-out tool as fol l ows:
(a) I nsert easy-out tool through access hol e i n
si de of transfer case and i nto l ock-pi n.
(b) Tap easy-out tool i nto l ock-pi n wi th hammer
unti l tool i s securel y engaged i nto the l ock-pi n.
(c) I nstal l a t-handl e, such as from a tap and di e
set, onto the easy-out tool .
(d) Securel y ti ghten the t-handl e onto the tool .
(e) I n one moti on, pul l upward and turn the
t-handl e counter-cl ockwi se to remove the l ock-pi n.
(4) Remove shi ft rai l by pul l i ng i t strai ght up and
out of fork (Fi g. 27).
(5) Remove mode fork and mai nshaft as assembl y
(Fi g. 28).
(6) Remove mode shi ft sl eeve and mode fork
assembl y from mai nshaft (Fi g. 29). Note posi ti on of
mode sl eeve i n fork and remove sl eeve.
Fig. 27 Shift Rail Removal
1 - SHIFT RAIL
2 - MODE FORK
Fig. 28 Mainshaft And Mode Fork Removal
1 - MAINSHAFT ASSEMBLY
2 - MODE FORK
Fig. 29 Separate Mode Fork And Sleeve
1 - MAINSHAFT
2 - MODE SLEEVE
3 - MODE FORK ASSEMBLY
(7) Remove i ntermedi ate cl utch shaft snap-ri ng
(Fi g. 30).
(8) Remove cl utch shaft thrust ri ng (Fi g. 31).
(9) Remove i ntermedi ate cl utch shaft (Fi g. 32).
(10) Remove di fferenti al snap-ri ng (Fi g. 33).
(11) Remove di fferenti al (Fi g. 34).
(12) Remove di fferenti al needl e beari ngs and both
needl e beari ng thrust washers from mai nshaft.
Fig. 30 Intermediate Clutch Shaft Snap-Ring
Removal
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
Fig. 31 Clutch Shaft Thrust Ring Removal
1 - CLUTCH SHAFT THRUST RING
Fig. 32 Intermediate Clutch Shaft Removal
Fig. 33 Differential Snap-Ring Removal
1 - DIFFERENTIAL SNAP-RING
(13) Sl i de l ow range fork pi n out of shi ft sector
sl ot.
(14) Remove l ow range fork and sl eeve (Fi g. 35).
(15) Remove shi ft sector.
(16) Remove the shi ft sector shaft bushi ng and
o-ri ng (Fi g. 36).
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Remove front beari ng retai ner bol ts.
(2) Remove front beari ng retai ner. Careful l y pry
retai ner l oose wi th screwdri ver (Fi g. 37). Posi ti on
screwdri ver i n sl ots cast i nto retai ner.
(3) Remove i nput gear snap-ri ng (Fi g. 38).
Fig. 34 Differential Removal
1 - DIFFERENTIAL
2 - MAINSHAFT
Fig. 35 Low Range Fork And Hub Removal
1 - LOW RANGE FORK
2 - FORK HUB
Fig. 36 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 37 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
(4) Remove i nput/l ow range gear assembl y from
beari ng wi th Tool Handl e C-4171 and Tool 7829A
(Fi g. 39).
(5) Remove l ow range gear snap-ri ng (Fi g. 40).
(6) Remove i nput gear retai ner, thrust washers
and i nput gear from l ow range gear (Fi g. 41).
Fig. 38 Input Gear Snap Ring Removal
1 - INPUT GEAR
2 - SNAP-RING
Fig. 39 Input And Low Range Gear Assembly
Removal
1 - INPUT-LOW RANGE GEARS
2 - SPECIAL TOOL 7829-A
Fig. 40 Remove Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
Fig. 41 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
(7) I nspect l ow range annul us gear (Fi g. 42). Gear
is not a serviceable component. If damaged,
replace gear and front case as assembly.
(8) Remove oi l seal s from fol l owi ng components:
front beari ng retai ner.
rear retai ner.
oi l pump.
case hal ves.
DIFFERENTIAL
(1) Mark di fferenti al case hal ves for reference.
(2) Remove di fferenti al case bol ts.
(3) I nvert di fferenti al on workbench.
(4) Separate top case from bottom case. Use sl ots
i n case hal ves to pry them apart (Fi g. 43).
(5) Remove thrust washers and pl anet gears from
case pi ns (Fi g. 44).
(6) Remove mai nshaft and sprocket gears from
bottom case (Fi g. 45). Note gear posi ti on for reference
before separati ng them.
CLEANING
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and al l
purpose cl eaner. Use compressed ai r to remove sol -
vent resi due from oi l feed passages i n the case
hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
Fig. 42 Inspecting Low Range Annulus Gear
1 - LOW RANGE ANNULUS GEAR
Fig. 43 Separating Differential Case Halves
1 - TOP CASE
2 - CASE BOLTS
3 - CASE BOLTS
4 - CASE SLOTS
5 - CASE BOLTS
Fig. 44 Planet Gears And Thrust Washer Removal
1 - MAINSHAFT GEAR
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
INSPECTION
MAINSHAFT/SPROCKET/HUB
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket. Mi nor ni cks and scratches can
be smoothed wi th an oi l stone. However, repl ace any
part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320-400 gri t emery cl oth but do not
try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 46). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300-400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
Fig. 46 Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
Fig. 45 Mainshaft And Sprocket Gear Removal
1 - MAINSHAFT GEAR
2 - SPROCKET GEAR
3 - BOTTOM CASE
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 47). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320-400 gri t emery cl oth.
I nspect the shi ft fork wear pads. The mode fork
pads are servi ceabl e and can be repl aced i f necessary.
The range fork pads are al so servi ceabl e.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
I nspect the retai ner components (Fi g. 48). Repl ace
the beari ng i f rough or noi sy. Check the retai ner for
cracks or wear i n the beari ng bore. Cl ean the
retai ner seal i ng surfaces wi th a scraper and 3M al l
purpose cl eaner. Thi s wi l l ensure proper adhesi on of
the seal er duri ng reassembl y.
Repl ace the sl i nger and seal outri ght; do not reuse
ei ther part.
Repl ace any part i f di storted, bent, or broken. Al so
repl ace the boot i f cut or torn. Repl ace the boot band
cl amps, do not reuse them.
Fig. 48 Rear Retainer - Typical
1 - REAR RETAINER 5 - BAND CLAMPS
2 - REAR BEARING I.D. MAINSHAFT RETAINING RING 6 - REAR SLINGER
3 - REAR SEAL 7 - REAR BEARING O.D. RETAINING RING
4 - BOOT 8 - REAR BEARING
Fig. 47 Shift Fork And Wear Pad Locations
1 - MODE FORK
2 - RANGE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces of the
yoke sl i nger (Fi g. 49). Thi s surface must be cl ean and
smooth to ensure proper seal l i fe. Repl ace the yoke
nut and seal washer as nei ther part shoul d be
reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320-400 gri t emery to
smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 50)
FRONT-REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Cl ean the seal i ng surfaces wi th a scraper and
3M al l purpose cl eaner. Thi s wi l l ensure proper
seal er adhesi on at assembl y. Repl ace the i nput
retai ner seal ; do not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai n-
l ess steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ASSEMBLY
Lubri cate transfer case components wi th automati c
transmi ssi on fl ui d or petrol eum jel l y (where i ndi -
cated) duri ng assembl y.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
Fig. 49 Seal Contact Surface Of Yoke Slinger
1 - FRONT SLINGER (PART OF YOKE)
2 - SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 50 Low Range Annulus Gear
1 - FRONT CASE
BEARING AND SEAL
(1) Remove snap-ri ng that retai ns front output
shaft front beari ng i n case (Fi g. 51). Then remove
beari ng. Use hammer handl e, or hammer and brass
punch to tap beari ng out of case.
(2) I nstal l new front output shaft front beari ng
wi th Tool Handl e C-4171 and I nstal l er 8033-A wi th
the tapered cone upward (Fi g. 52).
(3) I nstal l front beari ng snap-ri ng (Fi g. 51).
(4) Remove front output shaft seal usi ng an appro-
pri ate pry tool (Fi g. 53) or sl i de-hammer mounted
screw.
(5) I nstal l new front output shaft oi l seal wi th
I nstal l er 6952-A (Fi g. 54).
Fig. 51 Front Output Shaft Front Bearing Snap-Ring
Removal
1 - FRONT BEARING SNAP-RING
Fig. 52 Front Output Shaft Front Bearing Installation
2 - SPECIAL TOOL 8033-A
Fig. 53 Remove Front Output Shaft Seal
2 - PRYBAR
Fig. 54 Install Front Output Shaft Seal
1 - INSTALLER 6952-A
2 - TRANSFER CASE
(6) Remove i nput gear beari ng wi th Tool Handl e
C-4171 and Remover C-4210 (Fi g. 55).
(7) I nstal l snap-ri ng on new i nput gear beari ng.
(8) I nstal l new i nput gear beari ng wi th Tool Han-
dl e C-4171 and Remover C-4210. I nstal l beari ng far
enough to seat snap-ri ng agai nst case (Fi g. 56).
(9) Remove the i nput gear pi l ot beari ng by i nsert-
i ng a sui tabl y si zed dri ft i nto the spl i ned end of the
i nput gear and dri vi ng the beari ng out wi th the dri ft
and a hammer (Fi g. 57).
(10) I nstal l new pi l ot beari ng wi th I nstal l er 8128
Fig. 55 Input Gear Bearing Removal
Fig. 56 Seating Input Gear Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 57 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 58 Install Input Gear Pilot Bearing
1 - HANDLE C-4171
2 - INSTALLER 8128
3 - INPUT GEAR
(11) I nstal l new seal i n front beari ng retai ner wi th
(12) Remove output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 60).
(13) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 61). Lubri cate beari ng after
i nstal l ati on.
(14) I nstal l new seal i n oi l pump feed housi ng wi th
Speci al Tool 7888 (Fi g. 62).
Fig. 59 Front Bearing Retainer Seal Installation
Fig. 60 Remove Front Output Shaft Rear Bearing
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
Fig. 61 Install Front Output Shaft Rear Bearing
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 62 Oil Pump Seal Installation
1 - HOUSING SEAL
3 - OIL PUMP FEED HOUSING
(15) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 63).
(16) Remove rear retai ner beari ng wi th I nstal l er
8128 and Handl e C-4171, NV242HD onl y.
(17) I nstal l rear beari ng i n retai ner wi th Handl e
C-4171 and I nstal l er 5064 (Fi g. 64), NV242HD onl y.
DIFFERENTIAL
(1) Lubri cate di fferenti al components wi th auto-
mati c transmi ssi on fl ui d.
(2) I nstal l sprocket gear i n di fferenti al bottom case
(Fi g. 65).
(3) I nstal l di fferenti al pl anet gears and new thrust
washers (Fi g. 66). Be sure thrust washers are
installed at top and bottom of each planet gear.
(4) I nstal l di fferenti al mai nshaft gear (Fi g. 66).
Fig. 63 Pickup Tube O-Ring Installation
1 - PICKUP TUBE O-RING
Fig. 64 Installing Rear Bearing In Retainer
3 - REAR RETAINER
Fig. 65 Installing Differential Sprocket Gear
1 - SPROCKET GEAR
2 - BOTTOM CASE
Fig. 66 Installing Mainshaft And Planet Gears
1 - MAINSHAFT GEAR
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
(5) Al i gn and posi ti on di fferenti al top case on bot-
tom case (Fi g. 67). Al i gn usi ng scri be marks made at
di sassembl y.
(6) Whi l e hol di ng di fferenti al case hal ves together,
i nvert the di fferenti al and start the di fferenti al case
bol ts.
(7) Ti ghten di fferenti al case bol ts to speci fi ed
torque.
(1) Assembl e l ow range gear, i nput gear thrust
washers, i nput gear and i nput gear retai ner (Fi g. 68).
(2) I nstal l l ow range gear snap ri ng (Fi g. 69).
(3) Lubri cate i nput gear and l ow range gears wi th
automati c transmi ssi on fl ui d.
(4) Start i nput gear shaft i nto front case beari ng.
(5) Press i nput gear shaft i nto front beari ng.
(6) I nstal l new i nput gear snap ri ng (Fi g. 70).
(7) Appl y 3 mm (1/8 i n.) wi de bead of Mopar gas-
ket maker or si l i cone adhesi ve seal er to seal surface
of front beari ng retai ner.
(8) I nstal l front beari ng retai ner (Fi g. 71). Ti ghten
retai ner bol ts to 16 ft. l bs. (21 Nm) torque.
SHIFT FORKS, SECTOR, AND MAINSHAFT
(1) I nstal l the shi ft sector shaft o-ri ng and bush-
i ng.
(2) I nstal l shi ft sector.
(3) I nstal l new pads on l ow range fork, i f neces-
sary.
(4) Assembl e l ow range fork and sl eeve.
Fig. 67 Differential Case Assembly
1 - TOP CASE
2 - BOTTOM CASE
3 - CASE ALIGNMENT MARKS
Fig. 68 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
Fig. 69 Install Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
(5) Posi ti on l ow range fork and sl eeve i n case. Be
sure l ow range fork pi n i s engaged i n shi ft sector sl ot.
(6) I nstal l fi rst mai nshaft beari ng spacer on mai n-
shaft (Fi g. 72).
(7) I nstal l beari ng rol l ers on mai nshaft (Fi g. 72).
Coat beari ng rol l ers wi th generous quanti ty of petro-
l eum jel l y to hol d them i n pl ace.
(8) I nstal l remai ni ng beari ng spacer on mai nshaft
(Fi g. 72). Do not di spl ace any beari ngs whi l e i nstal l -
i ng spacer.
(9) I nstal l di fferenti al (Fi g. 73). Do not di spl ace
mai nshaft beari ngs when i nstal l i ng di fferenti al .
Fig. 70 Input Gear Snap-Ring Installation
1 - INPUT GEAR
2 - SNAP-RING
Fig. 71 Installing Front Bearing Retainer
Fig. 72 Installing Mainshaft Bearing Rollers and
Spacers
1 - MAINSHAFT BEARING ROLLERS
2 - BEARING SPACERS
Fig. 73 Differential Installation
1 - DIFFERENTIAL
2 - MAINSHAFT
(10) I nstal l di fferenti al snap-ri ng (Fi g. 74).
(11) I nstal l i ntermedi ate cl utch shaft (Fi g. 75).
(12) I nstal l cl utch shaft thrust washer (Fi g. 76).
(13) I nstal l cl utch shaft snap-ri ng (Fi g. 77).
(14) I nspect mode fork assembl y (Fi g. 78). Repl ace
pads and bushi ng i f necessary. Repl ace fork tube i f
bushi ngs i nsi de tube are worn or damaged. Al so
check spri ngs and sl i der bracket (Fi g. 78). Repl ace
worn, damaged components.
Fig. 74 Installing Differential Snap-Ring
1 - DIFFERENTIAL SNAP-RING
Fig. 75 Installing Intermediate Clutch Shaft
Fig. 76 Installing Clutch Shaft Thrust Washer
1 - CLUTCH SHAFT THRUST RING
Fig. 77 Installing Clutch Shaft Snap-Ring
1 - SNAP-RING
(15) I nstal l mode sl eeve i n mode fork (Fi g. 79).
Then i nstal l assembl ed sl eeve and fork on mai nshaft.
Be sure mode sl eeve spl i nes are engaged i n di fferen-
ti al spl i nes.
(16) I nstal l mode fork and mai nshaft assembl y i n
case (Fi g. 80). Rotate mai nshaft sl i ghtl y to engage
shaft wi th l ow range gears.
(17) Rotate mode fork pi n i nto shi ft sector sl ot.
Fig. 79 Installing Mode Fork And Sleeve
1 - MAINSHAFT
2 - MODE SLEEVE
3 - MODE FORK ASSEMBLY
Fig. 80 Assembled Mainshaft And Mode Fork
Installation
1 - MAINSHAFT ASSEMBLY
2 - MODE FORK
Fig. 78 Mode Fork Assembly Inspection
1 - SLIDER
2 - MODE FORK
3 - BUSHING/SPRING
4 - TUBE
5 - PADS
(18) I nstal l shi ft rai l (Fi g. 81). Be sure rai l i s
seated i n both shi ft forks.
(19) Rotate shi ft sector to al i gn l ockpi n hol e i n l ow
range fork wi th access hol e i n case.
(20) I nsert an easy-out i n range fork l ockpi n to
hol d i t securel y for i nstal l ati on (Fi g. 82). Lockpi n i s
sl i ghtl y tapered on one end. I nsert tapered end i nto
fork and rai l .
(21) I nsert l ockpi n through access hol e and i nto
shi ft fork (Fi g. 82). Then remove easy-out and seat
the pi n wi th pi n punch.
(22) I nstal l pl ug i n l ockpi n access hol e.
(23) I nstal l detent pl unger, detent spri ng and
detent pl ug i n case (Fi g. 83).
Fig. 81 Shift Rail Installation
1 - SHIFT RAIL
2 - MODE FORK
Fig. 82 Installing Low Range Fork Lockpin
1 - LOW RANGE FORK LOCK PIN
2 - ACCESS HOLE
3 - EASY-OUT
Fig. 83 Detent Pin, Spring And Plug Installation
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
(1) I nstal l front output shaft (Fi g. 84).
(2) I nstal l dri ve chai n (Fi g. 84). Engage chai n wi th
front output shaft sprocket teeth.
(3) I nstal l dri ve sprocket (Fi g. 84). Engage dri ve
sprocket teeth wi th chai n. Then engage sprocket
spl i nes wi th mai nshaft spl i nes.
(4) I nstal l dri ve sprocket snap-ri ng (Fi g. 85).
OIL PUMP AND REAR CASE
(1) I nsert oi l pi ckup tube i n oi l pump and attach
oi l screen and connector hose to pi ckup tube. Then
i nstal l assembl ed pump, tube and screen i n rear case
(Fi g. 86). Be sure screen i s seated i n case sl ot as
shown.
(2) I nstal l magnet i n front case pocket (Fi g. 87).
ket maker or si l i cone adhesi ve seal er to seal surface
of front case.
(4) Al i gn and i nstal l rear case on front case. Be
sure case l ocati ng dowel s are i n pl ace and that mai n-
shaft spl i nes are engaged i n oi l pump i nner gear.
(5) I nstal l and ti ghten front case-to-rear case bol ts
to 41 Nm (30 ft. l bs.) torque. Be sure to install a
washer under each bolt used at case dowel
locations.
Fig. 84 Drive Chain And Sprocket Installation
1 - DRIVE SPROCKET
2 - DRIVE CHAIN
Fig. 85 Drive Sprocket Snap-Ring Installation
1 - DRIVE SPROCKET
Fig. 86 Oil Screen And Pickup Tube Installation
1 - OIL PUMP
2 - OIL SCREEN
3 - CONNECTOR
4 - PICKUP TUBE
REAR RETAINER - NV242LD
(1) Appl y bead of Mopar Seal er, or Locti te
Ul tra Gray, to mati ng surface of rear retai ner. Seal er
bead shoul d be a maxi mum of 3/16 i n.
(2) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 20-27 Nm (15-20 ft. l bs.) torque.
(3) I nstal l rear beari ng I .D. retai ni ng ri ng and
spacer on output shaft.
(4) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(5) Sl i de seal onto Seal Protector 6992 (Fi g. 88).
Sl i de seal protector and seal onto output shaft.
(6) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th I nstal l er
C-4076-B and Handl e MD-998323 (Fi g. 89).
(7) I nstal l rear sl i nger wi th I nstal l er 8408.
(8) I nstal l boot on output shaft sl i nger and cri mp
retai ni ng cl amp wi th tool C-4975-A (Fi g. 90).
Fig. 88 Output Shaft Seal and Protector
3 - TRANSFER CASE
Fig. 87 Installing Case Magnet
1 - MAGNET
Fig. 89 Rear Seal Installation
2 - HANDLE
3 - TRANSFER CASE
Fig. 90 Slinger Boot Installation
1 - SPECIAL TOOL C-4975-A
2 - SLINGER
3 - BOOT
4 - CLAMP
NV242HD REAR RETAINER
(1) Appl y bead of Mopar Seal er, or Locti te
Ul tra Gray, to mati ng surface of rear retai ner. Seal er
bead shoul d be a maxi mum of 3/16 i n.
(2) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 20-27 Nm (15-20 ft. l bs.) torque.
(3) I nstal l new output shaft beari ng snap-ri ng
(Fi g. 91). Li ft mai nshaft sl i ghtl y to seat snap-ri ng i n
shaft groove, i f necessary.
ket maker or si l i cone adhesi ve seal er to mounti ng
surface of extensi on housi ng. Al l ow seal er to set-up
sl i ghtl y before proceedi ng.
(5) I nstal l extensi on housi ng on rear retai ner.
(6) I nstal l extensi on housi ng bol ts and ti ghten to
35-46 Nm (26-34 ft. l bs.).
COMPANION FLANGE
(1) Lubri cate compani on fl ange hub wi th transmi s-
si on fl ui d and i nstal l fl ange on front shaft.
(2) I nstal l new seal washer on front shaft.
(3) I nstal l fl ange on front shaft and ti ghten nut to
122-176 Nm (90-130 ft. l bs.).
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (26 ft. l bs.) torque (Fi g. 4).
(6) Al i gn and connect propel l er shafts. (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - I NSTALLATI ON)
(7) Fi l l transfer case wi th correct fl ui d. Check
transmi ssi on fl ui d l evel . Correct as necessary.
(8) I nstal l rear crossmember and ski d pl ate, i f
equi pped. Ti ghten crossmember bol ts to 41 Nm (30
ft. l bs.) torque.
(9) Remove transmi ssi on jack and support stand.
(10) Connect shi ft rod to transfer case range l ever.
(11) Connect transfer case vent hose and transfer
case posi ti on sensor.
(12) Adjust transfer case shi ft cabl e.
(13) Lower vehi cl e and veri fy transfer case shi ft
operati on.
Fig. 91 Install Output Bearing Snap-ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
SPECIFICATIONS
Plug, Detent 16-24 11.8-17.7 -
Bolt, Diff. Case 17-27 12.5-19.9 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Front Brg. Retainer 16-27 11.8-19.9 -
Bolt, Case Half 35-46 25.8-33.9 -
Nut, Front Yoke 122-176 90-130 -
Screw, Oil Pump 1.2-1.8 - 12-15
Nut, Range Lever 27-34 19.9-25 -
Bolt, Rear Retainer 35-46 25.8-33.9 -
Nuts, Mounting 35 25.8 -
Bolts, U-Joint 19 14 -
SPECIAL TOOLS
Installer, Seal - C-4076-B
Handle, Universal - C-4171
Remover, Bearing - C-4210
Puller, Slinger - MD-998056-A
Installer - MD-998323
Installer, Seal - 6952-A
Remover, Bearing - L-4454
Cup - 8148
Protector, Seal - 6992
Installer, Input Gear Bearing - 7829-A
Installer, Pump Housing Seal - 7888
Installer, Bearing - 8033-A
Installer, Boot Clamp - C-4975-A
FLUID
REFILL
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 92).
(2) Posi ti on drai n pan under transfer case.
(3) Remove drai n and fi l l pl ugs and drai n l ubri -
cant compl etel y.
(4) I nstal l drai n pl ug. Ti ghten pl ug to 20-34 Nm
(15-25 ft. l bs.).
(5) Remove drai n pan.
(6) Fi l l transfer case to bottom edge of fi l l pl ug
openi ng wi th Mopar Transfer Case Lubri cant.
(7) I nstal l and ti ghten fi l l pl ug to 20-34 Nm
(15-25 ft. l bs.).
REMOVAL
(2) Remove front propel l er shaft. (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Remove front output shaft compani on fl ange.
(4) Remove seal from front case wi th pry tool (Fi g.
93).
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 6952-A as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 94). Once seal i s started, conti nue tap-
pi ng seal i nto bore unti l i nstal l er tool seats agai nst
case.
(2) I nstal l compani on fl ange and ti ghten nut to
122-176 (90-130 ft. l bs.) torque.
(3) I nstal l front propel l er shaft. (Refer to 3 - DI F-
PROPELLER SHAFT - I NSTALLATI ON)
Fig. 92 Fill/Drain Plug and I.D. Tag Location -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
2 - PRYBAR
Fig. 94 Front Output Seal Installation
2 - TRANSFER CASE
POSITION SENSOR
DESCRIPTION
The transfer case posi ti on sensor (Fi g. 95) i s an
el ectroni c devi ce whose output can be i nterpreted to
i ndi cate the transfer cases current operati ng mode.
The sensor consi sts of a fi ve posi ti on, resi sti ve mul ti -
pl exed ci rcui t whi ch returns a speci fi c resi stance
val ue to the Powertrai n Control Modul e (PCM) for
each transfer case operati ng mode. The sensor i s
l ocated on the top of the transfer case, just l eft of the
transfer case centerl i ne and ri des agai nst the sector
pl ate roostercomb. The PCM suppl i es 5VDC (+/-
0.5V) to the sensor and moni tors the return vol tage
to determi ne the sector pl ate, and therefore the
transfer case, posi ti on.
OPERATION
Duri ng normal vehi cl e operati on, the Powertrai n
Control Modul e (PCM) moni tors the transfer case
posi ti on sensor return vol tage to determi ne the oper-
ati ng mode of the transfer case. Refer to the Operat-
i ng Mode Versus Resi stance tabl e for the correct
resi stance for each posi ti on (Fi g. 96).
OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2WD 1124-1243
2 4WD PART TIME 650-719
3 4WD FULL TIME 389-431
4 NEUTRAL 199-221
5 4WD LOW 57-64
Fig. 96 Position Sensor Linear Movement
1 - POSITION 1 - 10mm 0.5mm
6 - POSITION 6 - 20mm0.5mm - FULL EXTENSION
Fig. 95 Transfer Case Position Sensor and
Connector
1 - TRANSFER CASE POSITION SENSOR CONNECTOR
3 - TRANSFER CASE
4 - OUTPUT SPEED SENSOR CONNECTOR
REMOVAL
(2) Di sengage the transfer case posi ti on sensor
connector from the posi ti on sensor (Fi g. 97).
(3) Remove the posi ti on sensor from the transfer
case.
INSTALLATION
(1) I nspect the o-ri ng seal on the transfer case
posi ti on sensor. Repl ace the o-ri ng i f necessary.
(2) I nstal l the transfer case posi ti on sensor i nto
the transfer case. Torque the sensor to 20-34 Nm
(15-25 ft.l bs.).
(3) Engage the transfer case posi ti on sensor con-
nector to the posi ti on sensor.
(5) Veri fy proper sensor operati on.
REAR RETAINER BUSHING
AND SEAL - NV242HD
REMOVAL
(2) Remove rear propel l er shaft. (Refer to 3 - DI F-
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear retai ner seal .
(4) Usi ng Remover 6957, remove bushi ng from
rear retai ner (Fi g. 98).
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Posi ti on repl acement bushi ng i n rear retai ner
wi th fl ui d port i n bushi ng al i gned wi th sl ot i n
retai ner.
(3) Usi ng I nstal l er 8160, dri ve bushi ng i nto
retai ner unti l i nstal l er seats agai nst case (Fi g. 99).
(4) Usi ng I nstal l er C-3995-A, i nstal l seal i n rear
Fig. 97 Transfer Case Position Sensor and
Connector
1 - TRANSFER CASE POSITION SENSOR CONNECTOR
3 - TRANSFER CASE
4 - OUTPUT SPEED SENSOR CONNECTOR
Fig. 98 Rear Retainer Bushing Removal
1 - REMOVER 6957
2 - REAR RETAINER BUSHING
Fig. 99 Rear Retainer Bushing Install
2 - INSTALLER 8160
POSITION SENSOR (Continued)
(5) I nstal l the rear propel l er shaft. (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - I NSTALLATI ON)
(6) Veri fy proper fl ui d l evel .
SHIFT CABLE
REMOVAL
(3) Di sconnect the shi ft cabl e eyel et from the
bracket.
to shi ft l ever assembl y and shi ft cabl e.
(10) Remove transfer case shi ft cabl e from vehi cl e.
INSTALLATION
(3) I nstal l nuts to hol d seal pl ate to fl oor pan (Fi g.
103). Ti ghten nuts to 7 Nm (65 i n.l bs.).
Fig. 100 Install Rear Retainer Seal
Fig. 101 Transfer Case Shift Cable at Transfer Case
Fig. 102 Transfer Case Shift Cable at Shifter
1 - CLIP
2 - SHIFTER
1 - SEAL PLATES
REAR RETAINER BUSHING AND SEAL - NV242HD (Continued)
shi fter assembl y bracket. Seat cabl e i n bracket and
i nstal l cl i p (Fi g. 102).
(5) Veri fy the transfer case shi ft l ever (at consol e)
i s i n the NEUTRAL posi ti on.
(6) Snap the cabl e onto the shi ft l ever pi n (Fi g.
102).
bracket and i nstal l cl i p (Fi g. 101).
(9) Veri fy that the transfer case i s sti l l i n the
NEUTRAL posi ti on.
(10) Snap the shi ft cabl e onto the transfer case
shi ft l ever (Fi g. 101).
(12) Veri fy correct transfer case operati on i n al l
ranges.
transfer case shi ft cabl e.
SHIFT CABLE (Continued)
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 315
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 316
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV247 . . . . . . . . . . . . . . . . . . . . . . . 316
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 317
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 324
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 335
SPECIFICATIONS
TRANSFER CASE - NV247 . . . . . . . . . . . . . 336
SPECIAL TOOLS
TRANSFER CASE - NV247 . . . . . . . . . . . . . 337
FLUID
REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 338
REAR RETAINER BUSHING AND SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 339
SHIFT CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 340
DESCRIPTION
The NV247 (Fi g. 1) i s an on-demand 4-wheel dri ve
transfer case wi th two operati ng ranges and a neu-
tral posi ti on. Operati ng ranges are 4-hi gh and 4-l ow.
The 4-l ow range i s used for extra pul l i ng power i n
off-road si tuati ons.
TRANSFER CASE IDENTIFICATION
A ci rcul ar I .D. tag i s attached to the rear case of
each NV247 transfer case (Fi g. 2). The tag i ndi cates
the fol l owi ng i nformati on:
Model number
Seri al number
Assembl y number
Gear rati o
Locati on of manufacture
The transfer case seri al number al so represents
the date of bui l d.
Fig. 1 NV247 Transfer Case
Fig. 2 Transfer Case I.D. Tag
1 - FILL PLUG
2 - I.D. TAG
3 - DRAIN PLUG
OPERATION
Under normal dri vi ng condi ti ons, the system oper-
ates conventi onal l y, and the majori ty of avai l abl e
torque i s appl i ed to the rear wheel s. However, when
front-to-rear wheel speed vari ati ons exi st, the pro-
gressi ve di fferenti al transfers torque to the axl e wi th
the better tracti on, thus mi ni mi zi ng wheel spi n and
maxi mi zi ng control .
The key to thi s desi gn i s a progressi ve coupl i ng
(Fi g. 3), whi ch i s suppl i ed wi th pressuri zed oi l by a
gerotor styl e pump. The pump rotor and case are
dri ven by the front and rear dri veshafts respecti vel y,
and del i ver pressuri zed oi l fl ow to the coupl i ng i n
proporti on to thei r speed di fference. The progressi ve
coupl i ng contai ns a mul ti -di sc cl utch pack that i s
al ternatel y spl i ned to the front and rear dri veshafts,
and control s torque vari ati on between the front and
rear dri veshafts as di ctated by the pump.
A set of ori fi ces and val ves control the speed-di ffer-
enti al starti ng poi nt and rate of torque transfer ri se
i n the cl utch. Thi s al l ows the system to di sregard the
normal speed di fferences between axl es that resul t
from vari ati ons i n front-to-rear l oadi ng and typi cal
corneri ng.
Transfer case operati ng ranges are sel ected wi th a
fl oor mounted shi ft l ever. The shi ft l ever i s connected
to the transfer case range l ever by an adjustabl e
cabl e. Range posi ti ons are marked on the shi fter
bezel pl ate.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV247
TRANSFER CASE DIFFICULT TO
SHIFT OR WILL NOT SHIFT INTO
DESIRED RANGE
1. Vehicle speed too great to permit
shifting
1. Reduce speed to 3-4 km/h (2-3
mph) before attempting to shift
2. Transfer case external shift cable
binding
2. Lubricate, repair or replace cable,
or thighten loose components as
necessary
3. Insufficient or incorrect lubricant 3. Drain and refill to edge of fill hole
with correct lubricant
4. Internal components binding,
worn, or damaged
4. Disassemble unit and replace
worn or damaged components as
necessary
TRANSFER CASE NOISY IN ALL
MODES
1. Insufficient or incorrect lubricant 1. Drain and refill to edge of fill hole
with correct lubricant. If unit is still
noisy after drain and refill,
disassembly and inspection may
be required to locate source of
noise
Fig. 3 Progressive Coupling
NOISY INOR JUMPS OUT OF
4WD LOW RANGE
1. Transfer case not completely
engaged in 4WD LOW (possibly
from shift to 4L while rolling)
1. Stop vehicle, shift transfer case
to neutral, then shift back to 4WD
LOW
2. Shift linkage loose, binding, or is
misadjusted
2. Tighten, lubricate, or repair
linkage as necessary. Adjust linkage
if necessary
3. Range fork cracked, inserts
worn, or fork is binding on shift rail
3. Disassemble unit and repair as
necessary
4. Annulus gear or lockplate worn
or damaged
4. Disassemble unit and repair as
necessary
LUBRICANT LEAKING FROM
OUTPUT SHAFT SEALS OR FROM
VENT
1. Transfer case over filled 1. Drain to correct level
2. Vent closed or restricted 2. Clear or replace vent if necessary
3. Output shaft seals damaged or
installed correctly
3. Replace seals. Be sure seal lip
faces interior of case when installed.
Also be sure yoke seal surfaces are
not scored or nicked. Remove
scores and nicks with fine
sandpaper or replace yoke(s) if
necessary.
REMOVAL
(3) Remove transfer case drai n pl ug and drai n
transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember and ski d pl ate, i f
equi pped (Fi g. 4).
(7) Di sconnect front propel l er shaft from transfer
case at compani on fl ange. Remove rear propel l er
shaft from vehi cl e. (Refer to 3 - DI FFERENTI AL &
DRI VELI NE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
CAUTION: Do not allow propshafts to hang at
attached end. Damage to joint can result.
(8) Di sconnect transfer case cabl e from range
l ever.
(9) Di sconnect transfer case vent hose (Fi g. 5).
(10) Support transfer case wi th transmi ssi on jack.
(12) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(13) Pul l transfer case and jack rearward to di sen-
gage transfer case (Fi g. 5).
(14) Remove transfer case from under vehi cl e.
DISASSEMBLY
Posi ti on transfer case on shal l ow drai n pan.
Remove drai n pl ug and drai n l ubri cant remai ni ng i n
case.
Fig. 4 Crossmember Removal
1 - CROSSMEMBER
REAR RETAINER AND OIL PUMP
(1) Remove rear retai ner bol ts (Fi g. 6).
(2) Remove rear beari ng l ocati ng ri ng access pl ug
(Fi g. 7).
(3) Loosen rear retai ner wi th pry tool to break
seal er bead. Pry onl y agai nst retai ner boss as shown
(Fi g. 8).
(4) Remove rear retai ner as fol l ows:
(a) Spread rear beari ng l ocati ng ri ng wi th snap
ri ng pl i ers (Fi g. 9).
(b) Then sl i de retai ner off mai nshaft and rear
Fig. 5 Transfer Case Mounting
Fig. 6 Rear Retainer Bolt Removal
1 - REAR RETAINER
Fig. 7 Remove Rubber Access Plug
1 - PLUG
Fig. 8 Loosening Rear Retainer
1 - RETAINER BOSS
2 - PRY TOOL
3 - SEALER BEAD
4 - REAR RETAINER
(5) Remove rear beari ng snap-ri ng.
(6) Remove rear beari ng. Note posi ti on of beari ng
l ocati ng ri ng groove for assembl y reference.
(7) Di sengage oi l pi ckup tube from oi l pump and
remove oi l pump assembl y (Fi g. 11).
(8) Remove pi ck-up tube o-ri ng from oi l pump (Fi g.
12), i f necessary. Do not di sassembl e the oi l pump, i t
i s not servi ceabl e.
(1) Remove front compani on fl ange nut as fol l ows:
(a) Move range l ever to 4L posi ti on.
(b) Remove nut wi th socket and i mpact wrench.
(2) Remove compani on fl ange. I f fl ange i s di ffi cul t
to remove by hand, remove i t wi th beari ng spl i tter, or
wi th standard two jaw pul l er. Be sure pul l er tool i s
posi ti oned on fl ange and not on sl i nger as sl i nger wi l l
be damaged.
(3) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(4) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft.
NOTE: Note position of range lever so it can be re-
installed correctly.
Fig. 9 Disengaging Rear Bearing Locating Ring
1 - REAR RETAINER
2 - PARALLEL JAW SNAP-RING PLIERS
1 - REAR CASE
2 - REAR RETAINER
Fig. 11 Rear Bearing and Oil Pump Removal
1 - OIL PUMP
2 - TUBE O-RING
3 - OIL PICKUP TUBE
Fig. 12 Pick-up Tube O-ring Location
1 - OIL PUMP
2 - O-RING
REAR CASE
(1) Support transfer case so rear case i s faci ng
upward.
(2) Remove bol ts hol di ng front case to rear case.
The case al i gnment bol t requi re fl at washers (Fi g.
13).
(3) Loosen rear case wi th fl at bl ade screwdri ver to
break seal er bead. I nsert screwdri ver bl ade onl y i nto
notches provi ded at each end of case (Fi g. 14).
(4) Remove rear case (Fi g. 15).
PROGRESSIVE COUPLING
(1) Remove oi l pump l ocati ng snap-ri ng and pro-
gressi ve coupl i ng thrust washer from the mai nshaft
(Fi g. 16).
(2) Remove progressi ve coupl i ng from mai nshaft
(Fi g. 16).
Fig. 13 Rear Case Alignment Bolt Locations
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 14 Loosening Rear Case
1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE
Fig. 15 Rear Case Removal
1 - REAR HOUSING
2 - MAINSHAFT
3 - TRANSFER CASE
Fig. 16 Progressive Coupling Removal
1 - SNAP-RING
2 - PROGRESSIVE COUPLING
(1) Remove oi l pi ckup tube from rear case (Fi g.
17).
(2) Remove dri ve gear snap-ri ng (Fi g. 18).
(3) Di sengage dri ve gear (Fi g. 18). Pry gear
upward and off mai nshaft as shown.
(4) Remove front output shaft, dri ve chai n and
dri ve gear as assembl y (Fi g. 18).
(5) Remove output shaft dri ve gear snap ri ng.
(6) Remove output shaft dri ve gear from output
shaft.
(1) Remove detent pl ug, O-ri ng, detent spri ng and
detent pl unger (Fi g. 19).
(2) Remove shi ft rai l from shi ft fork and transfer
case housi ng.
(3) Rotate range shi ft fork unti l i t di sengages from
shi ft sector.
(4) Remove mai nshaft and shi ft fork from i nput
gear pi l ot beari ng.
NOTE: Loose needle bearings are used to support
the drive sprocket hub on the mainshaft. Do not lift
mainshaft by drive sprocket hub or needle bearings
will become dislodged.
(5) Wrap rag around mai nshaft underneath dri ve
sprocket hub and remove dri ve sprocket hub from
mai nshaft. Be sure to retri eve al l the dri ve sprocket
hub needl e beari ngs.
(6) Remove snap ri ng hol di ng cl utch sl eeve onto
mai nshaft.
Fig. 17 Oil Pickup Tube Removal
1 - OIL PICKUP TUBE
Fig. 18 Front Output Shaft, Drive Gear And Chain
Removal
1 - REAR HOUSING
2 - OUTPUT SHAFT AND SPROCKET
3 - MAINSHAFT SPROCKET
4 - SNAP-RING
5 - DRIVE CHAIN
Fig. 19 Detent Plug, Spring And Plunger Removal
1 - DETENT PLUG
2 - DETENT SPRING
3 - DETENT PLUNGER
4 - PLUG O-RING
(7) Remove range cl utch sl eeve, bl ockout spri ng,
l ocki ng cl utch, and l ocki ng cl utch spri ng from mai n-
shaft (Fi g. 20).
(8) Remove shi ft sector. Rotate and ti l t sector as
needed to remove i t (Fi g. 21).
(9) Remove shi ft sector bushi ng and O-ri ng (Fi g.
22).
(1) Turn front case on si de so front beari ng
retai ner i s accessi bl e.
(2) Remove front beari ng retai ner bol ts (Fi g. 23).
(3) Remove front beari ng retai ner as fol l ows:
(a) Loosen retai ner wi th fl at bl ade screwdri ver
to break seal er bead. To avoid damaging case
and retainer, position screwdriver blade only
in slots provided in retainer (Fig. 24).
(b) Then remove retai ner from case and gear.
Fig. 20 Range Clutch Sleeve, Blockout Spring,
Locking Clutch and Spring
1 - LOCKING CLUTCH SPRING
2 - BLOCKOUT SPRING
3 - SNAP-RING
4 - RANGE CLUTCH SLEEVE
5 - LOCKING CLUTCH
6 - DRIVE SPROCKET HUB
Fig. 21 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 22 Sector Bushing And O-Ring Removal
1 - SHIFT SECTOR BUSHING
2 - O-RING
Fig. 23 Front Bearing Retainer Bolt Removal
(4) Remove snap-ri ng that retai ns i nput gear shaft
i n front beari ng (Fi g. 25).
(5) Remove i nput and l ow range gear assembl y
(Fi g. 26).
(6) Remove oi l seal s from fol l owi ng components:
front beari ng retai ner.
rear retai ner.
case hal ves.
INPUT AND LOW RANGE GEAR
(1) Remove snap-ri ng that retai ns i nput gear i n
l ow range gear (Fi g. 27).
Fig. 24 Front Bearing Retainer Removal
2 - RETAINER NOTCH
3 - FLAT BLADE SCREWDRIVER
Fig. 25 Input Gear Snap-Ring Removal
1 - INPUT GEAR
2 - SNAP-RING
Fig. 26 Input And Low Range Gear Assembly
Removal
1 - INPUT AND LOW RANGE GEAR ASSEMBLY
Fig. 27 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
(2) Remove retai ner (Fi g. 28).
(3) Remove front tabbed thrust washer (Fi g. 29).
(4) Remove i nput gear (Fi g. 30).
(5) Remove rear tabbed thrust washer from l ow
range gear (Fi g. 31).
CLEANING
Cl ean the transfer case components wi th parts
cl eani ng sol vent. Fl ush the oi l passages i n the cases
and dri vetrai n components wi th sol vent. Thi s wi l l
hel p remove di rt and parti cl es from these passages.
Dry the transfer case components wi th compressed
ai r or al l ow them to ai r dry on cl ean shop towel s.
Appl y compressed ai r through al l oi l passages i n
the cases and gear components to cl ear them of any
resi due.
INSPECTION
MAINSHAFT
Exami ne the mai nshaft components careful l y for
evi dence of wear or damage.
Repl ace the thrust washers i f worn or damaged.
Repl ace the mai nshaft and sprocket gears i f the
teeth or gear bores are worn or damaged.
Repl ace the mai nshaft beari ngs i f worn, fl at spot-
ted, bri nel l ed, or damaged i n any way.
Repl ace the mai nshaft i f i t i s bent, exhi bi ts wear or
damage to the beari ng surfaces, spl i nes or gear teeth.
Fig. 28 Input Gear Retainer
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 29 Front Tabbed Thrust Washer
1 - FRONT TABBED THRUST WASHER
Fig. 30 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 31 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
INPUT AND LOW RANGE GEARS
I nspect the l ow range gear pi ni ons and pi ni on pi ns.
Repl ace the l ow range gear i f any of the pi ns or pi n-
i ons are worn or damaged.
I nspect the thrust washers, retai ner, and snap-
ri ng. Repl ace the snap-ri ng i f bent, or di storted.
Repl ace the thrust washers and retai ner i f worn,
cracked or damaged i n any way.
Exami ne the i nput gear careful l y. Be sure the gear
teeth and beari ng surfaces are i n good condi ti on.
Repl ace the gear i f wear or damage i s evi dent.
Check the i nput gear pi l ot beari ng. Rotate the
beari ng and check for roughness or noi se. Al so check
beari ng posi ti on i n the bore. The beari ng shoul d be
recessed approxi matel y 2.5 mm (0.100 i n.) bel ow the
top edge of the bore. The beari ng shoul d not be
seated at the bottom of the bore. Repl ace the beari ng
i f worn, or roughness i s evi dent. Repl ace both the
gear and beari ng i f the beari ng i s a l oose fi t i n the
bore.
GEAR CASE AND RETAINERS
Exami ne both case hal ves and retai ners careful l y.
Repl ace any retai ner or case hal f i f wear, cracks, or
other damage i s evi dent.
Check condi ti on of the l ow range annul us gear and
the shi ft rai l bushi ng i n the front case (Fi g. 32). The
l ow range annul us gear i s not a servi ceabl e part.
Repl ace the gear and case as an assembl y i f the gear
i s l oose, worn, or damaged. The shi ft rai l bushi ng i s
a servi ceabl e part and can be repl aced i f necessary.
Check the bushi ng i n the rear retai ner. Repl ace the
bushi ng i f worn or scored.
Exami ne the seal i ng surfaces of both case hal ves
and retai ners. Smal l burrs, or scratches on these sur-
faces can be reduced wi th crocus cl oth or a fi ne tooth
fi l e.
Exami ne condi ti on of the shi ft rai l bushi ng i n the
front case. I f the bushi ng i s worn or damaged, i t can
be removed wi th a bl i nd hol e type pul l er. A repl ace-
ment bushi ng can be i nstal l ed wi th a sui tabl e si ze
dri ver. Recess the bushi ng sl i ghtl y bel ow the edge of
the bore but do not seat i t al l the i nto the case.
GEARTRAIN
I nspect the mai nshaft spl i nes, gear teeth and bear-
i ng surfaces careful l y for evi dence of wear, or dam-
age. Repl ace the shaft i f necessary. do not attempt to
sal vage i t i f damaged.
The shi ft rai l and range fork are an assembl y.
Repl ace both parts i f ei ther i s damaged. However, the
nyl on pads i n the fork can be repl aced i f worn, or
cracked.
I nspect the transfer case snap-ri ngs cl osel y. Do not
attempt to sal vage a di storted snap-ri ng by strai ght-
eni ng or reshapi ng i t. Repl ace any snap-ri ng that i s
di storted, or worn.
I nspect the l ow range gear, i nput gear and the gear
thrust washers retai ner, and snap-ri ng. The l ow
range gear i s servi ced as an assembl y onl y. Repl ace
the gear i f the case or pi ni ons are damaged.
Duri ng i nspecti on, al so make sure the seal surface
of the i nput gear i s i n good condi ti on. Mi nor ni cks on
thi s surface can be reduced wi th crocus cl oth. How-
ever, repl ace the gear i f the seal surface i s severel y
scored or worn.
OIL PUMP AND PROGRESSIVE COUPLING
The oi l pump and progressi ve coupl i ng are not ser-
vi ceabl e components. Repl ace the coupl i ng as an
assembl y i f i t i s damaged. Repl ace the oi l pump as
an assembl y i f the gear teeth are worn, or i f the
pump has become damaged.
BEARINGS AND SEALS
The transfer case seal s shoul d be repl aced duri ng
overhaul . Use new seal s i n the i nput gear beari ng
retai ner, front case and rear retai ner. Al so repl ace
the yoke seal washer and the detent pl ug O-ri ng.
Check condi ti on of each transfer case beari ng.
Repl ace any beari ng exhi bi ti ng si gns of roughness,
wear, or damage.
Fig. 32 Low Range Annulus Gear Location
2 - SHIFT RAIL BUSHING
ASSEMBLY
Lubri cate transfer case components wi th Mopar
Transfer Case Lubri cant or petrol eum jel l y (where
i ndi cated) duri ng assembl y.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
BEARINGS AND SEALS
(1) Remove front output shaft seal from front case
wi th pry tool (Fi g. 33).
(2) Remove snap-ri ng that retai ns front output
shaft beari ng i n front case (Fi g. 34).
(3) Usi ng tool 6953, remove beari ng from front
case (Fi g. 35).
(4) Usi ng tool 6953, i nstal l new beari ng.
(5) I nstal l snap-ri ng to hol d beari ng i nto case.
2 - PRYBAR
Fig. 34 Output Shaft Front Bearing Snap-Ring
Removal
1 - FRONT CASE
3 - BEARING SNAP-RING
Fig. 35 Remove Output Shaft Front Bearing
1 - HANDLE C-4171
2 - REMOVER/INSTALLER 6953
(a) Pl ace new seal on tool . Garter spring on
seal goes toward interior of case.
pi ng seal i nto bore unti l i nstal l er tool bottoms
agai nst case.
(7) Remove the output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 37).
(8) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 38). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig.
39).
Fig. 37 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
2 - TRANSFER CASE
Fig. 38 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 39 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
(9) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng from i nsi de the annul us
gear openi ng i n the case. (Fi g. 40).
(10) I nstal l l ocati ng ri ng on new beari ng.
(11) Posi ti on case so forward end i s faci ng upward.
(12) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng i nto case. The beari ng
l ocati ng ri ng must be ful l y seated agai nst case sur-
face (Fi g. 41).
(13) Remove i nput gear pi l ot beari ng by i nserti ng
a sui tabl y si zed dri ft i nto the spl i ned end of the i nput
gear and dri vi ng the beari ng out wi th the dri ft and a
hammer (Fi g. 42).
(14) I nstal l new pi l ot beari ng wi th I nstal l er 8128
Fig. 40 Input Shaft Bearing Removal
Fig. 41 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 42 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 43 Install Input Gear Pilot Bearing
1 - HANDLE C-4171
2 - INSTALLER 8128
3 - INPUT GEAR
(15) Remove front beari ng retai ner seal wi th sui t-
abl e pry tool .
(16) I nstal l new front beari ng retai ner wi th
INPUT AND LOW RANGE GEAR
(1) Lubri cate gears and thrust washers (Fi g. 45)
wi th transfer case l ubri cant.
(2) I nstal l fi rst thrust washer i n l ow range gear
(Fi g. 45). Be sure washer tabs are properl y al i gned i n
gear notches.
(3) I nstal l i nput gear i n l ow range gear. Be sure
i nput gear i s ful l y seated.
(4) I nstal l remai ni ng thrust washer i n l ow range
gear and on top of i nput gear. Be sure washer tabs
are properl y al i gned i n gear notches.
(5) I nstal l retai ner on i nput gear and i nstal l snap-
ri ng.
(6) Al i gn and i nstal l l ow range/i nput gear assem-
bl y i n front case (Fi g. 46). Be sure l ow range gear
pi ni ons are engaged i n annul us gear and that i nput
gear shaft i s ful l y seated i n front beari ng.
Fig. 44 Install Front Bearing Retainer Seal
Fig. 45 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 46 Input/Low Range Gear Installation
1 - ANNULUS GEAR
2 - INPUT/LOW RANGE GEAR
(7) I nstal l snap-ri ng to hol d i nput/l ow range gear
i nto front beari ng (Fi g. 47).
(8) Cl ean gasket seal er resi due from retai ner and
i nspect retai ner for cracks or other damage.
(9) Appl y a 3 mm (1/8 i n.) bead of Mopar gasket
maker or si l i cone adhesi ve to seal i ng surface of
retai ner.
(10) Al i gn cavi ty i n seal retai ner wi th fl ui d return
hol e i n front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying Mopar gas-
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.
(11) I nstal l bol ts to hol d retai ner to transfer case
(Fi g. 48). Ti ghten to 21 Nm (16 ft. l bs.) of torque.
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 49).
(2) I nstal l shi ft sector (Fi g. 50).
(3) I nstal l l ocki ng cl utch spri ng, l ocki ng cl utch,
bl ockout spri ng, and range cl utch sl eeve, to mai n-
shaft as shown i n (Fi g. 51). I nstal l snap ri ng.
(4) I nstal l dri ve sprocket hub to mai nshaft and
manual l y l oad the needl e beari ngs.
(5) I nstal l new pads on range fork, i f necessary.
Fig. 47 Install Input Gear Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
Fig. 48 Install Front Bearing Retainer
Fig. 49 Sector O-Ring And Bushing Installation
1 - SECTOR BUSHING
2 - O-RING
Fig. 50 Shift Sector Installation
1 - SHIFT SECTOR
(6) I nstal l range shi ft fork to range cl utch sl eeve.
I nstal l mai nshaft/range shi ft fork assembl y i nto
transfer case and i nput pl anetary assembl y. Rotate
fork unti l i t engages wi th sl ot i n shi ft sector.
(7) I nstal l shi ft rai l to shi ft range fork and trans-
fer case housi ng.
(8) Rotate shi ft sector to NEUTRAL posi ti on.
(9) I nstal l new O-ri ng on detent pl ug (Fi g. 52).
(10) Lubri cate detent pl unger wi th transfer case
l ubri cant or l i ght coat of petrol eum jel l y.
(11) I nstal l detent pl unger, spri ng and pl ug (Fi g.
52).
(12) Veri fy that pl unger i s properl y engaged i n sector.
(1) Lubri cate front output shaft-sprocket assembl y,
dri ve chai n and dri ve sprocket wi th transfer case
l ubri cant.
(2) Assembl e dri ve chai n, dri ve sprocket and front
output shaft (Fi g. 53).
(3) Start dri ve sprocket on mai nshaft.
(4) Gui de front shaft i nto beari ng and dri ve
sprocket onto mai nshaft dri ve gear (Fi g. 53).
(5) I nstal l dri ve sprocket snap-ri ng (Fi g. 54).
Fig. 51 Range Clutch Sleeve, Blockout Spring,
Locking Clutch and Spring
1 - LOCKING CLUTCH SPRING
2 - BLOCKOUT SPRING
3 - SNAP-RING
4 - RANGE CLUTCH SLEEVE
5 - LOCKING CLUTCH
6 - DRIVE SPROCKET HUB
Fig. 52 Shift Detent Components
1 - DETENT PLUG
2 - DETENT SPRING
3 - DETENT PLUNGER
4 - PLUG O-RING
Fig. 53 Installing Drive Chain, Front Output Shaft
And Drive Sprocket
1 - FRONT OUTPUT SHAFT
2 - DRIVE CHAIN
3 - MAINSHAFT
4 - DRIVE GEAR
(6) I nstal l rol l er beari ngs i f removed.
(7) I nstal l progressi ve coupl i ng (Fi g. 55).
(8) I nstal l the progressi ve coupl i ng thrust washer
over the output shaft and agai nst the coupl i ng.
(9) I nstal l the oi l pump l ocati ng snap-ri ng onto the
output shaft.
(10) I nstal l oi l pi ckup tube i n rear case. Be sure
tube i s seated i n case notch as shown (Fi g. 56).
(11) I nstal l magnet i n front case pocket (Fi g. 57).
Fig. 54 Installing Drive Sprocket Snap-Ring
1 - MAINSHAFT DRIVE SPROCKET
Fig. 55 Progressive Coupling Installation
1 - SNAP-RING
2 - PROGRESSIVE COUPLING
Fig. 56 Oil Pickup Tube Installation
1 - CASE NOTCH
2 - OIL PICKUP TUBE ASSEMBLY
3 - CASE SLOT
Fig. 57 Installing Case Magnet
1 - MAGNET
(12) Cl ean seal i ng fl anges of front case and rear
case wi th a wax and grease remover.
(13) Appl y 3 mm (1/8 i n.) wi de bead of Mopar
gasket maker or si l i cone adhesi ve seal er to mounti ng
fl ange of front case. Work seal er bead around bol t
hol es as shown (Fi g. 58).
(14) Al i gn and i nstal l rear case on front case (Fi g.
59).
(15) Veri fy that oi l pi ckup tube i s sti l l seated i n
case notch and tube end i s poi nted toward mai nshaft
(Fi g. 60).
(16) I nstal l case attachi ng bol ts. Al i gnment bol ts
at each end of case are onl y ones requi ri ng washers
(Fi g. 61).
(17) Ti ghten case bol ts to 27-34 Nm (20-25 ft. l bs.)
torque.
Fig. 58 Applying Sealer To Front Case Flange
1 - FRONT CASE FLANGE
2 - SEALER BEAD
Fig. 59 Rear Case Installation
1 - REAR CASE
2 - FRONT CASE
Fig. 60 Checking Position Of Oil Pickup Tube
1 - TUBE O-RING
2 - CORRECT PICKUP TUBE POSITION
Fig. 61 Alignment Bolt
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
(1) I nstal l range l ever, washer and l ocknut on sec-
tor shaft (Fi g. 62). Ti ghten l ocknut to 27-34 Nm
(20-25 ft. l bs.) torque.
(2) I nstal l new seal washer on front output shaft
(Fi g. 63).
(3) Lubri cate fl ange hub wi th transfer case l ubri -
cant and i nstal l fl ange on front shaft.
(4) I nstal l new seal washer on front shaft.
(5) I nstal l compani on fl ange and new nut on front
output shaft.
(6) Ti ghten fl ange nut to 122-176 Nm (90-130 ft.
l bs.) torque. Use Tool C-3281, or si mi l ar tool to hol d
fl ange whi l e ti ghteni ng yoke nut.
REAR RETAINER AND OIL PUMP
(1) I nstal l new O-ri ng on fl anged end of oi l pi ckup
tube.
(2) I nstal l oi l pump (Fi g. 64).
(3) I nsert oi l pi ckup tube i n pump (Fi g. 65).
(4) I nstal l rear beari ng on mai nshaft (Fi g. 65).
Locati ng ri ng groove i n beari ng goes toward end of
mai nshaft.
(5) I nstal l rear beari ng retai ni ng snap-ri ng (Fi g.
66).
(6) I nstal l rear beari ng l ocati ng ri ng i n rear
retai ner, i f ri ng was removed duri ng overhaul .
Fig. 62 Range Lever Installation - Typical
1 - RANGE LEVER
2 - WASHER
3 - LOCKNUT
Fig. 63 Flange Seal Washer Installation
1 - YOKE SEAL WASHER
Fig. 64 Installing Oil Pump
1 - OIL PUMP
2 - TUBE O-RING
3 - OIL PICKUP TUBE
Fig. 65 Rear Bearing Installation
1 - REAR BEARING
Fig. 66 Rear Bearing Snap-Ring Installation
1 - REAR BEARING
3 - SNAP-RING
ket maker or si l i cone adhesi ve seal er to mounti ng
surface of rear retai ner. Al l ow seal er to set-up
sl i ghtl y before proceedi ng.
(8) Sl i de rear retai ner onto mai nshaft (Fi g. 67).
(9) Spread rear beari ng l ocati ng ri ng and sl i de
rear retai ner i nto pl ace on rear case (Fi g. 68).
(10) I nstal l and ti ghten rear retai ner bol ts to 27-34
Nm (20-25 ft. l bs.).
(11) I nstal l rubber access pl ug (Fi g. 69).
FINAL ASSEMBLY
(2) Level transfer case and fi l l i t wi th Mopar
Transfer Case Lubri cant. Correct fi l l l evel i s to bot-
tom edge of fi l l pl ug hol e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (26 ft. l bs.) torque (Fi g. 70).
Fig. 67 Rear Retainer Installation
1 - REAR CASE
2 - REAR RETAINER
Fig. 68 Engaging Rear Bearing Locating Ring
1 - REAR RETAINER
2 - PARALLEL JAW SNAP-RING PLIERS
Fig. 69 Installing Rubber Access Plug
1 - PLUG
Fig. 70 Install Transfer Case
(6) Connect front propel l er shaft and i nstal l rear
propel l er shaft. (Refer to 3 - DI FFERENTI AL &
DRI VELI NE/PROPELLER SHAFT/PROPELLER
SHAFT - I NSTALLATI ON)
(7) Fi l l transfer case wi th correct fl ui d. Check
transmi ssi on fl ui d l evel . Correct as necessary.
(8) I nstal l rear crossmember (Fi g. 71) and ski d
pl ate, i f equi pped. Ti ghten crossmember bol ts to 41
(9) Remove transmi ssi on jack and support stand.
(10) Veri fy transfer case i s i n NEUTRAL. Connect
shi ft cabl e to transfer case range l ever.
(11) Lower vehi cl e and veri fy transfer case shi ft
operati on.
(12) Adjust the transfer case shi ft cabl e, i f neces-
sary.
SPECIFICATIONS
Bolt, crossmember 41-47 30.2-34.7 -
Plug, Detent 16-24 11.8-17.7 -
Plugs, drain/fill 20-34 15-25 -
Bolts, front brg. retainer 16-24 11.8-17.7 -
Bolts, case half 27-34 19.9-25 -
Nut, companion flange 122-176 90-130 -
Bolts, rear extension 27-34 19.9-25 -
Lock-nut, shift 27-34 19.9-25 -
Nuts, T-case mount stud 33-41 24.3-30.2 -
Fig. 71 Crossmember Installation
1 - CROSSMEMBER
SPECIAL TOOLS
Installer, Seal - 6952-A
Remover, Bushing - 6957
Handle - C-4171
Installer, Bushing - 8145
Remover, Bearing - C-4210
Remover, Bearing - L-4454
Cup - 8148
FLUID
REFILL
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 72).
(2) Posi ti on drai n pan under transfer case.
(3) Remove drai n and fi l l pl ugs and drai n l ubri -
cant compl etel y.
(15-25 ft. l bs.).
(5) Remove drai n pan.
(6) Fi l l transfer case to bottom edge of fi l l pl ug
openi ng wi th Mopar Transfer Case Lubri cant.
(15-25 ft. l bs.).
REMOVAL
(2) Remove front propel l er shaft. (Refer to 3 - DI F-
(3) Remove front output shaft compani on shaft.
(4) Remove seal from front case wi th pry tool (Fi g.
73).
INSTALLATION
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
pi ng seal i nto bore unti l i nstal l er tool seats agai nst
case.
(2) I nstal l compani on fl ange and torque nut to
122-176 Nm (90-130 ft. l bs.).
(3) I nstal l front propel l er shaft. (Refer to 3 - DI F-
Installer, Bearign - 8128
Fig. 72 Fill/Drain Plug and I.D. Tag Location -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
2 - PRYBAR
REAR RETAINER BUSHING
AND SEAL
REMOVAL
(2) Remove rear propel l er shaft. (Refer to 3 - DI F-
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear retai ner seal .
(4) Usi ng Remover 6957, remove bushi ng from
rear retai ner (Fi g. 75).
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Posi ti on repl acement bushi ng i n rear retai ner
wi th fl ui d port i n bushi ng al i gned wi th sl ot i n
retai ner.
(3) Usi ng I nstal l er 8145, dri ve bushi ng i nto
retai ner unti l i nstal l er seats agai nst case (Fi g. 76).
(4) Usi ng I nstal l er C-3995-A, i nstal l seal i n rear
(5) I nstal l rear propel l er shaft. (Refer to 3 - DI F-
(6) Veri fy proper fl ui d l evel .
2 - TRANSFER CASE
Fig. 75 Rear Retainer Bushing Removal
1 - REMOVER 6957
Fig. 76 Rear Retainer Bushing Installation
2 - INSTALLER 8145
Fig. 77 Install Rear Retainer Seal
FRONT OUTPUT SHAFT SEAL (Continued)
SHIFT CABLE
REMOVAL
(3) Di sconnect the shi ft cabl e eyel et from the
bracket.
to shi ft l ever assembl y and shi ft cabl e.
(10) Remove transfer case shi ft cabl e from vehi cl e.
INSTALLATION
(3) I nstal l nuts to hol d seal pl ate to fl oor pan (Fi g.
80). Ti ghten nuts to 7 Nm (65 i n.l bs.).
shi fter assembl y bracket. Seat cabl e i n bracket and
i nstal l cl i p (Fi g. 79).
(5) Veri fy the transfer case shi ft l ever (at consol e)
i s i n the NEUTRAL posi ti on.
(6) Snap the cabl e onto the shi ft l ever pi n (Fi g.
79).
bracket and i nstal l cl i p (Fi g. 78).
(9) Veri fy that the transfer case i s sti l l i n the
NEUTRAL posi ti on.
(10) Snap the shi ft cabl e onto the transfer case
shi ft l ever (Fi g. 78).
(12) Veri fy correct transfer case operati on i n al l
ranges.
transfer case shi ft cabl e.
Fig. 78 Transfer Case Shift Cable at Transfer Case
Fig. 79 Transfer Case Shift Cable at Shifter
1 - CLIP
2 - SHIFTER
1 - SEAL PLATES
TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL RUNOUT . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - MATCH
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - TIRE ROTATION . 5
STANDARD PROCEDURE - WHEEL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5
TIRES
DESCRIPTION
DESCRIPTION - TIRES . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - RADIALPLY TIRES . . . . . . . 6
DESCRIPTION - TIRE INFLATION
PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - TIRE PRESSURE FOR
HIGH SPEED. . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - REPLACEMENT TIRES . . . . . 7
DIAGNOSIS AND TESTING - PRESSURE
GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - TIRE NOISE
OR VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - REPAIRING
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS - . . . . . . . . . . . . . . . . . . . . . 9
SPARE TIRE
DESCRIPTION - SPARE / TEMPORARY TIRE . . 10
WHEELS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - WHEEL
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 11
STUDS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
TIRE PRESSURE MONITORING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - TIRE PRESSURE
MONITORING SYSTEM . . . . . . . . . . . . . . . . . 12
SENSOR
REMOVAL - TIRE PRESSURE SENSOR/
TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION - TIRE PRESSURE SENSOR/
TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 13
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 1).
Lateral runout i s the wobble of the ti re or wheel .
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Dri ve vehi cl e a short di stance to el i mi nate ti re
fl at spotti ng from a parked posi ti on.
(2) Check wheel beari ngs and adjust i f adjustabl e
or repl ace i f necessary.
(3) Check the wheel mounti ng surface.
(4) Rel ocate wheel on the mounti ng, two studs
over from the ori gi nal posi ti on.
(5) Ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
(6) Check radi al runout. I f sti l l excessi ve, mark
ti re si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
WJ TIRES/WHEELS 22 - 1
(1) Remove ti re from wheel and mount wheel on
servi ce dynami c bal ance machi ne.
(2) Check wheel radi al runout (Fi g. 2) and l ateral
runout (Fi g. 3).
STEEL WHEELS: Radi al runout 0.040 i n., Lat-
eral runout 0.045 i n. (maxi mum)
ALUMI NUM WHEELS: Radi al runout 0.030 i n.,
Lateral runout 0.035 i n. (maxi mum)
(3) I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout,(Refer to 22 - TI RES/WHEELS -
STANDARD PROCEDURE) .
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND WHEEL
BALANCE
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two plane
balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
Off-vehi cl e bal anci ng i s recommended.
For stati c bal anci ng, fi nd the l ocati on of the heavy
spot causi ng the i mbal ance. Counter bal ance wheel
di rectl y opposi te the heavy spot. Determi ne wei ght
Fig. 1 Checking Tire/Wheel/Hub Runout
1 - RADIAL RUNOUT
2 - LATERAL RUNOUT
Fig. 2 Radial Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 3 Lateral Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
22 - 2 TIRES/WHEELS WJ
TIRES/WHEELS (Continued)
requi red to counter bal ance the area of i mbal ance.
Pl ace hal f of thi s wei ght on the inner ri m fl ange and
the other hal f on the outer ri m fl ange (Fi g. 4).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to l ocate the amount of wei ght to be appl i ed
to both the i nner and outer ri m fl ange (Fi g. 5).
Fig. 4 Static Unbalance & Balance
1 - HEAVY SPOT
2 - CENTER LINE OF SPINDLE
3 - ADD BALANCE WEIGHTS HERE
4 - CORRECTIVE WEIGHT LOCATION
5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP
Fig. 5 Dynamic Unbalance & Balance
1 - CENTER LINE OF SPINDLE
2 - ADD BALANCE WEIGHTS HERE
3 - CORRECTIVE WEIGHT LOCATION
4 - HEAVY SPOT WHEEL SHIMMY AND VIBRATION
STANDARD PROCEDURE - MATCH MOUNTING
Ti res and wheel s are currentl y not match mounted
at the factory. Match mounti ng i s a techni que used to
reduce runout i n the wheel /ti re assembl y. Thi s means
that the hi gh spot of the ti re i s al i gned wi th the l ow
spot on the wheel ri m. The hi gh spot on the ti re i s
marked wi th a pai nt mark or a bri ght col ored adhe-
si ve l abel on the outboard si dewal l . The l ow spot on
the ri m i s i denti fi ed wi th a l abel on the outsi de of the
ri m and a dot on the i nsi de of the ri m. I f the outsi de
l abel has been removed the ti re wi l l have to be
removed to l ocate the dot on the i nsi de of the ri m.
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
(1) Use a di al i ndi cator to l ocate the hi gh spot of
the ti re on the center tread ri b (Fi g. 6). Record the
i ndi cator readi ng and mark the hi gh spot on the ti re.
Pl ace a mark on the ti re at the val ve stem l ocati on
(Fi g. 7).
(2) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 8).
(3) Measure the total runout agai n and mark the
ti re to i ndi cate the hi gh spot.
(4) I f runout i s sti l l excessi ve use the fol l owi ng
procedures.
(a) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot and i s sti l l excessi ve, repl ace the
ti re.
(b) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot on the wheel , the wheel may be out
of speci fi cati ons,(Refer to 22 - TI RES/WHEELS -
DI AGNOSI S AND TESTI NG).
(c) I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 9). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount.
Fig. 6 Dial Indicator
Fig. 7 First Measurement On Tire
1 - REFERENCE MARK
2 - 1ST MEASUREMENT
HIGH SPOT MARK TIRE AND RIM
3 - WHEEL
4 - VALVE STEM
Fig. 8 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
STANDARD PROCEDURE - TIRE ROTATION
Ti res on the front and rear operate at di fferent
l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons they wear at
unequal rates and tend to devel op i rregul ar wear
patterns. These effects can be reduced by rotati ng
the ti res at regul ar i nterval s. The benefi ts of ti re
rotati on are:
I ncrease tread l i fe
Mai ntai n tracti on l evel s
A smooth, qui et ri de
The suggested method of ti re rotati on i s (Fi g. 10).
Other rotati on methods can be used, but they wi l l
not provi de al l the ti re l ongevi ty benefi ts.
INSTALLATION
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts. Thi s coul d affect the safety and han-
dl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on (Fi g. 11).
Never use oil or grease on studs or nuts.
Fig. 9 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
Fig. 10 Tire Rotation Pattern
Fig. 11 LUG NUT TIGHTENING PATTERN - TYPICAL
TIRES
DESCRIPTION
DESCRIPTION - TIRES
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl es requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
Rapi d accel erati on
Severe brake appl i cati ons
Hi gh speed dri vi ng
Excessi ve speeds on turns
Stri ki ng curbs and other obstacl es
Radi al -pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val shown i n the secti on on Ti re Rotati on.(Refer to 22
- TI RES/WHEELS - STANDARD PROCEDURE),
Thi s wi l l hel p to achi eve a greater tread l i fe.
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 12).
Performance ti res have a speed rati ng l etter after
the aspect rati o number. The speed rati ng i s not
al ways pri nted on the ti re si dewal l . These rati ngs
are:
Q up to 100 mph
S up to 112 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 (consul t the ti re manu-
facturer for the speci fi c speed rati ng)
An Al l Season type ti re wi l l have ei ther M +S, M
& S or MS (i ndi cati ng mud and snow tracti on)
i mpri nted on the si de wal l .
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to the Owners Manual for more i nformati on.
DESCRIPTION - RADIALPLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe and
ri de qual i ty, and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of
four. Under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
The use of ti res from di fferent manufactures on the
same vehi cl e i s NOT recommended. The proper ti re
pressure shoul d be mai ntai ned on al l four ti res.
DESCRIPTION - TIRE INFLATION PRESSURES
Under i nfl ati on wi l l cause rapi d shoul der wear, ti re
fl exi ng, and possi bl e ti re fai l ure (Fi g. 13).
Over i nfl ati on wi l l cause rapi d center wear and
l oss of the ti res abi l i ty to cushi on shocks (Fi g. 14).
I mproper i nfl ati on can cause:
Uneven wear patterns
Reduced tread l i fe
Reduced fuel economy
Fig. 12 Tire Identification
Unsati sfactory ri de
Vehi cl e dri ft
For proper ti re pressure speci fi cati on refer to the
Ti re I nfl ati on Pressure Chart provi ded wi th the vehi -
cl es Owners Manual . A Certi fi cati on Label on the
dri vers si de door pi l l ar provi des the mi ni mum ti re
and ri m si ze for the vehi cl e. The l abel al so l i st the
col d i nfl ati on pressure for these ti res at ful l l oad
operati on
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once a month. Ti re
pressure decreases as the ambi ent temperature
drops. Check ti re pressure frequentl y when ambi ent
temperature vari es wi del y.
Ti re i nfl ati on pressures are col d i nfl ati on pressure.
The vehi cl e must si t for at l east 3 hours to obtai n the
correct col d i nfl ati on pressure readi ng. Or be dri ven
l ess than one mi l e after si tti ng for 3 hours. Ti re
i nfl ati on pressures may i ncrease from 2 to 6 pounds
per square i nch (psi ) duri ng operati on. Do not reduce
thi s normal pressure bui l d-up.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
DESCRIPTION - TIRE PRESSURE FOR HIGH
SPEED
Where speed l i mi ts al l ow the vehi cl e to be dri ven
at hi gh speeds, correct ti re i nfl ati on pressure i s very
i mportant. For speeds up to and i ncl udi ng 120 km/h
(75 mph), ti res must be i nfl ated to the pressures
shown on the ti re pl acard. For conti nuous speeds i n
excess of 120 km/h (75 mph), ti res must be i nfl ated
to the maxi mum pressure speci fi ed on the ti re si de-
wal l .
Vehi cl es l oaded to the maxi mum capaci ty shoul d
not be dri ven at conti nuous speeds above 75 mph
(120 km/h).
For emergency vehi cl es that are dri ven at speeds
over 90 mph (144 km/h), speci al hi gh speed ti res
must be used. Consul t ti re manufacturer for correct
i nfl ati on pressure recommendati ons.
DESCRIPTION - REPLACEMENT TIRES
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
Ri de
Noi se
Handl i ng
Durabi l i ty
Tread l i fe
Tracti on
Rol l i ng resi stance
Speed capabi l i ty
I t i s recommended that ti res equi val ent to the ori g-
i nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res may cause i nterference
wi th vehi cl e components. Under extremes of suspen-
si on and steeri ng travel , i nterference wi th vehi cl e
components may cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
Fig. 13 Under Inflation Wear
1 - THIN TIRE THREAD AREAS
Fig. 14 Over Inflation Wear
1 - THIN TIRE THREAD AREA
TIRES (Continued)
DIAGNOSIS AND TESTING - PRESSURE
GAUGES
A qual i ty ai r pressure gauge i s recommended to
check ti re pressure. After checki ng the ai r pressure,
repl ace val ve cap fi nger ti ght.
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 15).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 16).
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 16).
DIAGNOSIS AND TESTING - TIRE NOISE OR
VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on and
decel erati on. The engi ne, di fferenti al and exhaust
noi ses wi l l change as speed vari es, whi l e the ti re
noi se wi l l usual l y remai n constant.
STANDARD PROCEDURE - REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 17). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Defl ate ti re compl etel y before removi ng the ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
torque speci fi cati on (Refer to 22 - TI RES/WHEELS/
WHEELS - SPECI FI CATI ONS).
Fig. 15 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
CLEANING
Remove the protecti ve coati ng on the ti res before
del i very of a vehi cl e. Thi s coati ng may cause deteri -
orati on of the ti res.
To remove the protecti ve coati ng, appl y warm
water and l et i t soak for a few mi nutes. Afterwards,
scrub the coati ng away wi th a soft bri stl e brush.
Steam cl eani ng may al so be used to remove the coat-
i ng.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or a wire brush for cleaning.
SPECIFICATIONS
TIRES
SPECIFICATIONS
TIRE P225/75R16
TIRE P245/70R16
TIRE P235/65R17
SPECIFICATIONS -
SPECIFICATIONS
DESCRIPTION - RIM SPECIFICATION - TIRE
BASE LAREDO (2.7L &
4.0L)
16x7
P225/75R16
OPTIONAL LAREDO
(2.7L, 4.0L, 4.7L)
16x7
P245/70R16
LAREDO 4.7L (JAPAN &
AUSTRALIA)
17x7.5
P235/65R17
OPTIONAL LAREDO (UP
COUNTRY)
17x7.5
P235/65R17
BASE LIMITED
17x7.5
P235/65R17
OPTIONAL LIMITED (UP
COUNTRY)
& OVERLAND
17x7.5
P235/65R17
BASE WHEEL / SNOW
TIRE
P235/65R17
Fig. 16 Tire Wear Patterns
Fig. 17 Tire Repair Area
1 - REPAIRABLE AREA
TIRES (Continued)
SPARE TIRE
DESCRIPTION - SPARE / TEMPORARY TIRE
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty, then rei nstal l ed.
Do not exceed speeds of 50 M.P.H. when usi ng the
temporary spare ti re. Refer to Owners Manual for
compl ete detai l s.
WHEELS
DESCRIPTION
The ri m si ze i s on the vehi cl e safety certi fi cati on
l abel l ocated on the dri vers door shut face. The si ze
of the ri m i s determi ned by the dri vetrai n package.
Ori gi nal equi pment wheel s/ri ms are desi gned for
operati on up to the speci fi ed maxi mum vehi cl e capac-
i ty.
Al l model s use stamped steel , cast al umi num or
forged al umi num wheel s. Every wheel has rai sed sec-
ti ons between the ri m fl anges and ri m drop wel l
cal l ed safety humps (Fi g. 18) .
I ni ti al i nfl ati on of the ti re forces the bead over
these rai sed secti ons. I n case of rapi d l oss of ai r pres-
sure, the rai sed secti ons hel p hol d the ti re on the
wheel .
appl i cati ons. Al l al umi num and some steel wheel s
have wheel stud nuts wi th an enl arged nose. Thi s
enl arged nose i s necessary to ensure proper retenti on
of the wheel s. Do not use repl acement studs or nuts
wi th a di fferent desi gn or l esser qual i ty.
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
I nspect wheel s for:
Excessi ve run out
Dents or cracks
Damaged wheel l ug nut hol es
Ai r Leaks from any area or surface of the ri m
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
I f a wheel i s damaged an ori gi nal equi pment
repl acement wheel shoul d be used. When obtai ni ng
repl acement wheel s, they shoul d be equi val ent i n
l oad carryi ng capaci ty. The di ameter, wi dth, offset,
pi l ot hol e and bol t ci rcl e of the wheel shoul d be the
same as the ori gi nal wheel .
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE. USED WHEELS ARE NOT RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
REPLACEMENT
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts. Thi s coul d affect the safety and han-
dl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on. Never
use oil or grease on studs or nuts.
Wheel s must be repl aced i f they have:
Excessi ve runout
Fig. 18 Safety Rim
1 - FLANGE
2 - RIDGE
3 - WELL
Bent or dented
Leak ai r through wel ds
Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
Load carryi ng capaci ty
Di ameter
Wi dth
Offset
Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
SPECIFICATIONS
TORQUE CHART
Lug Nut
1/2 X 20 with 60Cone
115-150 85-115
STUDS
REMOVAL
CAUTION: Do not use a hammer to remove wheel
studs.
(3) Remove brake cal i per, cal i per adapter and
rotor,(Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/ROTORS - REMOVAL).
(4) Remove stud from hub wi th Remover C-4150A
(Fi g. 19).
INSTALLATION
CAUTION: Do not use a hammer to remove wheel
studs.
(1) I nstal l the new stud i nto the hub fl ange.
(2) I nstal l the three washers onto the stud, then
i nstal l the l ug nut wi th the fl at si de of the nut
agai nst the washers.
(3) Ti ghten the l ug nut unti l the stud i s pul l ed
i nto the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove the l ug nut and washers.
(5) I nstal l the brake rotor, cal i per adapter, and
cal i per,(Refer to 5 - BRAKES/HYDRAULI C/ME-
CHANI CAL/DI SC BRAKE CALI PERS - I NSTALLA-
TI ON).
(6) I nstal l the wheel and ti re assembl y, use new
l ug nut on stud or studs that were repl aced.
(7) Remove the support and l ower vehi cl e.
Fig. 19 Wheel Stud Removal
1 - REMOVER
2 - WHEEL STUD
WHEELS (Continued)
TIRE PRESSURE MONITORING
DESCRIPTION
The EVI C wi l l moni tor the ti re pressure si gnal s
from the fi ve ti re sensors and determi ne i f any ti re
has gone bel ow the l ow pressure threshol d or rai sed
above the hi gh pressure threshol d. Refer to the tabl e
bel ow.
LOW TIRE PRESSURE THRESHOLDS
SYSTEM STATUS
INDICATOR
TIRE PRESSURE
ON 179 kPa (26 PSI)
OFF 214 kPa (31 PSI)
HIGH TIRE PRESSURE THRESHOLDS
SYSTEM STATUS
INDICATOR
TIRE PRESSURE
ON 310 kPa (45 PSI)
OFF 276 kPa (40 PSI)
The Remote Ti re Pressure Moni tors (RTPM) are
not i nternal l y servi ceabl e. For a Sensor Fai l ure or
Low Battery faul t, the RTPM must be repl aced.
OPERATION
I f equi pped wi th the Ti re Pressure Moni tori ng Sys-
tem, each of the vehi cl es fi ve wheel s wi l l have a
val ve stem wi th a pressure sensor and radi o trans-
mi tter bui l t i n. Si gnal s from the ti re pressure sensors
are recei ved and i nterpreted by the El ectroni c Vehi -
cl e I nformati on Center (EVI C). A sensor i n a
mounted wheel wi l l broadcast i ts detected pressure
once per mi nute when the vehi cl e i s movi ng faster
than 40 km/h (25 mph). The spare ti re sensor wi l l
broadcast once every hour. Each sensors broadcast i s
uni quel y coded so that the EVI C can determi ne l oca-
ti on. The i ndi vi dual ti re pressures can be di spl ayed
graphi cal l y on the EVI C
DIAGNOSIS AND TESTING - TIRE PRESSURE
MONITORING SYSTEM
Al l Ti re Pressure Moni tori ng System Faul ts are
speci fi c to one l ocati on. I f a BATTERY LOW or
SENSOR FAI LURE faul t i s detected, the l ocati on
wi l l be di spl ayed. The appropri ate sensor/transmi tter
can then be repl aced. I f a si ngl e sensor/transmi tter
cannot be detected by the EVI C, repl ace that sensor
transmi tter. I f none of the sensors/transmi tters can
be detected, refer to symptoms i n the EVI C secti on.
For addi ti onal system descri pti on and di agnosi s,
refer to Ti re Pressure Moni tori ng i n the Body Di ag-
nosti c manual .
SENSOR
REMOVAL - TIRE PRESSURE SENSOR/
TRANSMITTER
(1) Remove the ti re/wheel from the vehi cl e.
CAUTION: When removing the stick on balancing
weights from the wheel, do not use an abrasive
cleaner or a cleaner which will damage the protec-
tive finish on the wheel.
(2) Remove the bal anci ng wei ghts from the wheel .
NOTE: The cap used on this valve stem contains an
O-ring seal to prevent contamination and moisture
from entering the valve stem. Retain this valve stem
cap for re-use. Do not substitute a regular valve
stem cap in its place.
(3) Remove the cap from the val ve stem.
NOTE: The valve stem used on this vehicle is made
of aluminum and the core is nickel plated brass.
The original valve stem core must be reinstalled
and not substituted for a valve stem core made of a
different material. This is required to prevent corro-
sion in the valve stem caused by the different met-
als.
(4) Usi ng the appropri ate tool , remove the core
from the val ve stem (Fi g. 20).
(5) Let the ti re ful l y defl ate.
Fig. 20 REMOVING VALVE STEM CORE - TYPICAL
1 - WHEEL
2 - VALVE STEM
3 - TIRE
4 - VALVE STEM CORE TOOL
CAUTION: The pressure transmitter must be
removed from the wheel and dropped into the tire
prior to breaking the bead and dismounting the tire.
Failure to do this will greatly increase the risk of
damaging the pressure transducer when servicing
the tire.
(6) Remove nut mounti ng val ve stem of pressure
sensor/transmi tter to the wheel (Fi g. 21). Drop sen-
sor/transmi tter i nto ti re.
CAUTION: When breaking the top and bottom bead
of the tire off the wheel, care must be used so the
bead breaking mechanism on the tire changer does
not damage the wheel. This includes the surface of
the wheel flange on the inside of the wheel.
(7) Usi ng the ti re changer manufacturers proce-
dure, fi rst break down the upper bead of the ti re.
Then break down the bottom bead of the ti re.
CAUTION: When dismounting the upper tire bead
from the wheel, the proper procedure must be used.
Not using the proper procedure will result in dam-
age to the wheel and tire.
(8) Di smount the upper bead of the ti re from the
wheel . The upper bead must be fully dis-
mounted from the wheel to remove the tire
pressure transmitter fromthe inside of the tire.
The bottom bead of the tire does not need to be
removed from the wheel.
(9) Pul l upward on the ti re (Fi g. 22). Reach i nto
the ti re and remove the pressure sensor/transmi tter
from i nsi de the ti re.
INSTALLATION - TIRE PRESSURE SENSOR/
TRANSMITTER
NOTE: When installing the tire pressure sensor/
transmitter, inspect the sealing O-ring at the bottom
of the valve stem for any sign of damage or deteri-
oration. Replace O-ring if necessary, before install-
ing the pressure transmitter on the wheel. Also, be
sure the surface of the wheel that the O-ring seals
against is clean and not damaged.
Fig. 21 VALVE STEM/PRESSURE TRANSMITTER -
TYPICAL
1 - NUT
2 - WHEEL
3 - TIRE
4 - VALVE STEM
Fig. 22 PRESSURE TRANSMITTER REMOVAL -
TYPICAL
1 - TIRE
2 - WHEEL
3 - PRESSURE TRANSMITTER
SENSOR (Continued)
(1) I nstal l the ti re pressure sensor/transmi tter on
the wheel (Fi g. 23).
(2) Ti ghten the ti re pressure sensor/transmi tter
mounti ng nut to a torque of 11 Nm (97 i n. l bs.) (Fi g.
24). When ti ghteni ng the sensor/transmi tter nut,
hol d the transmi tter so i t does not rotate. I f the sen-
sor/transmi tter rotates so the top edge i s not l evel
wi th the wheel (Fi g. 25), damage to the transmi tter
wi l l occur when mounti ng the ti re. I f the top edge of
the transmi tter i s not l evel wi th the wheel , i t can be
rotated i nto posi ti on by l i ghtl y tappi ng i t wi th your
hand.
CAUTION: When mounting the upper bead of the
extended mobility tire, the proper procedure must
be used. Not using the proper procedure will result
in damage to the wheel and tire.
(3) Mount the upper bead of the ti re on the wheel .
(4) I nstal l the ori gi nal or an OEM repl acement
val ve stem cap on the val ve stem.
(5) Usi ng a soap sol uti on, check that no ai r l eak i s
present where the val ve stem mounts to the wheel .
(6) Bal ance the ti re/wheel assembl y usi ng the cor-
rect procedure for usi ng wheel fl ange mount and
sti ck-on wheel wei ghts. For bal anci ng i nformati on
and wheel wei ght posi ti oni ng, (Refer to 22 - TI RES/
WHEELS - STANDARD PROCEDURE).
(7) I nstal l the ti re/wheel on the vehi cl e (Refer to
22 - TI RES/WHEELS - STANDARD PROCEDURE).
(8) Program the i denti fi cati on code for the new ti re
pressure sensor/transmi tter i nto the TPM modul e.
(9) Veri fy that the TPM modul e has been pro-
grammed wi th the i denti fi cati on code from the new
ti re pressure sensor/transmi tter Refer to the appropi -
ate el ectri cal secti on. I f the i denti fi cati on code and
ti re pressure threshol ds from the new ti re pressure
transmi tter are present i n the recei vers memory the
new ti re pressure transmi tter has been correctl y pro-
grammed to the recei ver.
Fig. 23 TIRE PRESSURE SENSOR/TRANSMITTER -
TYPICAL
1 - WHEEL
2 - TIRE PRESSURE TRANSMITTER
Fig. 24 TIGHTENING SENSOR/TRANSDUCER -
TYPICAL
1 - TORQUE WRENCH
2 - WHEN TORQUING TRANSMITTER MOUNTING NUT DO NOT
LET THIS END OF TRANSMITTER ROTATE AWAY FROM THE
WHEEL
3 - WHEEL
4 - TIRE PRESSURE TRANSMITTER
Fig. 25 CORRECTLY POSITIONED SENSOR/TRAN -
TYPICAL
1 - THE TOP EDGES OF THE TIRE PRESSURE SENSOR/
TRANSMITTER MUST BE FLUSH WITH THE WHEEL HERE
2 - WHEEL
3 - TIRE PRESSURE SENSOR/TRANSMITTER
SENSOR (Continued)
BODY
TABLE OF CONTENTS
page page
BODY
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 1
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - DRILLING AND
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . 4
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DECKLID/HATCH/LIFTGATE/TAILGATE . . . . . . . . 5
DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . 11
DOORS - REAR . . . . . . . . . . . . . . . . . . . . . . . . . 19
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTRUMENT PANEL SYSTEM . . . . . . . . . . . . . 36
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 93
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . 105
BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . 112
BODY
WATER LEAKS
Water l eaks can be caused by poor seal i ng,
i mproper body component al i gnment, body seam
porosi ty, mi ssi ng pl ugs, or bl ocked drai n hol es. Cen-
tri fugal and gravi tati onal force can cause water to
dri p from a l ocati on away from the actual l eak poi nt,
maki ng l eak detecti on di ffi cul t. Al l body seal i ng
poi nts shoul d be water ti ght i n normal wet-dri vi ng
condi ti ons. Water fl owi ng downward from the front of
the vehi cl e shoul d not enter the passenger or l uggage
compartment. Movi ng seal i ng surfaces wi l l not
al ways seal water ti ght under al l condi ti ons. At
ti mes, si de gl ass or door seal s wi l l al l ow water to
enter the passenger compartment duri ng hi gh pres-
sure washi ng or hard dri vi ng rai n (severe) condi -
ti ons. Overcompensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng
a repai r, water test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear, and body components are properl y
al i gned and seal ed. I f component al i gnment or seal -
i ng i s necessary, refer to the appropri ate secti on of
thi s group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the condi ti ons causi ng a water l eak have
been determi ned, si mul ate the condi ti ons as cl osel y
as possi bl e.
I f a l eak occurs wi th the vehi cl e parked i n a
steady l i ght rai n, fl ood the l eak area wi th an open-
ended garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds
i n a steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the
spray i n a di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mu-
l ate thi s condi ti on. Thi s method can be used when
the l eak occurs when the vehi cl e accel erates, stops or
turns. I f the l eak occurs on accel erati on, hoi st the
front of the vehi cl e. I f the l eak occurs when braki ng,
hoi st the back of the vehi cl e. I f the l eak occurs on l eft
turns, hoi st the l eft si de of the vehi cl e. I f the l eak
occurs on ri ght turns, hoi st the ri ght si de of the vehi -
cl e. For hoi sti ng recommendati ons refer to Group 0,
Lubri cati on and Mai ntenance, General I nformati on
secti on.
WATER LEAK DETECTION
To detect a water l eak poi nt-of-entry, do a water
test and watch for water tracks or dropl ets formi ng
on the i nsi de of the vehi cl e. I f necessary, remove i nte-
ri or tri m covers or panel s to gai n vi sual access to the
WJ BODY 23 - 1
l eak area. I f the hose cannot be posi ti oned wi thout
bei ng hel d, have someone hel p do the water test.
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak
appears, fi nd the hi ghest poi nt of the water track or
drop. The hi ghest poi nt usual l y wi l l show the poi nt of
entry. After l eak poi nt has been found, repai r the
l eak and water test to veri fy that the l eak has
stopped.
Locati ng the entry poi nt of water that i s l eaki ng
i nto a cavi ty between panel s can be di ffi cul t. The
trapped water may spl ash or run from the cavi ty,
often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on an i ncl i ne.
MIRROR INSPECTION METHOD
When a l eak poi nt area i s vi sual l y obstructed, use
a sui tabl e mi rror to gai n vi sual access. A mi rror can
al so be used to defl ect l i ght to a l i mi ted-access area
to assi st i n l ocati ng a l eak poi nt.
BRIGHT LIGHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can
be detected wi thout water testi ng. Posi ti on the vehi -
cl e i n a bri ghtl y l i t area. From i nsi de the darkened
l uggage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the open-
i ng.
PRESSURIZED LEAK TEST METHOD
When a water l eak i nto the passenger compart-
ment cannot be detected by water testi ng, pressuri ze
the passenger compartment and soap test exteri or of
the vehi cl e. To pressuri ze the passenger compart-
ment, cl ose al l doors and wi ndows, start engi ne, and
set heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to ensure adequate vol tage to the bl ower.
Wi th i nteri or pressuri zed, appl y di sh detergent sol u-
ti on to suspected l eak area on the exteri or of the
vehi cl e. Appl y detergent sol uti on wi th spray devi ce or
soft bri stl e brush. I f soap bubbl es occur at a body
seam, joi nt, seal or gasket, the l eak entry poi nt coul d
be at that l ocati on.
WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai rti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai rti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
cross wi nds. Over compensati ng on door or gl ass
adjustments to stop wi nd noi se that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After a repai r pro-
cedure has been performed, test vehi cl e to veri fy
noi se has stopped before returni ng vehi cl e to use.
Wi nd noi se can al so be caused by i mproperl y fi tted
exteri or mol di ngs or body ornamentati on. Loose
mol di ngs can fl utter, creati ng a buzzi ng or chatteri ng
noi se. An open cavi ty or protrudi ng edge can create a
whi stl i ng or howl i ng noi se. I nspect the exteri or of the
vehi cl e to veri fy that these condi ti ons do not exi st.
VISUAL INSPECTION BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and
body components are al i gned and seal ed. I f compo-
nent al i gnment or seal i ng i s necessary, refer to the
appropri ate secti on of thi s group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Dri ve the vehi cl e to veri fy the general l ocati on
of the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm
(6 i n.) l engths al ong weatherstri ps, wel d seams or
mol di ngs. After each l ength i s appl i ed, dri ve the vehi -
cl e. I f noi se goes away after a pi ece of tape i s appl i ed,
remove tape, l ocate, and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd-rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
23 - 2 BODY WJ
BODY (Continued)
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
sengers cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri od-
i cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng).
(a) Spray a smal l amount of l ock cyl i nder l ubri -
cant di rectl y i nto the l ock cyl i nder.
(b) Appl y a smal l amount to the key and i nsert
i t i nto the l ock cyl i nder.
(c) Rotate i t to the l ocked posi ti on and then back
to the unl ocked posi ti on several ti mes.
(d) Remove the key. Wi pe the l ubri cant from i t
wi th a cl ean cl oth to avoi d soi l i ng of cl othi ng.
STANDARD PROCEDURE - DRILLING AND
WELDING
When hol es must be dri l l ed or punched i n an i nner
body panel , veri fy depth of space to the outer body
panel , el ectri cal wi ri ng, or other components. Dam-
age to vehi cl e can resul t.
Do not wel d exteri or panel s unl ess combusti bl e
materi al on the i nteri or of vehi cl e i s removed from
the repai r area. Fi re or hazardous condi ti ons, can
resul t.
Al ways have a fi re exti ngui sher ready for use when
wel di ng.
SPECIFICATIONS
BODY LUBRICANTS
COMPONENT SERVICE INTERVAL LUBRICANT
Door Hinges As Required
Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Door Latches As Required
Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Hood Latch, Release Mechanism and
Safety Latch
As Required
(When Performing Other
Underhood Service)
Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Hood Hinges As Required Engine Oil
Seat Track and Release Mechanism As Required
EP (2)
Liftgate Hinge As Required
EP (2)
Liftgate Support Arms As Required Engine Oil
Liftgate Latches As Required White Spray Lubricant (3)
Liftgate Release Handle (Pivot and Slide
Contact Surfaces)
As Required
EP (2)
Window System Components As Required White Spray Lubricant (3)
Lock Cylinders Twice a Year Lock-Cylinder Lubricant (4)
Parking Brake Mechanism As Required
EP (1)
1 = Mopar Wheel Bearing Grease (High
Temp)
2 = Mopar Multi-Mileage Lubricant
3 = Mopar Spray White Lube
4 = Mopar Lock Cylinder Lubricant
WJ BODY 23 - 3
BODY (Continued)
SPECIFICATIONS - TORQUE
BUCKET SEAT BACK FRAME RECLINER BOLTS TO SEAT CUSHION
FRAME
28 20
BUCKET SEAT RECLINER TO SEAT BACK FRAME BOLTS 28 20
BUCKET SEAT TRACK ADJUSTER NUTS TO SEAT CUSHION FRAME 28 20
FRONT BUCKET SEAT TO FLOOR PAN BOLTS 40 30
FRONT BUCKET SEAT TO FLOOR PAN FRONT BOLTS 40 30
FRONT DOOR HINGE BOLTS 35 26
FRONT DOOR LATCH TO DOOR SCREWS 10 89
FRONT DOOR STRIKER TO B-PILLAR 28 20
HOOD LATCH TO RADIATOR CROSSMEMBER 11 8
LIFT GATE LATCH STRIKER TO D-PILLAR NUTS 10 89
REAR DOOR LATCH TO DOOR SCREWS 10 89
REAR DOOR STRIKER TO C-PILLAR SCREWS 28 20
REAR SEAT BACK LATCH/HINGE TO SEAT BACK FRAME 28 20
REAR SEAT BACK LEFT SIDE SUPPORT BRACKET TO CENTER PIVOT
BRACKET
28 20
REAR SEAT BACK RIGHT SIDE SUPPORT BRACKET 28 20
REAR SEAT CUSHION LATCH BASE PANEL SCREWS 8 75
REAR SEAT CUSHION TO FLOOR PAN BOLTS 11 8
SUNROOF MODULE TO ROOF PANEL NUTS 11 8
SPECIAL TOOLS
BODY
Remover, Moldings C-4829
23 - 4 BODY WJ
BODY (Continued)
DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLIP-UP GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLIP-UP GLASS LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLIP-UP GLASS LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FLIP-UP GLASS SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LIFTGATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADJUSTMENTS
LIFTGATE ADJUSTMENT . . . . . . . . . . . . . . . . 9
TRIM PANEL
REMOVAL
REMOVAL - LIFTGATE TRIM PANEL . . . . . . . . 9
REMOVAL - LOWER LIFTGATE OPENING
TRIM PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION
INSTALLATION - LIFTGATE TRIM PANEL . . . 10
INSTALLATION - LOWER LIFTGATE
OPENING TRIM PANEL . . . . . . . . . . . . . . . . . 10
LIFTGATE INSULATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
EXTERIOR HANDLE
REMOVAL
(1) Remove the l i ftgate tri m panel refer to (Refer
GATE/TRI M PANEL - REMOVAL).
(2) Remove the l atch, outsi de handl e l i nkage, and
power l ock connector.
(3) Remove the fasteners attachi ng the outsi de
handl e to the l i ftgate.
(4) Remove the outsi de handl e from the l i ftgate.
INSTALLATION
(1) Posi ti on the outsi de handl e on the l i ftgate.
(2) I nstal l the fasteners attachi ng outsi de handl e
to l i ftgate.
(3) Connect outsi de handl e l i nk and power l ock
connector.
(4) I nstal l l i ftgate tri m panel , refer to (Refer to 23
- BODY/DECKLI D/HATCH/LI FTGATE/TAI LGATE/
TRI M PANEL - I NSTALLATI ON).
FLIP-UP GLASS
REMOVAL
CAUTION: DO NOT DISCONNECT THE PROP ROD
CYLINDERS WITH THE LIFTGATE FLIP UP GLASS
CLOSED. THE PROP ROD PISTONS ARE OPER-
ATED BY HIGH PRESSURE GAS. THIS PRESSURE
COULD CAUSE DAMAGE AND/OR PERSONAL
INJURY IF THEY ARE REMOVED WHILE THE PIS-
TONS ARE COMPRESSED.
(1) Usi ng a tri m sti ck or other sui tabl e devi ce, sep-
arate the fl i p up gl ass hi nge cover from the hi nge on
the l i ftgate (Fi g. 1).
(2) Open l i ftgate fl i p up gl ass. Support the gl ass
for ease of repai r.
(3) Usi ng a smal l fl at bl ade or equi val ent tool , gen-
tl y pry open the l ocki ng caps on the end of the prop
rods.
(4) Remove prop rod cyl i nders from bal l studs.
(5) Lower the fl i p up gl ass.
(6) Remove hi nge fasteners from l i ftgate.
(7) Separate fl i p up gl ass from l i ftgate.
WJ DECKLID/HATCH/LIFTGATE/TAILGATE 23 - 5
INSTALLATION
(1) Posi ti on fl i p up gl ass on l i ftgate.
(2) I nstal l hi nge fasteners, hand ti ght onl y.
(3) Wi th the gl ass panel i n the ful l y open posi ti on,
ful l y rai sed posi ti on, push the gl ass forward to com-
pl etel y seat the hi nges. Ti ghten hi nge fasteners to
6Nm (60 i n. l bs.).
(4) I nstal l prop rods on bal l studs and compress
l ocki ng caps to l ock rods on bal l studs.
(5) Lower the fl i p up gl ass and i nstal l the fl i p up
gl ass hi nge cover.
(6) Check the fl i p up gl ass for proper al i gnment
and l atchi ng.
FLIP-UP GLASS LATCH
REMOVAL
(1) Open l i ftgate fl i p up gl ass.
(2) Remove the tri m panel (Refer to 23 - BODY/
DECKLI D/HATCH/LI FTGATE/TAI LGATE/TRI M
PANEL - REMOVAL).
(3) Remove l atch (Fi g. 2).
(4) Di sconnect swi tch connectors.
(5) Remove l atch from l i ftgate.
INSTALLATION
(1) Posi ti on the l atch on the l i ftgate (Fi g. 2).
(2) Connect swi tch connectors.
(3) Adjust l atch to the proper posi ti on, and ti ghten
the fasteners to 11 Nm (100 i n. l bs.).
Fig. 1 Flip-Up Glass
1 - FLIP-UP GLASS
2 - HINGE COVER
3 - SUPPORT PROP
4 - BUMPER
5 - BUMPER
Fig. 2 Flip-up Glass Latch
1 - LATCH
2 - LIFTGATE
23 - 6 DECKLID/HATCH/LIFTGATE/TAILGATE WJ
FLIP-UP GLASS (Continued)
(4) Cl ose fl i p up gl ass panel and veri fy proper
operati on.
(5) I nstal l l i ftgate tri m panel , refer to (Refer to 23 -
BODY/DECKLI D/HATCH/LI FTGATE/TAI LGATE/TRI M
PANEL - I NSTALLATI ON).
FLIP-UP GLASS LATCH
STRIKER
REMOVAL
(1) Rai se fl i p up gl ass panel .
(2) Mark the posi ti on of the handl e/stri ker on the
gl ass panel .
(3) Remove the screws attachi ng the handl e/stri ker
to the gl ass.
INSTALLATION
(1) Posi ti on the handl e/stri ker on the gl ass panel
and al i gn the reference marks.
(2) I nstal l the screws attachi ng the handl e/stri ker
to the gl ass panel . Ti ghten the fasteners to 6 Nm (60
i n. l bs.).
FLIP-UP GLASS SWITCH
REMOVAL
(1) Remove l i cense pl ate l amp housi ng/tri m panel
from l i ftgate, refer to (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - EXTERI OR/LI CENSE PLATE
LAMP UNI T - REMOVAL).
(2) Squeeze the l ocki ng tabs i nward to rel ease the
swi tch from the housi ng.
(3) Di sconnect the swi tch harness connector,
remove the swi tch from the housi ng.
INSTALLATION
(1) I nstal l swi tch harness connector.
(2) Posi ti on swi tch i n housi ng, snap swi tch i nto
pl ace.
(3) I nstal l l i cense pl ate l amp housi ng/tri m panel
onto l i ftgate, refer to (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - EXTERI OR/LI CENSE PLATE
LAMP UNI T - I NSTALLATI ON).
HINGE
REMOVAL
NOTE: It is not necessary to remove the liftgate to
replace one or both hinges. The hinges can be
replaced one at a time.
(1) Open the l i ftgate. Support the l i ftgate for ease
of repai r.
(2) Remove the l i ftgate header tri m panel .
(3) Mark the hi nge l ocati on wi th a grease penci l or
other sui tabl e devi ce.
(4) Remove the hi nge screws (Fi g. 5).
(5) Remove hi nge.
INSTALLATION
NOTE: It is not necessary to remove the liftgate to
replace one or both hinges. The hinges can be
replaced one at a time.
(1) Posi ti on the hi nge on the roof panel and on the
l i ftgate. (Use 3M Fast and Fi rm or equi val ent on
the hi nge to body mati ng surfaces as a seal ant.
(2) I nstal l and ti ghten hi nge screws at roof panel
to 28Nm (21 ft. l bs.).
(3) I nstal l hi nge screws at l i ftgate. Ti ghten screws
to 28Nm (21 ft. l bs.).
(4) I nstal l l i ftgate header tri m panel .
(5) Check the l i ftgate for proper al i gnment and
operati on.
FLIP-UP GLASS LATCH (Continued)
LATCH
REMOVAL
(1) Rai se the l i ftgate.
(2) Remove the l i ftgate tri m panel (Fi g. 3).
(3) Di sconnect the power connector.
(4) Di sconnect the outsi de handl e l i nk from the l atch.
(5) Remove the l atch screws and remove l atch.
INSTALLATION
(1) I nstal l the l atch i nto the l i ftgate and ti ghten
the screws to 7Nm (5 ft. l bs.).
(2) Connect the outsi de handl e to the l i ftgate l atch.
(3) Pl ug i n the connector for the power.
(4) I nstal l the l i ftgate tri m panel .
LATCH STRIKER
REMOVAL
(1) Rai se l i ftgate.
(2) Remove tai l l amp, refer to (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/TAI L
LAMP - REMOVAL).
(3) Remove nuts attachi ng stri ker to D-pi l l ar (Fi g. 4).
(4) Separate stri ker from D-pi l l ar.
INSTALLATION
(1) Posi ti on stri ker on D-pi l l ar.
(2) I nstal l nuts attachi ng stri ker to D-pi l l ar. Ti ghten
nuts to 10 Nm (7 ft. l bs.) torque (Fi g. 4).
(3) I nstal l tai l l amp (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - EXTERI OR/TAI L LAMP -
I NSTALLATI ON).
Fig. 3 LIFTGATE LATCH
1 - LATCH
2 - LIFTGATE
3 - CONNECTOR
4 - ACTUATOR
5 - CLIP
6 - OUTSIDE HANDLE TO LATCH ROD
7 - OUTSIDE HANDLE
Fig. 4 Liftgate Latch Striker
1 - D-PILLAR
2 - STRIKER
LIFTGATE
REMOVAL
CAUTION: DO NOT DISCONNECT THE SUPPORT ROD
CYLINDERS WITH THE LIFTGATE CLOSED. THE SUP-
PORT ROD PISTONS ARE OPERATED BY HIGH PRES-
SURE GAS. THIS PRESSURE COULD CAUSE DAMAGE
AND /OR PERSONAL INJURY IF THEY ARE REMOVED
WHILE THE PISTONS ARE COMPRESSED.
(1) Open the l i ftgate. Support the l i ftgate for ease
of repai r.
(2) Remove the l i ftgate tri m panel .
(3) Remove the prop rods from the l i ftgate.
(4) Unpl ug the wi re harnesses and di sconnect the
washer hose.
(5) Mark the hi nge l ocati on wi th a wax penci l or
other sui tabl e devi ce (Fi g. 5).
(6) Remove the hi nge screws and remove l i ftgate
from vehi cl e.
INSTALLATION
(1) Posi ti on the l i ftgate on the vehi cl e and al i gn
the wi tness marks.
(2) I nstal l the hi nge screws at l i ftgate. Ti ghten
hi nge screws to 28Nm (21ft. l bs.).
(3) Connect the wi re harnesses and the washer
hose.
(4) I nstal l the tri m panel .
(5) I nstal l the prop rods.
(6) Cl ose the l i ftgate and check for proper l atchi ng
and al i gnment.
ADJ USTMENTS
LIFTGATE ADJUSTMENT
The posi ti on of the l i ftgate can be adjusted upward
or downward by the use of sl ots i n the hi nge. An
i nward or outward adjustment i s achi eved by use of
sl ots i n the body. I f an i nward or outward adjustment
i s needed, use 3M Fast and Fi rm or equi val ent on
the hi nge to body mati ng surface as a seal ant.
TRIM PANEL
REMOVAL
REMOVAL - LIFTGATE TRIM PANEL
NOTE: The liftgate trim panel is attached with
screws and spring clips.
(1) Rai se the l i ftgate.
(2) Remove the screws securi ng the l i ftgate tri m
panel to the l i ftgate (Fi g. 6).
(3) Di sconnect the rear wi ndow defroster wi res.
(4) Usi ng a tri m sti ck, or other sui tabl e tool , pry
the l i ftgate tri m panel off the l i ftgate.
Fig. 5 Liftgate
1 - HINGE
2 - LIFTGATE
Fig. 6 Liftgate Trim Panel
1 - LIFTGATE
2 - LIFTGATE TRIM PANEL
REMOVAL - LOWER LIFTGATE OPENING TRIM
PANEL
(1) Remove screws at outboard end of l ower l i ft-
gate tri m panel .
(2) Open the spare ti re cover and remove the
screws near the center of the l ower l i ftgate tri m
panel (Fi g. 7).
(3) Remove the l ower l i ftgate tri m panel .
INSTALLATION
INSTALLATION - LIFTGATE TRIM PANEL
NOTE: The liftgate trim panel is attached with
screws and spring clips.
(1) Al i gn the l i ftgate tri m panel spri ng cl i ps and
press the panel i nto the l i ftgate.
(2) I nstal l the tri m panel screws.
(3) Connect the rear defroster wi res.
INSTALLATION - LOWER LIFTGATE OPENING
TRIM PANEL
(1) Al i gn the screw hol es and l ocators to the hol es
i n the l i ftgate openi ng.
(2) I nstal l the screws i n the l i ftgate openi ng tri m
panel .
(3) I nstal l the spare ti re cover.
LIFTGATE INSULATOR
REMOVAL
(1) Remove the l i ftgate tri m panel , refer to (Refer
GATE/TRI M PANEL - REMOVAL).
(2) Separate the l i ftgate i nsul ator from the l i ftgate
and tri m panel (Fi g. 8).
INSTALLATION
(1) Thoroughl y cl ean the area of any adhesi ve or
i nsul ati on materi al .
(2) I nstal l the i nsul ator i n the l i ftgate.
(3) I nstal l the l i ftgate tri m panel refer to (Refer to
23 - BODY/DECKLI D/HATCH/LI FTGATE/TAI L-
GATE/TRI M PANEL - I NSTALLATI ON).
Fig. 7 Liftgate Opening Trim Panel
1 - UPPER LIFTGATE OPENING TRIM PANEL
2 - LOWER LIFTGATE OPENING TRIM PANEL
Fig. 8 Liftgate Insulator Pad
1 - LIFTGATE
2 - INSULATION PAD
TRIM PANEL (Continued)
DOOR - FRONT
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
ADJUSTMENTS
DOOR ADJUSTMENT . . . . . . . . . . . . . . . . . . 12
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
GLASS RUN CHANNEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSIDE HANDLE ACTUATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
ADJUSTMENTS
DOOR LATCH . . . . . . . . . . . . . . . . . . . . . . . . 16
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
WINDOW REGULATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
CHECK STRAP
REMOVAL
(1) Remove the waterdam, refer to (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - REMOVAL).
(2) Remove speaker.
(3) Remove screws attachi ng door check to A-pi l l ar.
(4) Remove nuts attachi ng door check to door (Fi g.
1).
(5) Remove door check through speaker l ocati on
hol e.
INSTALLATION
(1) Posi ti on door check on door through speaker
l ocati on hol e (Fi g. 1).
(2) I nstal l nuts attachi ng door check to door.
(3) I nstal l screws attachi ng door check to A-pi l l ar.
(4) I nstal l speaker.
(5) I nstal l the waterdam, refer to (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - I NSTALLA-
TI ON).
Fig. 1 Door Check
1 - DOOR CHECK
2 - FRONT DOOR
WJ DOOR - FRONT 23 - 11
DOOR
REMOVAL
(1) Di sconnect front door harness connector (Fi g.
2).
(2) Support door wi th padded fl oor jack.
(3) Remove retai ni ng cl i ps from hi nge pi ns.
(4) Tap out hi nge pi ns.
(5) Separate door from vehi cl e.
INSTALLATION
(1) Posi ti on door at vehi cl e and al i gn hi nges.
(2) I nstal l hi nge pi ns.
(3) I nstal l retai ni ng cl i ps for hi nge pi ns.
(4) Connect front door harness connector (Fi g. 2).
ADJ USTMENTS
DOOR ADJUSTMENT
Mi nor adjustment for al i gnment of the door i s
made by movi ng the l atch stri ker.
IN AND OUT
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker i nward i f the door charac-
ter l i ne i s outboard of the body character l i ne or tap
the l atch stri ker outward i f the door character l i ne i s
i nboard of the body character l i ne.
(3) I nspect the al i gnment. I f correct, ti ghten
stri ker to 28 Nm (21 ft. l bs.).
UP AND DOWN
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker downward i f the door
character l i ne i s hi gher than the body character l i ne
or tap the l atch stri ker upward i f the door character
l i ne i s l ower than the body character l i ne.
(3) I nspect the al i gnment. I f correct, ti ghten to 28
Nm (21 ft. l bs.).
DOOR GLASS
REMOVAL
(1) Locate gl ass to ful l down posi ti on.
(3) Remove i nner bel t weatherstri p, refer to (Refer
to 23 - BODY/WEATHERSTRI P/SEALS/FDR I NNER
BELT WEATHERSTRI P - REMOVAL).
(4) Remove outer bel t weatherstri p, refer to (Refer
to 23 - BODY/WEATHERSTRI P/SEALS/FDR OUTER
(5) Locate gl ass to 3/4 up posi ti on.
(6) Usi ng a l ong fl at bl ade or hook type tool , di s-
engage cl i ps (Fi g. 3) attachi ng gl ass retai ner to gl ass
l i ft pl ate.
(7) Careful l y push bottom of gl ass panel outward
to di sengage gl ass retai ner studs from l i ft pl ate (Fi g.
4).
(8) Li ft gl ass upward and out of door.
INSTALLATION
(1) Lower gl ass i nto posi ti on.
(2) Careful l y al i gn gl ass retai ner studs wi th l i ft
pl ate and i nsert studs i nto l i ft pl ate.
Fig. 2 Front Door Harness Connector
2 - DOOR
Fig. 3 Front Door Glass Clips
1 - GLASS
2 - RETAINER
3 - CLIP
4 - LIFT PLATE
5 - REGULATOR
6 - CLIP
23 - 12 DOOR - FRONT WJ
(3) Engage cl i ps attachi ng gl ass retai ner to gl ass
l i ft pl ate.
(5) I nstal l outer bel t weatherstri p, (Refer to 23 -
BODY/WEATHERSTRI P/SEALS/FDR OUTER BELT
WEATHERSTRI P - I NSTALLATI ON).
(6) I nstal l i nner bel t weatherstri p, (Refer to 23 -
BODY/WEATHERSTRI P/SEALS/FDR I NNER BELT
(7) I nstal l waterdam, refer to (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - I NSTALLATI ON).
EXTERIOR HANDLE
REMOVAL
(1) Remove gl ass run channel , refer to (Refer to 23
- BODY/DOOR - FRONT/GLASS RUN CHANNEL -
REMOVAL).
(2) Di sconnect l ock cyl i nder to l atch rod.
(3) Di sconnect outsi de handl e to l atch rod
(4) Remove fasteners attachi ng outsi de handl e to
door (Fi g. 5).
(5) Remove outsi de handl e from door.
(6) Di sconnect anti -theft harness connector, i f
equi pped.
(7) Separate outsi de handl e from vehi cl e.
INSTALLATION
(1) Posi ti on outsi de handl e at door (Fi g. 5).
(2) Connect anti -theft harness connector, i f
equi pped.
(3) Posi ti on outsi de handl e i n door.
(4) I nstal l fasteners attachi ng outsi de handl e to
door.
(5) Connect outsi de handl e to l atch rod
(6) Connect l ock cyl i nder to l atch rod.
(7) I nstal l gl ass run channel , refer to (Refer to 23 -
BODY/DOOR - FRONT/GLASS RUN CHANNEL -
I NSTALLATI ON).
GLASS RUN CHANNEL
REMOVAL
NOTE: Only the rearward glass run channel is ser-
viceable.
to 23 - BODY/WEATHERSTRI P/SEALS/FDR I NNER
(3) Remove outer bel t weatherstri p, refer to (Refer
to 23 - BODY/WEATHERSTRI P/SEALS/FDR OUTER
(4) Remove bol t attachi ng run channel to i nner
door panel (Fi g. 6).
(5) Peel back gl ass run channel weatherstri p on
rear run channel .
(6) Pul l gl ass run channel downward to separate
from door.
Fig. 4 Front Door Glass Retainer
1 - GLASS
2 - RETAINER
3 - LIFT PLATE
4 - STUD
Fig. 5 Front Door Outside Handle
1 - DOOR
2 - OUTSIDE HANDLE
DOOR GLASS (Continued)
(7) Remove gl ass run channel from door.
INSTALLATION
(1) Posi ti on gl ass run channel i n door (Fi g. 6).
(2) Al i gn gl ass run channel wi th door frame run
channel and sl i de channel upward to secure door.
(3) Press gl ass run channel weatherstri p i nto rear
run channel .
(4) I nstal l bol t attachi ng run channel to i nner door
panel .
(5) I nstal l outer bel t weatherstri p, (Refer to 23 -
(6) I nstal l i nner bel t weatherstri p, (Refer to 23 -
(7) I nstal l the waterdam, (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - I NSTALLATI ON).
HINGE
REMOVAL
(1) Open and support door.
(2) Usi ng a wax penci l , or other sui tabl e devi ce,
reference mark the hi nge pl acement
(3) Di sconnect the door wi re harness.
(4) Remove the door check from the A pi l l ar (Fi g.
7).
(5) Remove the fasteners retai ni ng the door hi nge
to the door (Fi g. 8).
(6) Remove the door.
(7) Remove the hi nge from the A pi l l ar.
Fig. 6 Front Door Glass Run Channel
1 - DOOR
2 - GLASS
3 - GLASS RUN CHANNEL
4 - REGULATOR Fig. 7 Front Door Check
1 - DOOR CHECK
2 - FRONT DOOR
Fig. 8 Front Door Hinges
1 - WASHER
2 - UPPER HINGE
3 - FRONT DOOR
4 - LOWER HINGE
5 - WASHER
GLASS RUN CHANNEL (Continued)
INSTALLATION
(1) Posi ti on hi nge on A pi l l ar. (Use 3M Fast and
Fi rm or equi val ent on the hi nge to body mati ng sur-
face as a seal ant.)
(2) I nstal l hi nge to body bol ts, but do not ti ghten.
(3) Al i gn the hi nge to the reference marks and
torque the bol ts to 35Nm (26 ft. l bs.).
(4) I nstal l the door on the hi nge and al i gn wi th the
reference marks.
(5) Ti ghten the door to hi nge fasteners.
(6) For adjustment see door adjustment procedure.
REMOVAL
(1) Remove door tri m panel , refer to (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - REMOVAL).
(2) Di sconnect l atch and l ock rods from i nsi de han-
dl e actuator.
(3) Remove screws attachi ng i nsi de handl e actua-
tor to tri m panel (Fi g. 9).
(4) Separate i nsi de handl e actuator from tri m
panel .
INSTALLATION
(1) Posi ti on i nsi de handl e actuator i n tri m panel .
(2) I nstal l screws attachi ng i nsi de handl e actuator
to tri m panel (Fi g. 9).
(3) Connect l atch and l ock rods to i nsi de handl e
actuator.
(4) I nstal l door tri m panel , refer to (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - I NSTALLA-
TI ON).
LATCH
REMOVAL
(1) Remove gl ass run channel , refer to (Refer to 23
- BODY/DOOR - FRONT/GLASS RUN CHANNEL -
REMOVAL).
(2) Remove screws attachi ng door l atch to door
(Fi g. 10).
(3) Di sconnect al l rods from door l atch.
(4) Di sconnect wi re harness connector, i f equi pped.
(5) Separate door l atch from door.
INSTALLATION
(1) Posi ti on door l atch at door.
(2) Connect wi re harness connector, i f equi pped.
(3) Connect al l rods to door l atch.
(4) I nstal l screws attachi ng door l atch to door.
Ti ghten screws to 10 Nm (7 ft. l bs.) torque (Fi g. 10).
(5) I nstal l gl ass run channel , refer to (Refer to 23 -
I NSTALLATI ON).
Fig. 9 Front Door Inside Handle Actuator
1 - INSIDE HANDLE ACTUATOR
2 - DRIVERS DOOR TRIM PANEL
3 - SCREW
Fig. 10 Door Latch
1 - DOOR
2 - LATCH
3 - ISOLATOR
HINGE (Continued)
ADJ USTMENTS
DOOR LATCH
DOOR LATCH ADJUSTMENT
(1) Locate access hol e (Fi g. 11).
(2) I nsert a 5/32-i nch hex-wrench through hol e and
i nto adjustment screw. Loosen screw.
(3) Operate outsi de handl e button several ti mes to
rel ease any restri cti on because of mi s-al i gnment.
(4) Ti ghten adjustment screw to 3 Nm (30 i n-l bs)
torque.
(5) Test handl e button and l ock cyl i nder for proper
operati on.
LATCH STRIKER
REMOVAL
(1) Remove screws attachi ng stri ker to B-pi l l ar.
(2) Separate stri ker and spacer from B-pi l l ar (Fi g.
12).
INSTALLATION
(1) Posi ti on stri ker and spacer on B-pi l l ar.
(2) I nstal l screws attachi ng stri ker to B-pi l l ar.
Ti ghten screws to 28 Nm (20 ft. l bs.) torque (Fi g.
12).
LOCK CYLINDER
REMOVAL
(1) Remove outsi de door handl e, refer to (Refer to
23 - BODY/DOOR - FRONT/EXTERI OR HANDLE -
REMOVAL).
(2) Remove screw securi ng l ock cyl i nder retai ner
to outsi de door handl e (Fi g. 13).
(3) Separate l ock cyl i nder from door handl e.
(4) Di sconnect l ock cyl i nder swi tch, i f equi pped.
Fig. 11 Door Latch Adjustment
1 - ACCESS HOLE
2 - DOOR
3 - LATCH MOUNTING BOLTS
4 - LATCH
Fig. 12 Front Door Latch Striker
1 - B-PILLAR
2 - SPACER
3 - STRIKER
Fig. 13 Front Door Lock Cylinder
2 - LOCK CYLINDER
3 - ANTI-THEFT SWITCH
4 - RETAINER
LATCH (Continued)
INSTALLATION
(1) Connect l ock cyl i nder swi tch, i f equi pped.
(2) Posi ti on l ock cyl i nder i n door handl e.
(3) Posi ti on l ock cyl i nder retai ner and i nstal l
screw (Fi g. 13).
(4) I nstal l outsi de door handl e, refer to (Refer to
23 - BODY/DOOR - FRONT/EXTERI OR HANDLE -
I NSTALLATI ON).
TRIM PANEL
REMOVAL
(1) Remove tri m pl ug from mi rror fl ag bezel .
(2) Remove screws attachi ng tri m panel to door
(Fi g. 14).
(3) Usi ng tri m remover (C-4829 or equi val ent),
detach tri m panel peri meter push-i n fasteners from
door i nner panel .
(4) Li ft tri m panel upward and separate from door.
(5) I f equi pped, di sconnect harness connectors for
power accessori es.
(6) Di sconnect l atch rods from i nsi de handl e actua-
tor.
(7) Separate tri m panel from vehi cl e.
INSTALLATION
(1) Connect l atch rods to i nsi de handl e actuator.
(2) I f equi pped, connect harness connectors to
power accessori es.
(3) Posi ti on tri m panel on door i nner panel .
(4) Press tri m panel push-i n fasteners i nward
around peri meter of door.
(5) I nstal l screws attachi ng tri m panel to door
(Fi g. 14).
(6) I nstal l tri m pl ug i n mi rror fl ag bezel .
WATERDAM
REMOVAL
(2) Peel the waterdam from door.
(3) Route al l harnesses and l i nkage rods through
waterdam as necessary.
(4) Separate waterdam from door (Fi g. 15).
INSTALLATION
(1) Waterdam contact surface must be free of con-
tami nants. Cl ean as necessary.
(3) Posi ti on waterdam on door and al i gn al l hol es.
(4) Press waterdam on door (Fi g. 15).
TI ON).
Fig. 14 Front Door Trim Panel
2 - NUTSERT
3 - TRIM PLUG
4 - TRIM PANEL
5 - PUSH-IN FASTENER
7 - LATCH RODS
Fig. 15 Front Door Waterdam
1 - INSULATOR PAD
LOCK CYLINDER (Continued)
WINDOW REGULATOR
REMOVAL
(1) Remove front door gl ass, refer to (Refer to 23 -
BODY/DOOR - FRONT/DOOR GLASS - REMOVAL).
(2) Loosen bol ts attachi ng regul ator to i nner door
panel (Fi g. 16).
(3) Remove bol t attachi ng regul ator to i nner door
panel (Fi g. 17).
(4) Li ft regul ator upward to di sengage bol ts from
door i nner panel .
(5) Di sengage power wi ndow regul ator harness
connector, i f equi pped.
(6) Remove regul ator through access hol e i n door.
INSTALLATION
(1) Posi ti on regul ator i n door through access hol e.
(2) Engage power wi ndow regul ator harness con-
nector, i f equi pped.
(3) Li ft regul ator upward and engage bol ts i n door
i nner panel key hol e sl ots.
(4) I nstal l bol t attachi ng regul ator to i nner door
panel .
(5) Ti ghten bol ts attachi ng regul ator to i nner door
panel .
(6) I nstal l front door gl ass, refer to (Refer to 23 -
I NSTALLATI ON).
Fig. 16 Front Door Regulator Bolts
1 - FRONT DOOR
2 - REMOVE BOLT
3 - LOOSEN BOLTS
Fig. 17 Front Door Window Regulator
1 - FRONT DOOR
2 - REGULATOR
DOORS - REAR
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
WINDOW REGULATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
CHECK STRAP
REMOVAL
(1) Remove waterdam, refer to (Refer to 23 -
BODY/DOORS - REAR/WATERDAM - REMOVAL).
(2) Remove speaker.
(3) Remove screws attachi ng door check to B-pi l l ar.
(4) Remove nuts attachi ng door check to door (Fi g.
1).
(5) Remove door check through speaker l ocati on
hol e.
INSTALLATION
(1) Posi ti on door check on door through speaker
l ocati on hol e.
(2) I nstal l nuts attachi ng door check to door (Fi g.
1).
(3) I nstal l screws attachi ng door check to B-pi l l ar.
(4) I nstal l speaker.
DOORS - REAR/WATERDAM - I NSTALLATI ON).
Fig. 1 Door Check
1 - DOOR CHECK
2 - REAR DOOR
WJ DOORS - REAR 23 - 19
DOOR
REMOVAL
(1) Di sconnect rear door harness connector (Fi g. 2).
(2) Support door wi th padded fl oor jack.
(3) Remove retai ni ng cl i ps from hi nge pi ns.
(4) Tap out hi nge pi ns.
(5) Separate door from vehi cl e.
INSTALLATION
(1) Posi ti on door at vehi cl e and al i gn hi nges.
(2) I nstal l hi nge pi ns.
(3) I nstal l retai ni ng cl i ps for hi nge pi ns.
(4) Connect rear door harness connector (Fi g. 2).
DOOR GLASS
REMOVAL
to 23 - BODY/WEATHERSTRI P/SEALS/RDR I NNER
(3) Remove stati onary gl ass, refer to (Refer to 23 -
BODY/STATI ONARY GLASS/DOOR GLASS -
REMOVAL).
(4) Di sengage cl i ps attachi ng wi ndow gl ass to l i ft
pl ate.
(5) Press studs out of l i ft pl ate.
(6) Li ft wi ndow gl ass from door (Fi g. 3).
INSTALLATION
(1) Posi ti on wi ndow gl ass i n door (Fi g. 3).
(2) Engage studs i nto l i ft pl ate.
(3) Engage cl i ps attachi ng wi ndow gl ass to l i ft
pl ate.
(4) I nstal l stati onary gl ass, refer to (Refer to 23 -
BODY/STATI ONARY GLASS/DOOR GLASS -
I NSTALLATI ON).
(5) I nstal l i nner bel t weatherstri p, refer to (Refer
to 23 - BODY/WEATHERSTRI P/SEALS/RDR I NNER
BELT WEATHERSTRI P - I NSTALLATI ON).
EXTERIOR HANDLE
REMOVAL
(2) Locate gl ass to ful l up posi ti on.
(3) Di sconnect l ock knob to l atch rod.
(4) Di sconnect outsi de handl e to l atch rod.
(5) Remove fasteners attachi ng outsi de handl e to
door (Fi g. 4).
(6) Remove outsi de handl e from door.
(7) Separate outsi de handl e from vehi cl e.
Fig. 2 Rear Door Harness Connector
Fig. 3 Glass Channel
1 - GLASS
2 - REGULATOR
23 - 20 DOORS - REAR WJ
INSTALLATION
(1) Posi ti on outsi de handl e i n door.
(2) I nstal l fasteners attachi ng outsi de handl e to
door (Fi g. 4).
(3) Connect outsi de handl e to l atch rod.
(4) Connect l ock knob to l atch rod.
HINGE
REMOVAL
(1) Open front door and rear door.
(2) Reference mark hi nges for i nstal l ati on (Fi g. 5).
(3) Support rear door for removal of hi nges.
(4) Remove B pi l l ar tri m.
(5) Remove nuts hol di ng door to hi nge.
(6) Remove door.
(7) Remove bol ts hol di ng hi nge to B pi l l ar.
INSTALLATION
(1) I nstal l hi nge on B pi l l ar and al i gn reference
marks (Fi g. 5).
(2) I nstal l bol ts hol di ng hi nge to B pi l l ar. Ti ghten
bol ts to 35Nm (23 ft. l bs.).
(3) I nstal l door on hi nge and al i gn reference
marks. I nstal l bol ts and ti ghten to 35Nm (26 ft.
l bs.).
(4) Check door for fi t and ease of operati on. Adjust
as necessary, refer to (Refer to 23 - BODY/DOOR -
FRONT/DOOR - ADJUSTMENTS).
(5) I nstal l B pi l l ar tri m.
Fig. 4 Front
1 - DOOR
2 - OUTSIDE HANDLE
Fig. 5 Rear Door Hinge
1 - UPPER HINGE
2 - WASHER
3 - WASHER
4 - LOWER HINGE
5 - REAR DOOR
EXTERIOR HANDLE (Continued)
REMOVAL
BODY/DOORS - REAR/TRI M PANEL - REMOVAL).
(2) Di sconnect l atch and l ock rods from i nsi de han-
dl e actuator.
(3) Remove screws attachi ng i nsi de handl e actua-
tor to tri m panel (Fi g. 6).
(4) Separate i nsi de handl e actuator from tri m
panel .
INSTALLATION
(1) Posi ti on i nsi de handl e actuator i n tri m panel .
(2) I nstal l screws attachi ng i nsi de handl e actuator
to tri m panel (Fi g. 6).
(3) Connect l atch and l ock rods to i nsi de handl e
actuator.
BODY/DOORS - REAR/TRI M PANEL - I NSTALLA-
TI ON).
LATCH
REMOVAL
(2) Remove screws attachi ng l atch to door (Fi g. 7).
(3) Di sconnect rods from door l atch.
(4) Separate door l atch from door.
INSTALLATION
(1) posi ti on l atch i n door.
(2) Connect rods to door l atch.
(3) I nstal l screws attachi ng l atch to door. Ti ghten
screws to 10 Nm (95 i n. l bs.) torque (Fi g. 7).
Fig. 6 Rear Door Inside Handle Actuator
1 - REAR DOOR TRIM PANEL
2 - SCREW
3 - INSIDE HANDLE ACTUATOR
Fig. 7 Rear Door Latch
1 - DOOR
2 - LATCH
3 - OUTSIDE HANDLE
LATCH STRIKER
REMOVAL
(1) Remove screws attachi ng stri ker to C-pi l l ar
(Fi g. 8).
(2) Separate stri ker and spacer from vehi cl e.
INSTALLATION
(1) Posi ti on stri ker and spacer on C-pi l l ar.
(2) I nstal l screws. Ti ghten to 28 Nm (250 i n. l bs.)
torque.
TRIM PANEL
REMOVAL
(1) Remove screws attachi ng tri m panel to door
(Fi g. 9).
(2) Usi ng tri m remover (C-4829 or equi val ent),
detach tri m panel peri meter push-i n fasteners from
door i nner panel .
(3) Li ft tri m panel upward and separate from door.
(4) I f equi pped, di sconnect harness connectors for
power accessori es.
(5) Di sconnect l atch rods from i nsi de handl e actuator.
(6) Separate tri m panel from vehi cl e.
INSTALLATION
(1) Connect l atch rods to i nsi de handl e actuator.
(2) I f equi pped, connect harness connectors to
power accessori es.
(3) Posi ti on tri m panel on door i nner panel .
(4) Press tri m panel push-i n fasteners i nward
around peri meter of door.
(5) I nstal l screws attachi ng tri m panel to door (Fi g. 9).
WATERDAM
REMOVAL
BODY/DOORS - REAR/TRI M PANEL - REMOVAL).
(2) Peel the waterdam from door.
(4) Separate waterdam from door (Fi g. 10).
Fig. 8 Rear Door Latch Striker
1 - TAPPING PLATE
2 - SPACER
3 - STRIKER
Fig. 9 Rear Door Trim Panel
1 - TRIM PANEL
2 - NUTSERT
4 - LATCH RODS
Fig. 10 Rear Door Waterdam
1 - INSULATOR PAD
INSTALLATION
(1) Waterdam contact surface must be free of con-
tami nants. Cl ean as necessary.
(3) Posi ti on waterdam on door and al i gn al l hol es
(Fi g. 10).
(4) Press waterdam on door.
BODY/DOORS - REAR/TRI M PANEL - I NSTALLA-
TI ON).
WINDOW REGULATOR
REMOVAL
(2) Remove the stati onary gl ass, refer to (Refer to
23 - BODY/STATI ONARY GLASS/DOOR GLASS -
REMOVAL).
(3) Rai se the door gl ass and support.
(4) Di sconnect the speaker harness and power wi n-
dow harness, i f equi pped.
(5) Remove the wi ndow cl i ps retai ni ng regul ator
(Fi g. 11).
(6) Remove the door gl ass.
(7) Remove the fasteners retai ni ng the regul ator
(Fi g. 12).
(8) Remove the regul ator.
INSTALLATION
(1) Posi ti on the wi ndow regul ator i n the door.
(2) I nstal l the fasteners retai ni ng the regul ator
(Fi g. 12).
(3) I nstal l the door gl ass.
(4) I nstal l the wi ndow cl i ps retai ni ng regul ator
(Fi g. 11).
(5) Lower the door gl ass.
(6) I nstal l the stati onary gl ass, refer to (Refer to
23 - BODY/STATI ONARY GLASS/DOOR GLASS -
I NSTALLATI ON).
(7) Connect the power wi ndow and speaker har-
ness i f equi pped.
(8) I nstal l the waterdam, refer to (Refer to 23 -
BODY/DOORS - REAR/WATERDAM - I NSTALLA-
TI ON).
(9) Cycl e the gl ass and check for proper operati on.
Fig. 11 Window Regulator Retainer Clips
1 - GLASS
2 - RETAINER
3 - CLIP
4 - LIFT PLATE
5 - REGULATOR
6 - CLIP
Fig. 12 Rear Door Window Regulator
1 - DOOR
2 - REGULATOR
WATERDAM (Continued)
EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL
REMOVALFRONT DOOR . . . . . . . . . . . . . . . 25
REMOVALREAR DOOR . . . . . . . . . . . . . . . . 26
REMOVALFENDER/QUARTER PANEL . . . . . 26
INSTALLATION
INSTALLATIONFRONT DOOR . . . . . . . . . . . 26
INSTALLATIONREAR DOOR . . . . . . . . . . . . 26
INSTALLATIONFENDER/QUARTER PANEL . 26
COWL GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
D-PILLAR APPLIQUE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
D-PILLAR AIR EXHAUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
AIR EXHAUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
EXTERIOR NAME PLATES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
FUEL FILL DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
HEADLAMP MOUNTING MODULE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
LUGGAGE RACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
SIDE VIEW MIRROR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
SIDE VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
ROCK RAIL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
BODY SIDE MOLDINGS
REMOVAL
REMOVALFRONT DOOR
(1) Open the front door.
(2) Usi ng a tri m sti ck, pry the upper rear edge off
the door. Conti nue to the front edge of the front door
(Fi g. 1).
(3) Usi ng a heat gun, warm the adhesi ve tape on
the l ower edge of the cl addi ng and pul l the cl addi ng
from the door.
Fig. 1 Front Door Cladding
1 - CLADDING
WJ EXTERIOR 23 - 25
REMOVALREAR DOOR
(1) Open the rear door.
(2) Usi ng a tri m sti ck, pry the upper rear edge off
the door. Conti nue towards the front edge of the rear
door (Fi g. 2).
(3) Usi ng a heat gun, warm the adhesi ve tape on
the bottom of the cl addi ng and remove the cl addi ng.
REMOVALFENDER/QUARTER PANEL
(1) Remove the screws at wheel openi ng (Fi g. 3).
(2) Usi ng a tri m sti ck, gentl y pry bottom of cl ad-
di ng up.
(3) Li ft upwards and remove cl addi ng.
INSTALLATION
INSTALLATIONFRONT DOOR
(1) Cl ean the area thoroughl y wi th Mopar Super
Kl een, or equi val ent.
(2) Al i gn the body si de cl addi ng wi th the sl ots i n
the door. Press the adhesi ve pad to the door and snap
the retai ners i nto the sl ots.
INSTALLATIONREAR DOOR
(1) Cl ean the area thoroughl y wi th Mopar Super
(2) Al i gn the body si de cl addi ng wi th the sl ots i n
the door. Press the adhesi ve pad to the door and snap
the retai ners i nto the sl ots.
INSTALLATIONFENDER/QUARTER PANEL
(1) Thoroughl y cl ean the area wi th Mopar Super
Kl een or equi val ent.
(2) Al i gn the cl addi ng wi th the screw hol es i n the
fender.
(3) Press the cl addi ng i n pl ace.
(4) I nstal l the screws at the wheel openi ng.
Fig. 2 Rear Door Cladding
1 - CLADDING
Fig. 3 Front Fender/ Quarter Panel
1 - SCREW
2 - QUARTER PANEL CLADDING
3 - FRONT FENDER CLADDING
4 - SCREW
23 - 26 EXTERIOR WJ
BODY SIDE MOLDINGS (Continued)
COWL GRILLE
REMOVAL
(1) Remove wi per arms, refer to (Refer to 8 -
ELECTRI CAL/WI PERS/WASHERS/WI PER ARMS -
REMOVAL).
(2) Remove pl enum seal .
(3) Remove pl asti c push nuts attachi ng cowl cover
to cowl (Fi g. 4).
(4) Remove wi ndshi el d washer tubes at connector.
(5) Remove cowl cover from cowl .
INSTALLATION
(1) Posi ti on cowl cover on cowl .
(2) I nstal l wi ndshi el d washer tubes at connector.
(3) I nstal l pl asti c push nuts attachi ng cowl cover
to cowl (Fi g. 4).
(4) I nstal l pl enum seal .
(5) I nstal l wi ndshi el d wi per arms, refer to (Refer
to 8 - ELECTRI CAL/WI PERS/WASHERS/WI PER
ARMS - I NSTALLATI ON).
D-PILLAR APPLIQUE
REMOVAL
(1) Usi ng a tri m sti ck, careful l y pry appl i que from
panel (Fi g. 5).
INSTALLATION
(1) Posi ti on appl i que on panel wi th retai ners
al i gned.
(2) Press appl i que fi rml y i n pl ace.
D-PILLAR AIR EXHAUSTER
REMOVAL
(1) Remove D-pi l l ar appl i que, refer to (Refer to 23
- BODY/EXTERI OR/COWL GRI LLE SCREEN -
REMOVAL).
(2) Careful l y pry ai r exhauster from D-pi l l ar usi ng
a fl at bl ade screwdri ver (Fi g. 5).
INSTALLATION
(1) Reseal ai r exhauster usi ng foam tape.
(2) I nstal l ai r exhauster on D-pi l l ar.
(3) I nstal l D-pi l l ar appl i que, refer to (Refer to 23 -
BODY/EXTERI OR/COWL GRI LLE SCREEN -
I NSTALLATI ON).
AIR EXHAUSTER
REMOVAL
(1) Remove tai l l amp, refer to (Refer to 8 - ELEC-
LAMP - REMOVAL).
(2) Usi ng a tri m sti ck, pry the top of the ai r
exhauster downward to detach the retai ni ng cl i ps.
(3) Separate ai r exhauster from vehi cl e (Fi g. 5).
INSTALLATION
(1) Posi ti on ai r exhauster i n openi ng.
(2) Press ai r exhauster i nward to secure.
(3) I nstal l tai l l amp, refer to (Refer to 8 - ELEC-
LAMP - I NSTALLATI ON).
Fig. 4 Cowl Cover
1 - PLASTIC NUT
2 - COWL COVER
Fig. 5 D-Pillar Applique & Air Exhauster
1 - D-PILLAR EXHAUSTER
2 - D-PILLAR APPLIQUE
3 - CLIP
4 - TAIL LAMP EXHAUSTER
WJ EXTERIOR 23 - 27
EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
(1) Appl y a l ength of maski ng tape on the body,
paral l el to the top edge of the namepl ate to use as a
gui de, i f necessary.
(2) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun. Do not exceed 52C
(120F) when heati ng embl em.
(3) I nsert a pl asti c tri m sti ck or a hard wood
wedge behi nd the embl em to separate the adhesi ve
backi ng from the body.
(4) Cl ean adhesi ve resi due from body wi th MOPAR
Super Cl ean sol vent or equi val ent.
INSTALLATION
(1) Remove protecti ve cover from adhesi ve tape on
back of embl em.
(2) Posi ti on embl em properl y on body.
(3) Press embl em fi rml y to body wi th pal m of
hand.
(4) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun to assure adhesi on.
Do not exceed 52C (120F) when heati ng embl em.
FRONT FENDER
REMOVAL
(1) Usi ng a wax crayon or equi val ent, mark posi -
ti on of fender.
(2) Remove front fender l i ner.
(3) Pul l back fasci a and remove screws attachi ng
fender to fasci a.
(4) Remove screws attachi ng l ower fender bracket
l ocated behi nd fasci a.
(5) Remove screws attachi ng fender to rocker
panel (Fi g. 6).
(6) Remove screws attachi ng rear of fender to
A-pi l l ar brackets.
(7) Open hood.
Fig. 6 Fender Mounting
1 - BODY
2 - FENDER
23 - 28 EXTERIOR WJ
(8) Loosen screw under hood hi nge, attachi ng
fender to engi ne compartment rai l .
(9) Remove screws attachi ng fender to engi ne com-
partment rai l (Fi g. 7).
(10) Ri ght fender onl y:
(a) I f equi pped, remove radi o antenna.
(11) Separate fender from body.
INSTALLATION
(1) Posi ti on fender on body.
(2) Ri ght fender onl y:
(a) I f equi pped, i nstal l radi o antenna.
(3) I nstal l al l screws fi nger-ti ght.
(4) Al i gn fender wi th adjacent body panel s and
wax crayon reference marks.
(5) Ti ghten al l screws.
(6) I nstal l i nner fender l i ner.
FUEL FILL DOOR
REMOVAL
(1) Open the fuel fi l l er door.
(2) Remove the screws attachi ng the door to the
quarter panel (Fi g. 8).
(3) Remove the door from the panel .
INSTALLATION
(1) Posi ti on the fuel fi l l er door on the quarter
panel wi th the screw hol es al i gned.
(2) I nstal l the screws attachi ng the fuel fi l l er door
to the quarter panel .
GRILLE
REMOVAL
(1) Remove fasci a, refer to (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT FASCI A - REMOV-
AL).
(2) Di sengage retai ners attachi ng gri l l e i nsert to
gri l l e/fasci a.
(3) Separate gri l l e i nsert from gri l l e/fasci a (Fi g. 9).
INSTALLATION
(1) Posi ti on gri l l e i nsert i n gri l l e/fasci a (Fi g. 9).
(2) Engage retai ners attachi ng gri l l e i nsert to
gri l l e/fasci a.
Fig. 7 Upper Fender Mounting
1 - FENDER
2 - BODY
Fig. 8 Fuel Filler Door
1 - FUEL FILL DOOR
Fig. 9 Grille Insert
1 - GRILLE/FASCIA
2 - INSERT
WJ EXTERIOR 23 - 29
FRONT FENDER (Continued)
(3) I nstal l fasci a, refer to (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT FASCI A - I NSTAL-
LATI ON).
HEADLAMP MOUNTING
MODULE
REMOVAL
CAUTION: Take special care when handling the
HMM not to damage the upper mounting tabs. Step
#3 must be performed prior to removing HMM from
the vehicle to prevent damage to HMM.
(1) Remove fasci a, refer to (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT FASCI A - REMOV-
AL).
(2) Remove i nner fender l i ner.
(3) Reach i nto the wheel house openi ng and di sen-
gage the retai ner attachi ng the HMM to each si de of
the body.
(4) Remove bol ts attachi ng headl amp mounti ng
modul e to body (Fi g. 10).
(5) Di sconnect headl amp wi re harness connectors.
(6) Separate headl amp mounti ng modul e from
vehi cl e.
INSTALLATION
(1) Posi ti on headl amp mounti ng modul e at vehi cl e.
(2) Connect headl amp wi re harness connectors.
(3) Engage the retai ner attachi ng the HMM to
each si de of the body.
(4) I nstal l bol ts attachi ng headl amp mounti ng
modul e to body (Fi g. 10).
(5) I nstal l i nner fender l i ner.
(6) I nstal l front fasci a, refer to (Refer to 13 -
- I NSTALLATI ON).
LUGGAGE RACK
REMOVAL
NOTE: The skid strips are attached to the roof
panel with adhesive.
(1) Usi ng a tri m sti ck, or other sui tabl e devi ce, pry
support cover off.
(2) I f necessary, sl i de the crossbars to expose the
screws attachi ng the sl i de rai l s to the supports.
(3) Remove the screws retai ni ng the sl i de rai l s to
the supports.
Fig. 10 Headlamp Mounting Module
1 - CONNECTOR
2 - CONNECTOR
3 - MOUNTING BRACKET
4 - HEADLAMP MODULE
23 - 30 EXTERIOR WJ
GRILLE (Continued)
(4) Remove the screws attachi ng the supports to
the roof panel .
(5) Separate the supports from the roof panel .
NOTE: If a crossbar needs to be serviced, the for-
ward or rearward supports will have to be removed.
INSTALLATION
(1) Posi ti on the supports on the roof panel and
i nstal l the screw. Be sure that the gasket i s properl y
seated.
(2) Posi ti on the l uggage rack on the supports.
(3) I nstal l the screws attachi ng the si de rai l s to
the supports.
(4) Posi ti on the supports covers on the supports
and press i nto pl ace.
SIDE VIEW MIRROR GLASS
REMOVAL
(1) Wi th damaged mi rror sti l l on vehi cl e, posi ti on
mi rror gl ass down and centered.
(2) Posi ti on a wi de l everage devi ce between the
bottom edge of the gl ass and the mi rror shel l .
(3) Fi rml y appl y pressure i n an upward di recti on
unti l gl ass assembl y di sengages from adapter pl ate.
(4) Di sconnect the heater wi re termi nal , i f
equi pped, or the EC pl ug, i f equi pped.
INSTALLATION
(1) Connect the heater wi re termi nal or the EC
pl ug, i f equi pped.
(2) Posi ti on the repl acement gl ass i n the mi rror
shel l and al i gn the four snap tabs wi th the four cav-
i ti es i n the shel l .
(3) Appl y fi rm pressure i nward unti l the repl ace-
ment gl ass assembl y engages wi th the adapter pl ate.
Correct assembl y wi l l resul t i n a fi rm cl i ck. Gl ass
assembl y shoul d exhi bi t even gaps to the shel l when
compl ete.
(4) Pul l l i ghtl y on corners of gl ass assembl y to
ensure al l four snaps are engaged and there i s no
free pl ay.
SIDE VIEW MIRROR
REMOVAL
(2) Di sengage power mi rror harness connector, i f
equi pped.
(3) Remove mi rror fl ag seal .
(4) Remove nuts attachi ng mi rror to door (Fi g. 11).
(5) Separate mi rror from door.
INSTALLATION
(1) Posi ti on mi rror on door. Veri fy that gasket seal
i s properl y posi ti oned.
(2) I nstal l nuts attachi ng mi rror to door (Fi g. 11).
(3) I nstal l mi rror retai ni ng nuts.
(4) I nstal l mi rror fl ag seal .
(5) Engage power mi rror harness connector, i f
equi pped.
TI ON).
Fig. 11 Side View Mirror
1 - SIDEVIEW MIRROR
2 - MIRROR FLAG SEAL
3 - CONNECTOR
WJ EXTERIOR 23 - 31
LUGGAGE RACK (Continued)
ROCK RAIL
REMOVAL
(1) Remove the bol ts and remove the rock rai l .
(Fi g. 12)
INSTALLATION
NOTE: Shims may be used to adjust rock rail posi-
tioning, if required.
(1) Loosen the rear bracket sl i de bol ts. (Fi g. 13)
(2) I nstal l the rock rai l and i nstal l the bol ts.
(3) Ti ghten the front bol ts to 27 Nm (20 ft. l bs.).
(4) Sl i de the rear bracket to contact the mounti ng
surface and ti ghten the rear mounti ng bol ts to 27
Nm (20 ft. l bs.).
(5) Ti ghten the sl i de bol ts to 27 Nm (20 ft. l bs.).
(6) Loosen the end cap bol ts and sl i de the end caps
agai nst the body.
(7) Ti ghten the end cap bol ts.
Fig. 12 ROCK RAIL
1 - ROCK RAIL
2 - J-NUTS (3)
3 - J-NUTS (3)
4 - BOLTS (3)
5 - BOLTS (3)
Fig. 13 REAR ROCK RAIL BRACKET
1 - REAR BRACKET
2 - ROCK RAIL
3 - REAR BRACKET BOLTS (2)
4 - END CAP BOLTS (2 PER CAP)
5 - END CAP (2)
23 - 32 EXTERIOR WJ
HOOD
TABLE OF CONTENTS
page page
GAS PROP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
HOOD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
ADJUSTMENTS
HOOD ADJUSTMENT . . . . . . . . . . . . . . . . . . 34
INSULATION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
LATCH RELEASE CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
GAS PROP
REMOVAL
(1) Rai se and support hood.
(2) Usi ng a smal l fl at bl ade, pry the retai ner
attachi ng hood support prop to l ower bal l stud.
(3) Sl i de retai ner attachi ng hood support prop
upper bal l stud downward.
(4) Di sconnect hood support prop from l ower bal l
stud and rotate support prop upward and di sconnect
from upper bal l stud (Fi g. 1).
INSTALLATION
(1) Posi ti on hood support prop on upper bal l stud
(Fi g. 1).
(2) Sl i de retai ner upward to secure support prop to
upper bal l stud.
(3) Posi ti on support prop on l ower bal l stud and
press retai ner i nward to secure.
HINGE
REMOVAL
(1) Rai se and support hood.
(2) Usi ng a wax crayon or equi val ent, mark posi -
ti on of hi nge.
(3) Remove hood hi nge prop rod.
(4) Remove nuts attachi ng hi nge to hood (Fi g. 1).
(5) Remove bol ts attachi ng hi nge to body.
(6) Separate hi nge from vehi cl e.
INSTALLATION
(1) Posi ti on hi nge on vehi cl e and al i gn reference
marks.
(2) I nstal l bol ts attachi ng hi nge to body.
(3) I nstal l nuts attachi ng hi nge to hood.
(4) I nstal l hood hi nge prop rod.
HOOD
REMOVAL
(1) Rai se hood.
(2) I f equi pped, di sconnect underhood l amp har-
ness connector. (Connector i s l ocated under cowl
cover).
(3) Usi ng a wax crayon or equi val ent, mark l oca-
ti on of hood hi nges on hood for i nstal l ati on al i gn-
ment.
(4) Support hood i n the open posi ti on.
(5) Remove hood support prop rods.
Fig. 1 Hood Support Prop
1 - HOOD
2 - COVER
3 - HINGE
4 - PROP
WJ HOOD 23 - 33
(6) Remove bol ts attachi ng hi nges to hood.
(7) Wi th the ai d of a hel per, remove hood from
vehi cl e.
INSTALLATION
(1) Posi ti on hood on hi nges.
(2) I nstal l bol ts fi nger-ti ght.
(3) Al i gn hi nges wi th i nstal l ati on reference marks
and ti ghten bol ts.
(4) I nstal l hood support prop rods.
(5) Connect underhood l amp connector.
(6) I nspect hood for proper al i gnment and adjust
as necessary.
ADJ USTMENTS
HOOD ADJUSTMENT
The hood attachi ng hol es are enl arged to ai d front,
back and si de to si de adjustment.
(1) I f hood i s l ow i n rel ati on to cowl panel , i nsert
shi ms between hi nge and hood.
(2) Adjust hood bumper i n or out to adjust hood-
to-fender hei ght al i gnment.
(3) Adjust the hood l atch as necessary. Ti ghten the
nuts to 11Nm (8 ft. l bs.).
(4) Al i gn the l atch stri ker so that stri ker enters
the l atch squarel y and wi thout bi ndi ng.
INSULATION
REMOVAL
(1) Rai se the hood.
(2) Remove the i nsul ati on panel fasteners.
(3) Remove the hood i nsul ati on panel .
INSTALLATION
(1) Posi ti on the i nsul ati on panel on the undersi de
of the hood.
(2) I nstal l the i nsul ati on panel fasteners.
(3) Cl ose the hood.
LATCH
REMOVAL
(1) Remove nuts attachi ng l atch to radi ator cross-
member support (Fi g. 2).
(2) Di sconnect hood rel ease cabl e from l atch.
(3) Separate l atch from vehi cl e.
INSTALLATION
(1) Connect l atch rel ease cabl e to l atch.
(2) Posi ti on l atch on radi ator crossmember sup-
port.
(3) I nstal l nuts attachi ng l atch to radi ator cross-
member support. Ti ghten nuts to 11 Nm (8 ft. l bs.)
torque (Fi g. 2).
Fig. 2 Hood Latch
1 - HOOD RELEASE CABLE
2 - LATCH
3 - BUMPER
23 - 34 HOOD WJ
HOOD (Continued)
LATCH RELEASE CABLE
REMOVAL
(1) Di sconnect cabl e from hood l atch (Fi g. 3).
(2) Di sconnect cabl e from retai ni ng cl i ps on l eft
i nner fender panel .
(3) Remove l eft cowl si de tri m panel .
(4) Remove fasteners attachi ng cabl e bracket to
cowl si de panel (Fi g. 4).
(5) Route cabl e through dash panel and remove i t
from under i nstrument panel .
INSTALLATION
(1) Route cabl e through hol e i n dash panel i nto
(2) Pul l cabl e forward and seat grommet i n dash
panel .
(3) Posi ti on cabl e bracket on cowl si de panel and
i nstal l fasteners (Fi g. 4).
(4) I nstal l l eft cowl si de tri m panel .
(5) Route and i nstal l cabl e i n retai ni ng cl i ps on l eft
i nner fender panel .
(6) Connect cabl e to hood l atch (Fi g. 3).
Fig. 3 Hood Latch
1 - HOOD LATCH
Fig. 4 Hood Release Cable
1 - LOWER COWL
3 - RELEASE HANDLE
WJ HOOD 23 - 35
INSTRUMENT PANEL SYSTEM
TABLE OF CONTENTS
page page
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
CLUSTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
GLOVE BOX
STANDARD PROCEDURE - GLOVE BOX
ROLL DOWN . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
GLOVE BOX LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
GLOVE BOX LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTRUMENT PANEL END CAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTRUMENT PANEL STUCTURAL DUCT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTRUMENT PANEL TOP COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTRUMENT PANEL TOP PAD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTRUMENT PANEL C-CHANNEL COVER
BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTRUMENT PANEL CENTER BEZEL -
LOWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTRUMENT PANEL CENTER BEZEL - UPPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTRUMENT PANEL CENTER FLOOR
TUNNEL BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTRUMENT PANEL COURTESY LAMP
BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTRUMENT PANEL INTERMEDIATE
BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTRUMENT PANEL LOWER RIGHT CENTER
BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTRUMENT PANEL PLENUM BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTRUMENT PANEL STEERING COLUMN
BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTRUMENT PANEL STEERING COLUMN
SUPPORT BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTRUMENT PANEL TRIM BEZEL - DRIVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTRUMENT PANEL TRIM BEZEL -
PASSENGER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
POWER OUTLET DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
STEERING COLUMN OPENING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
23 - 36 INSTRUMENT PANEL SYSTEM WJ
REMOVAL
INJURY.
cabl e.
(2) Remove the tri m from the ri ght and l eft A-pi l -
l ars. (Refer to 23 - BODY/I NTERI OR/A-PI LLAR
TRI M - REMOVAL).
(4) Remove the four nuts that secure the i nstru-
ment panel to the studs on the dash panel near the
wi ndshi el d fence l i ne (Fi g. 1).
(5) Remove the scuff pl ates from the ri ght and l eft
front door si l l s. (Refer to 23 - BODY/I NTERI OR/
DOOR SI LL SCUFF PLATE - REMOVAL).
(6) Remove the tri m panel s from the ri ght and l eft
i nner cowl si des. (Refer to 23 - BODY/I NTERI OR/
COWL TRI M - REMOVAL).
(7) Remove the consol e from the fl oor panel trans-
mi ssi on tunnel . (Refer to 23 - BODY/I NTERI OR/
FLOOR CONSOLE - REMOVAL).
(8) Remove the fuse cover from the Juncti on Bl ock
(JB). (Refer to 8 - ELECTRI CAL/POWER DI STRI BU-
TI ON/FUSE COVER - REMOVAL).
(11) Remove the steeri ng col umn bracket from the
(Refer to 23 - BODY/I NSTRUMENT PANEL/I P
STEERI NG COLUMN BRACKET - REMOVAL).
Fig. 1 Instrument Panel to Dash Panel Mounting
1 - STUD (4)
2 - NUT (4)
4 - DASH PANEL
WJ INSTRUMENT PANEL SYSTEM 23 - 37
(12) Remove the screw that secures the l ower ti l t-
i ng steeri ng col umn shroud to the steeri ng col umn
mul ti -functi on swi tch mounti ng housi ng (Fi g. 2).
(13) Unsnap the two hal ves of the ti l ti ng steeri ng
col umn shroud from each other and remove both
hal ves from the steeri ng col umn.
connectors from the fol l owi ng steeri ng col umn compo-
nents (Fi g. 3):
the two l ower cl ockspri ng connector receptacl es
the l eft mul ti -functi on swi tch connector recepta-
cl e
the ri ght mul ti -functi on swi tch connector recep-
tacl e
the two i gni ti on swi tch connector receptacl es
the shi fter i nterl ock sol enoi d connector recepta-
cl e
i f the vehi cl e i s so equi pped, the Sentry Key
I mmobi l i zer Modul e (SKI M) connector receptacl e.
(15) Turn the i gni ti on swi tch to the On posi ti on,
then rel ease and remove the shi fter i nterl ock cabl e
connector from the i gni ti on l ock housi ng receptacl e.
(16) Turn the i gni ti on swi tch back to the Lock
posi ti on to prevent steeri ng wheel rotati on and the
l oss of cl ockspri ng centeri ng fol l owi ng steeri ng col -
umn removal .
(17) Remove the bol t that secures the coupl er to
the l ower steeri ng col umn shaft (Fi g. 4).
4 - SCREW
Fig. 3 Steering Column Connections
1 - LEFT MULTIFUNCTION SWITCH CONNECTOR
2 - LOWER CLOCKSPRING CONNECTORS
3 - RIGHT MULTIFUNCTION SWITCH CONNECTOR
4 - SHIFTER INTERLOCK CABLE CONNECTOR
5 - SHIFTER INTERLOCK SOLENOID CONNECTOR
6 - IGNITION SWITCH CONNECTOR RECEPTACLES
7 - SKIM CONNECTOR
Fig. 4 Steering Column Mounting
1 - COLUMN MOUNTING NUTS
2 - COUPLER BOLT
INSTRUMENT PANEL SYSTEM (Continued)
(18) Remove the four nuts that secure the steeri ng
col umn to the studs on the i nstrument panel steeri ng
col umn support bracket.
(19) Remove the steeri ng col umn from the i nstru-
ment panel . Be certai n that the steeri ng wheel i s
l ocked and secured from rotati on to prevent the l oss
of cl ockspri ng centeri ng.
(20) Di sconnect the l eft and ri ght body wi re har-
ness connectors, the I gni ti on Off Draw (I OD) wi re
harness connector and the fused B(+) wi re harness
connector from the connector receptacl es of the JB
(Fi g. 5).
connectors from the fol l owi ng fl oor panel transmi s-
si on tunnel components (Fi g. 6):
the Ai rbag Control Modul e (ACM) connector
receptacl e
the park brake swi tch termi nal
the transmi ssi on shi fter connector receptacl e.
(22) Remove the two nuts that secure the i nstru-
ment panel wi re harness ground eyel ets to the studs
on the fl oor panel transmi ssi on tunnel i n front of and
behi nd the ACM.
(23) Di sengage the retai ners that secure the
i nstrument panel wi re harness to the fl oor panel
(24) Remove the i nstrument panel to center fl oor
tunnel bracket from the i nstrument panel and the
I NSTRUMENT PANEL/I P CENTER FLOOR TUN-
NEL BRACKET - REMOVAL).
(25) Remove the one screw that secures the fl oor
duct to the heater and ai r condi ti oner housi ng near
the dri ver si de of the fl oor panel transmi ssi on tunnel
and remove the duct from the housi ng.
(26) I f the vehi cl e i s equi pped wi th the manual
heati ng and ai r condi ti oni ng system, di sconnect the
vacuum harness connector l ocated near the dri ver
si de of the fl oor panel transmi ssi on tunnel behi nd
the dri ver si de fl oor duct.
(27) Remove the one screw that secures the i nstru-
ment panel steeri ng col umn support bracket to the
dri ver si de end of the heater and ai r condi ti oner
housi ng (Fi g. 7).
(28) Remove the one screw that secures the i nstru-
ment panel steeri ng col umn support bracket to the
i ntermedi ate bracket on the dri ver si de dash panel
(Fi g. 8).
1 - SNAP CLIPS
2 - SCREW
3 - CONNECTOR
5 - IOD CONNECTOR
8 - SCREW
9 - CONNECTOR
10 - JUNCTION BLOCK
Fig. 6 Floor Panel Transmission Tunnel
1 - AIRBAG CONTROL MODULE CONNECTOR
2 - PARK BRAKE SWITCH CONNECTOR
4 - NUT (2)
5 - STUD
6 - GROUND EYELET
7 - RETAINER
8 - STUD
9 - GROUND EYELET
11 - TRANSMISSION SHIFTER CONNECTOR
Fig. 7 Instrument Panel to Heater-A/C Housing -
Driver Side
1 - HEATER AND AIR CONDITIONER HOUSING
2 - FLOOR DUCT
3 - INSTRUMENT PANEL STEERING COLUMN SUPPORT
BRACKET
4 - SCREW
Fig. 8 Instrument Panel to Intermediate Bracket
Mounting
1 - DASH PANEL
2 - SCREW
BRACKET
4 - INTERMEDIATE BRACKET
(29) Remove the nut that secures the i nstrument
panel steeri ng col umn support bracket to the stud on
the dri ver si de cowl pl enum panel (Fi g. 9).
(30) Remove the two screws that secure the i nstru-
ment panel to the dri ver si de cowl si de i nner panel
(Fi g. 10).
(31) Remove the end cap from the i nstrument
I NSTRUMENT PANEL END CAP - REMOVAL).
MENT PANEL/I P LOWER RI GHT CENTER BEZEL
- REMOVAL).
connector from the l ower cavi ty of the i nl i ne connec-
tor on the passenger si de cowl si de i nner panel (Fi g.
11).
(34) Di sconnect the two hal ves of the radi o
antenna coaxi al cabl e connector near the ri ght cowl
si de i nner panel under the end of the i nstrument
panel .
Fig. 9 Instrument Panel to Cowl Plenum Mounting
1 - COWL PLENUM PANEL
2 - JUNCTION BLOCK
BRACKET
4 - NUT
5 - STUD
Fig. 10 Instrument Panel to Driver Side Cowl Side
Inner Panel Mounting
2 - SCREW (2)
3 - COWL SIDE PANEL
Fig. 11 Instrument Panel Passenger Side
Connection
1 - INLINE CONNECTOR
(35) Di sconnect the two i nstrument panel wi re
harness connectors from the two heater and ai r con-
di ti oner housi ng connectors l ocated near the bl ower
motor on the passenger si de end of the housi ng (Fi g.
12).
(36) Remove the two screws that secure the pas-
senger si de i nstrument panel structural duct to the
heater and ai r condi ti oner housi ng (Fi g. 13).
(37) Remove the two screws that secure the i nstru-
ment panel to the passenger si de cowl si de i nner
panel (Fi g. 14).
(38) Wi th the ai d of an assi stant, l i ft the i nstru-
ment panel assembl y upward off of the studs on the
dash panel near the wi ndshi el d fence l i ne and to di s-
engage the mol ded pl asti c hook formati ons on the
i nstrument panel structural duct from the gui de
hol es at each cowl si de i nner panel .
(39) Pul l the i nstrument panel rearward from the
dash panel and the cowl si de i nner panel s and remove i t
through the dri ver si de front door of the vehi cl e.
Fig. 12 Heater and Air Conditioner Housing
Connections
2 - HVAC HOUSING
4 - BLOWER MOTOR
Fig. 13 Passenger Side Instrument Panel to
Heater-A/C Housing Mounting
3 - SCREW (2)
Fig. 14 Instrument Panel to Passenger Side Cowl
Side Inner Panel Mounting
1 - COWL SIDE INNER PANEL
3 - SCREW (2)
INSTALLATION
INJURY.
(1) Pri or to i nstal l i ng the i nstrument panel i nto
the vehi cl e, l oosen the three nuts that secure the
i nstrument panel i ntermedi ate bracket and the accel -
erator pedal assembl y to the studs on the dash panel
(Fi g. 8).
(2) Wi th the ai d of an assi stant, l oad the i nstru-
ment panel assembl y through the dri ver si de front
door of the vehi cl e and hang i t on the studs on the
dash panel near the wi ndshi el d fence l i ne (Fi g. 1).
(3) Be certai n that the mol ded pl asti c hook forma-
ti ons on the i nstrument panel structural duct are
i nserted i nto and seated i n the gui de hol es at each
cowl si de i nner panel .
(4) Loosel y i nstal l the two screws that secure each
end of the i nstrument panel to the cowl si de i nner
panel s.
the passenger si de i nstrument panel structural duct
to the heater and ai r condi ti oner housi ng (Fi g. 13).
bracket to the dri ver si de end of the heater and ai r
condi ti oner housi ng (Fi g. 7). Ti ghten the screw to
11.8 Nm (105 i n. l bs.).
(7) Ti ghten the two screws that secure each end of
the i nstrument panel to the cowl si de i nner panel s
(Fi g. 10) and (Fi g. 14). Ti ghten the screws to 11.8
Nm (105 i n. l bs.).
bracket to the i ntermedi ate bracket on the dri ver
si de dash panel (Fi g. 8). Ti ghten the screw to 11.3
Nm (100 i n. l bs.).
(9) Ti ghten the three nuts that secure the i nstru-
ment panel i ntermedi ate bracket and the accel erator
pedal assembl y to the studs on the dash panel .
(10) I nstal l and ti ghten the four nuts that secure
the i nstrument panel to the studs on the dash panel
near the wi ndshi el d fence l i ne. Ti ghten the nuts to
11.8 Nm (105 i n. l bs.).
i nstrument panel steeri ng col umn support bracket to
the stud on the dri ver si de cowl pl enum panel (Fi g.
9). Ti ghten the nut to 28.2 Nm (250 i n. l bs.).
(12) Rei nstal l the i nstrument panel to center fl oor
tunnel bracket onto the i nstrument panel and the
I NSTRUMENT PANEL/I P CENTER FLOOR TUN-
NEL BRACKET - I NSTALLATI ON).
(13) Reconnect the two i nstrument panel wi re har-
ness connectors to the two heater and ai r condi ti oner
housi ng connectors l ocated near the bl ower motor on
the passenger si de end of the housi ng (Fi g. 12).
(14) Reconnect the two hal ves of the radi o antenna
coaxi al cabl e connector near the ri ght cowl si de i nner
panel under the end of the i nstrument panel .
connector to the l ower cavi ty of the i nl i ne connector
on the passenger si de cowl si de i nner panel and
ti ghten the connector screw (Fi g. 11). Ti ghten the
screw to 4 Nm (36 i n. l bs.).
(16) Rei nstal l the l ower ri ght center bezel onto the
- I NSTALLATI ON).
(17) Rei nstal l the end cap onto the i nstrument
I NSTRUMENT PANEL END CAP - I NSTALLA-
TI ON).
(18) I f the vehi cl e i s equi pped wi th the manual
heati ng and ai r condi ti oni ng system, reconnect the
vacuum harness connector l ocated near the dri ver
si de of the fl oor panel transmi ssi on tunnel behi nd
the dri ver si de fl oor duct.
(19) Posi ti on the dri ver si de fl oor duct to the
heater and ai r condi ti oner housi ng near the dri ver
si de of the fl oor panel transmi ssi on tunnel (Fi g. 7).
the dri ver si de fl oor duct to the heater and ai r con-
di ti oner housi ng near the dri ver si de of the fl oor
panel transmi ssi on tunnel . Ti ghten the screw to 2.2
Nm (20 i n. l bs.).
(21) Route the i nstrument panel wi re harness to
the fl oor panel transmi ssi on tunnel and engage the
retai ners that secure the harness to the mounti ng
brackets on the tunnel (Fi g. 6).
(22) I nstal l the i nstrument panel wi re harness
ground eyel ets to the studs on the fl oor panel trans-
mi ssi on tunnel i n front of and behi nd the ai rbag con-
trol modul e and secure the eyel ets wi th nuts. Ti ghten
the nuts to 7.3 Nm (65 i n. l bs.).
connectors to the fol l owi ng fl oor panel transmi ssi on
tunnel components:
the Ai rbag Control Modul e (ACM) connector
receptacl e
the park brake swi tch termi nal
the transmi ssi on shi fter connector receptacl e.
(24) Reconnect the l eft and ri ght body wi re har-
ness connectors, the I gni ti on Off Draw (I OD) wi re
harness connector and the fused B(+) wi re harness
connector to the connector receptacl es of the Juncti on
Bl ock (JB) and ti ghten the connector screws (Fi g. 5).
(25) Engage the l ower steeri ng col umn shaft wi th
the steeri ng shaft coupl er and posi ti on the steeri ng
col umn to the mounti ng studs on the i nstrument
panel steeri ng col umn support bracket (Fi g. 4).
the steeri ng col umn to the studs on the i nstrument
panel steeri ng col umn support bracket. Ti ghten the
nuts to 11.8 Nm (105 i n. l bs.).
(27) I nstal l and ti ghten the bol t that secures the
coupl er to the l ower steeri ng col umn shaft. Ti ghten
the bol t to 49 Nm (36 ft. l bs.).
(28) Turn the i gni ti on swi tch to the On posi ti on,
then i nstal l the shi fter i nterl ock cabl e connector i nto
the i gni ti on l ock housi ng receptacl e.
connectors to the fol l owi ng steeri ng col umn compo-
nents (Fi g. 3):
the two l ower cl ockspri ng connector receptacl es
the l eft mul ti -functi on swi tch connector recepta-
cl e
the ri ght mul ti -functi on swi tch connector recep-
tacl e
the two i gni ti on swi tch connector receptacl es
the shi fter i nterl ock sol enoi d connector recepta-
cl e
i f the vehi cl e i s so equi pped, the Sentry Key
I mmobi l i zer Modul e (SKI M) connector receptacl e.
shroud to the steeri ng col umn mul ti -functi on swi tch
mounti ng housi ng, then i nstal l and ti ghten the screw
that secures the shroud to the housi ng (Fi g. 2).
(31) Posi ti on the upper ti l ti ng steeri ng col umn
shroud over the steeri ng col umn. Al i gn the upper and
l ower shrouds wi th each other and snap the two
hal ves together.
(32) Rei nstal l the steeri ng col umn bracket onto the
(Refer to 23 - BODY/I NSTRUMENT PANEL/I P
STEERI NG COLUMN BRACKET - I NSTALLA-
TI ON).
(34) Rei nstal l the cl uster bezel onto the i nstru-
PANEL/CLUSTER BEZEL - I NSTALLATI ON).
(35) Rei nstal l the fuse cover onto the Juncti on
Bl ock (JB). (Refer to 8 - ELECTRI CAL/POWER DI S-
TRI BUTI ON/FUSE COVER - I NSTALLATI ON).
(36) Rei nstal l the consol e onto the fl oor panel
transmi ssi on tunnel . (Refer to 23 - BODY/I NTERI -
OR/FLOOR CONSOLE - I NSTALLATI ON).
(37) Rei nstal l the tri m panel s onto the ri ght and
l eft i nner cowl si des. (Refer to 23 - BODY/I NTERI -
OR/COWL TRI M - I NSTALLATI ON).
(38) Rei nstal l the scuff pl ates onto the ri ght and
l eft front door si l l s. (Refer to 23 - BODY/I NTERI OR/
DOOR SI LL SCUFF PLATE - I NSTALLATI ON).
(39) Rei nstal l the top cover onto the i nstrument
I NSTRUMENT PANEL TOP COVER - I NSTALLA-
TI ON).
(40) Rei nstal l the tri m onto the ri ght and l eft
A-pi l l ars. (Refer to 23 - BODY/I NTERI OR/A-PI LLAR
CLUSTER BEZEL
REMOVAL
INJURY.
cabl e.
(2) Pl ace the ti l t steeri ng wheel i n i ts ful l y l owered
posi ti on.
fl at-bl aded tool , gentl y pry each of the four corners of
the cl uster bezel away from the i nstrument panel far
enough to di sengage the four snap cl i ps from thei r
receptacl es (Fi g. 15).
(4) Bei ng certai n not to scratch the i nstrument
cl uster l ens wi th the two snap cl i ps on the l ower
edge of the cl uster bezel , rol l the top of the cl uster
bezel rearward over the top of the steeri ng col umn.
(5) I f the vehi cl e i s so equi pped, reach behi nd the
cl uster bezel to access and di sconnect the i nstrument
panel wi re harness connector for the headl amp l evel -
i ng swi tch from the swi tch connector receptacl e.
panel .
INSTALLATION
INJURY.
(1) Posi ti on the cl uster bezel onto the i nstrument
panel (Fi g. 15).
(2) I f the vehi cl e i s so equi pped, reach behi nd the
cl uster bezel to access and reconnect the i nstrument
panel wi re harness connector for the headl amp l evel -
i ng swi tch to the swi tch connector receptacl e.
(3) Bei ng certai n not to scratch the i nstrument
cl uster l ens wi th the two snap cl i ps on the l ower
edge of the cl uster bezel , sl i de the l ower edge of the
cl uster bezel forward and down over the top of the
steeri ng col umn to posi ti on i t onto the i nstrument
panel .
(4) Al i gn the two snap cl i ps on the l ower edge of
the cl uster bezel wi th thei r receptacl es i n the i nstru-
ment panel .
(5) Press fi rml y on the cl uster bezel over each of
the l ower snap cl i p l ocati ons unti l each of the snap
cl i ps i s ful l y engaged i n i ts receptacl e.
(6) Al i gn the two receptacl es on the upper edge of
the cl uster bezel wi th the snap cl i ps on the i nstru-
ment panel .
(7) Press fi rml y on the cl uster bezel over each of
the upper snap cl i p l ocati ons unti l each of the snap
cl i ps i s ful l y engaged i n i ts receptacl e.
Fig. 15 Cluster Bezel Remove/Install
2 - INSTRUMENT PANEL CLUSTER BEZEL
GLOVE BOX
STANDARD PROCEDURE - GLOVE BOX ROLL
DOWN
INJURY.
cabl e.
(2) Open the gl ove box unti l the i ntegral stops on
the back edge of the gl ove box bi n are resti ng agai nst
the rubber stop bumpers i n the upper gl ove box open-
i ng rei nforcement.
(3) Usi ng hand pressure, l i ft upward on the arm of
the pneumati c gl ove box door damper on the out-
board si de of the gl ove box bi n to unsnap the damper
connector feature from the keyed sl ot i n the bi n (Fi g.
16).
(4) Reach i nto the gl ove box and wi th the mi ddl e
fi nger of each hand, defl ect the rubber fl ap of the two
gl ove box stop bumpers on the upper gl ove box open-
i ng rei nforcement toward the front of the vehi cl e.
(5) Wi th the gl ove box stop bumpers defl ected, rol l
the gl ove box door downward unti l the i ntegral stops
on the back edge of the gl ove box bi n pass through
the rubber stop bumper openi ngs i n the upper gl ove
box openi ng rei nforcement (Fi g. 17)
(6) Before rol l i ng the gl ove box back up i nto the
i nstrument panel , grasp the pneumati c gl ove box
damper arm and pul l the connector feature rearward
to the end of i ts travel . The rubber stop bumpers wi l l
be defl ected automati cal l y by the i ntegral stops on
the back of the gl ove box when the gl ove box i s rol l ed
back up i nto the i nstrument panel .
(7) Wi th the gl ove box stops ori ented behi nd the
stop bumpers, posi ti on the connector feature of the
damper to the keyed sl ot on the outboard end of the
gl ove box bi n.
(8) Usi ng hand pressure, press downward on the
damper arm unti l the damper connector feature
snaps back i nto the keyed sl ot.
Fig. 16 Glove Box Damper
1 - BIN
2 - DAMPER
3 - CONNECTOR
4 - GLOVE BOX DOOR
Fig. 17 Glove Box Roll Down
1 - GLOVE BOX DOOR
REMOVAL
INJURY.
cabl e.
(2) Rol l the gl ove box down from the i nstrument
GLOVE BOX - STANDARD PROCEDURE - GLOVE
BOX ROLL DOWN).
NOTE: Be certain to use care not to damage or
remove the glove box hinge bumpers on the lower
instrument panel glove box opening reinforcement
when removing the glove box from the instrument
panel.
(3) Fi rml y gri p both ends of the gl ove box door,
then twi st and pul l the door as necessary to di sen-
gage the i nboard hi nge hook from the i nboard hi nge
pi n on the i nstrument panel and reori ent the hook to
the undersi de of the hi nge pi n (Fi g. 18).
(4) Rai se the gl ove box door unti l i t i s perpendi cu-
l ar to the i nstrument panel .
(5) Twi st the door sl i ghtl y i n the countercl ockwi se
di recti on and use a ji ggl i ng acti on to di sengage the
remai ni ng two hi nge hooks from thei r respecti ve
hi nge pi ns on the i nstrument panel .
(6) Remove the gl ove box from the i nstrument
panel .
INSTALLATION
INJURY.
NOTE: Be certain to use care not to damage or
remove the glove box hinge bumpers on the lower
instrument panel glove box opening reinforcement
when installing the glove box onto the instrument
panel.
(1) Posi ti on the gl ove box to the i nstrument panel
wi th the outboard hi nge hook ori ented over the out-
board hi nge pi n and the center hi nge hook ori ented
under the center hi nge pi n (Fi g. 18).
(2) Rai se the gl ove box door unti l i t i s perpendi cu-
l ar to the i nstrument panel .
(3) Fi rml y gri p both ends of the gl ove box door and
twi st the door sl i ghtl y i n the cl ockwi se di recti on to
engage the i nboard gl ove box hi nge hook over the
i nboard hi nge pi n on the i nstrument panel .
BOX ROLL DOWN).
Fig. 18 Glove Box Remove/Install
1 - GLOVE BOX HINGE HOOKS AND HINGE PINS (3)
GLOVE BOX (Continued)
GLOVE BOX LATCH
REMOVAL
INJURY.
cabl e.
(2) Rol l down the gl ove box from the i nstrument
BOX ROLL DOWN).
(3) Remove the three screws that secure the gl ove
box l atch to the i nner gl ove box door (Fi g. 19).
(4) Li ft up on the l atch handl e on the outer gl ove
box door far enough to l oosen the l atch assembl y on
the i nner gl ove box door.
(5) Remove the l atch uni t from the i nner gl ove box
door.
INSTALLATION
INJURY.
(1) Posi ti on the l atch uni t to the i nner gl ove box
door (Fi g. 19).
(2) Gui de the l atch handl e i nto the l atch handl e
pocket on the outer gl ove box door.
the gl ove box l atch to the i nner gl ove box door.
BOX ROLL DOWN).
Fig. 19 Glove Box Latch Remove/Install
1 - SCREW (3)
2 - LATCH HANDLE
3 - LATCH HANDLE POCKET
4 - BIN
5 - HINGE HOOKS
6 - DOOR
7 - GLOVE BOX LATCH
8 - STOPS
GLOVE BOX LATCH STRIKER
REMOVAL
INJURY.
cabl e.
(2) I f the i nboard gl ove box l atch stri ker i s bei ng
servi ced, remove the l ower ri ght center bezel from
the i nstrument panel . (Refer to 23 - BODY/I NSTRU-
- REMOVAL). I f the outboard gl ove box l atch stri ker
i s bei ng servi ced, remove the end cap from the
MENT PANEL/I NSTRUMENT PANEL END CAP -
REMOVAL).
(3) Remove the one screw that secures the upper
mounti ng fl ange of the gl ove box l atch stri ker to the
i nstrument panel structural duct at ei ther si de of the
gl ove box openi ng (Fi g. 20).
(4) Pul l the upper mounti ng fl ange of the gl ove box
l atch stri ker downward to di sengage the hook forma-
ti on on the l ower end of the stri ker from the mount-
i ng hol e i n the i nstrument panel structural duct.
(5) Remove the gl ove box l atch stri ker from the
i nstrument panel .
INSTALLATION
INJURY.
(1) Posi ti on the gl ove box l atch stri ker to the
i nstrument panel .
(2) Engage the hook formati on on the l ower end of
the gl ove box l atch stri ker i n the mounti ng hol e i n
the i nstrument panel structural duct.
(3) Rol l the upper mounti ng fl ange of the gl ove box
l atch stri ker upward unti l i t i s fl ush wi th the i nstru-
ment panel structural duct on ei ther si de of the gl ove
box openi ng.
upper mounti ng fl ange of the gl ove box l atch stri ker
to the i nstrument panel structural duct (Fi g. 20).
(5) I f the i nboard gl ove box l atch stri ker was ser-
vi ced, rei nstal l the l ower ri ght center bezel onto the
- I NSTALLATI ON). I f the outboard gl ove box l atch
stri ker was servi ced, rei nstal l the end cap onto the
MENT PANEL/I NSTRUMENT PANEL END CAP -
I NSTALLATI ON).
Fig. 20 Glove Box Latch Striker Remove/Install
1 - SCREW
2 - GLOVE BOX LATCH STRIKER
INSTRUMENT PANEL END CAP
REMOVAL
INJURY.
cabl e.
(2) Unl atch and open the gl ove box.
board end of the end cap to the i nstrument panel top
pad (Fi g. 21).
(4) Remove the three screws that secure the end
cap to the i nstrument panel gl ove box openi ng.
(5) Pul l the end cap strai ght back from the i nstru-
ment panel to di sengage the one snap cl i p that
secures i t to the receptacl e i n the i nstrument panel
structural duct.
(6) Remove the end cap from the i nstrument
panel .
INSTALLATION
INJURY.
(1) Be certai n that the gl ove box catch bumper i s
i nstal l ed i n the mounti ng hol e nearest the outboard
end of the end cap extensi on over the i nstrument
panel upper gl ove box openi ng rei nforcement (Fi g.
21).
(2) Posi ti on the end cap to the i nstrument panel .
Be certai n that the end of the end cap extensi on near
the center of the upper gl ove box openi ng rei nforce-
ment i s posi ti oned underneath the end of the exten-
si on from the l ower ri ght center bezel .
(3) Al i gn the snap cl i p on the end cap wi th the
receptacl e on the i nstrument panel structural duct.
(4) Press fi rml y on the i nstrument panel end cap
over the snap cl i p l ocati on unti l the snap cl i p i s ful l y
engaged i n i ts receptacl e.
the end cap to the i nstrument panel gl ove box open-
i ng. Ti ghten the screws to 2.2 Nm (20 i n. l bs.).
the outboard end of the end cap to the i nstrument
panel top pad. Ti ghten the screw to 2.2 Nm (20 i n.
l bs.).
(7) Cl ose and l atch the gl ove box.
Fig. 21 Instrument Panel End Cap Remove/Install
2 - END CAP
3 - SCREW (4)
4 - BUMPER
5 - LOWER RIGHT CENTER BEZEL
INSTRUMENT PANEL
STUCTURAL DUCT
REMOVAL
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN, OR
SERVICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN-
UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
(2) Remove the i nstrument panel from the vehi cl e.
(Refer to 23 - BODY/I NSTRUMENT PANEL -
REMOVAL).
(3) Pl ace the i nstrument panel on a sui tabl e work
surface. Be certai n to take the proper precauti ons to
protect the i nstrument panel from any possi bl e cos-
meti c damage.
(4) Remove al l of the i ndi vi dual components that
remai n secured to the i nstrument panel structural duct
as descri bed el sewhere i n thi s servi ce i nformati on.
INSTALLATION
INJURY.
(1) Rei nstal l al l of the i ndi vi dual components that
were removed from the i nstrument panel structural
duct as descri bed el sewhere i n thi s servi ce i nforma-
ti on.
(2) Rei nstal l the i nstrument panel i nto the vehi cl e.
I NSTALLATI ON).
INSTRUMENT PANEL TOP
COVER
REMOVAL
INJURY.
cabl e.
fl at-bl aded tool , gentl y pry the rear edge (farthest
from the wi ndshi el d) of the top cover up and away
from the i nstrument panel far enough to di sengage
the four snap cl i p retai ners from thei r receptacl es i n
the i nstrument panel top pad (Fi g. 22).
(3) Remove the top cover from the top of the
i nstrument panel .
Fig. 22 Instrument Panel Top Cover Remove/Install
1 - ULTRA LIGHT SENSOR PLUG
2 - SEAL
3 - INSTRUMENT PANEL TOP COVER
INSTALLATION
INJURY.
(1) I f the vehi cl e i s not equi pped wi th the opti onal
automati c headl amps l i ght sensor/vehi cl e theft secu-
ri ty system i ndi cator, be certai n that the hol e pl ug i s
i nstal l ed i n the cl earance hol e l ocated to the out-
board si de of the dri ver si de defroster outl et i n the
i nstrument panel top cover (Fi g. 22).
(2) Before i nstal l i ng the top cover onto the top of
the i nstrument panel , be certai n that the rubber top
cover seal i s properl y posi ti oned on the forward edge
of the top cover panel .
(3) Posi ti on the top cover onto the top of the
i nstrument panel .
(4) Al i gn the four snap cl i ps on the top cover wi th
the snap cl i p receptacl es i n the i nstrument panel top
pad.
(5) Press fi rml y downward on the top cover over
each of the four snap cl i p l ocati ons unti l each of the
snap cl i ps i s ful l y seated i n thei r receptacl es i n the
i nstrument panel top pad.
INSTRUMENT PANEL TOP PAD
REMOVAL
INJURY.
cabl e.
(2) Remove the tri m from the ri ght and l eft A-pi l -
l ars. (Refer to 23 - BODY/I NTERI OR/A-PI LLAR
TRI M - REMOVAL).
(4) Remove the four nuts that secure the i nstru-
ment panel top pad to the studs on the dash panel
near the wi ndshi el d fence l i ne (Fi g. 23).
(5) Remove the speakers from the i nstrument
panel top pad. (Refer to 8 - ELECTRI CAL/AUDI O/
SPEAKER - REMOVAL - I NSTRUMENT PANEL
SPEAKER).
(6) Di sengage the retai ner that secures each of the
two i nstrument panel wi re harness speaker take outs
to the mounti ng hol e i n the i nstrument panel top
pad. Tuck the l oose ends of these speaker take outs
down the defroster ducts to keep them out of the way
duri ng the remai nder of thi s procedure.
(7) I f the vehi cl e i s so equi pped, remove the two
screws that secure the automati c headl amp l i ght sen-
sor/vehi cl e theft securi ty system i ndi cator uni t to the
i nstrument panel top pad just outboard of the dri ver
si de defroster outl et. Move the sensor/i ndi cator uni t
towards the wi ndshi el d to keep i t out of the way dur-
i ng the remai nder of thi s procedure.
(11) Rol l the gl ove box down from the i nstrument
BOX ROLL DOWN).
(12) Remove the end cap from the passenger si de
l ower outboard end of the i nstrument panel . (Refer to
23 - BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL END CAP - REMOVAL).
- REMOVAL).
(14) Remove the gl ove box l amp and swi tch from
LAMPS/LI GHTI NG - I NTERI OR/GLOVE BOX
LAMP/SWI TCH - REMOVAL).
INSTRUMENT PANEL TOP COVER (Continued)
(15) Remove the two l arge screws on the gl ove box
openi ng upper rei nforcement that secure the top pad
to the i nstrument panel structural duct (Fi g. 24).
(16) Remove the two smal l screws on the gl ove box
openi ng upper rei nforcement that secure the panel
outl ets to the i nstrument panel structural duct.
(17) Remove the center upper bezel from the
MENT PANEL/I P CENTER BEZEL - UPPER -
REMOVAL).
(18) Remove the center l ower bezel from the
MENT PANEL/I P CENTER BEZEL - LOWER -
REMOVAL).
(19) Remove the four screws that secure the radi o
to the i nstrument panel structural duct. Pul l the
radi o out of the i nstrument panel onl y far enough to
access the screws that secure the top pad to the
(20) Remove the four screws that secure the heat-
er-A/C control to the i nstrument panel structural
duct. Pul l the heater-A/C control out of the i nstru-
ment panel onl y far enough to access the screws that
secure the top pad to the i nstrument panel structural
duct.
(21) Remove al l of the screws that secure the
peri meter of the top pad to the i nstrument panel
structural duct.
Fig. 23 Instrument Panel Top Pad to Dash Panel Mounting
1 - STUD (4)
2 - NUT (4)
4 - DASH PANEL
Fig. 24 Instrument Panel Top Pad to Glove Box
Opening Mounting
1 - PASSENGER SIDE TRIM BEZEL
2 - PANEL OUTLETS
3 - SMALL SCREWS
4 - LARGE SCREWS
5 - GLOVE BOX OPENING UPPER REINFORCEMENT
INSTRUMENT PANEL TOP PAD (Continued)
(22) Remove the front bi n from the fl oor consol e.
REMOVAL).
(23) Reach through the front bi n openi ng of the
fl oor consol e to access and remove the two screws
that secure the center fl oor tunnel bracket to the
i nstrument panel .
fl oor consol e to access and l oosen the two nuts that
secure the center fl oor tunnel bracket to the studs on
the fl oor panel transmi ssi on tunnel .
(25) Sl i de the center fl oor tunnel bracket rearward
i n the vehi cl e far enough to di sengage the l ocati ng
hol e i n the l ower fl ange of the top pad from the l ocat-
i ng pi n on the i nstrument panel structural duct (Fi g.
25).
(26) Remove the i nstrument panel top pad from
INSTALLATION
INJURY.
I f the top pad i s bei ng repl aced wi th a new uni t, be
certai n to transfer or i nstal l the panel outl ets and
the passenger si de tri m bezel to the new uni t before
i t i s i nstal l ed on the i nstrument panel structural
duct. (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/DI STRI BUTI ON/AI R OUTLETS - REMOVAL)
and (Refer to 23 - BODY/I NSTRUMENT PANEL/I P
TRI M BEZEL - PASSENGER - REMOVAL).
(1) Posi ti on the i nstrument panel top pad over the
i nstrument panel structural duct and the studs on
the dash panel near the wi ndshi el d fence l i ne.
(2) Route the i nstrument panel wi re harness take
out for the gl ove box l amp and swi tch uni t to the
swi tch mounti ng hol e i n the upper gl ove box openi ng
rei nforcement.
fl oor consol e to engage the l ocati ng hol e i n the l ower
fl ange of the top pad wi th the l ocati ng pi n on the
fl oor consol e to sl i de the center fl oor tunnel bracket
forward i n the vehi cl e far enough to capture the
l ower fl ange of the top pad between the bracket and
the structural duct.
fl oor consol e to i nstal l and ti ghten the two screws
that secure the center fl oor tunnel bracket to the
i nstrument panel . Ti ghten the screws to 11.8 Nm
(105 i n. l bs.).
Fig. 25 Instrument Panel Top Pad Remove/Install
1 - STRUCTURAL DUCT
2 - LOCATING PIN
4 - LOWER FLANGE
5 - CENTER FLOOR TUNNEL BRACKET
fl oor consol e to access and ti ghten the two nuts that
secure the center fl oor tunnel bracket to the studs on
the fl oor panel transmi ssi on tunnel . Ti ghten the nuts
to 11.8 Nm (105 i n. l bs.).
(7) Rei nstal l the front bi n i nto the fl oor consol e.
I NSTALLATI ON).
(8) I nstal l and ti ghten al l of the screws that secure
the peri meter of the top pad to the i nstrument panel
structural duct. Ti ghten the screws to 2.2 Nm (20 i n.
l bs.).
the heater-A/C control to the i nstrument panel struc-
tural duct. Ti ghten the screws to 2.2 Nm (20 i n.
l bs.).
the radi o to the i nstrument panel structural duct.
(11) Rei nstal l the center l ower bezel onto the
MENT PANEL/I P CENTER BEZEL - LOWER -
I NSTALLATI ON).
(12) Rei nstal l the center upper bezel onto the
MENT PANEL/I P CENTER BEZEL - UPPER -
I NSTALLATI ON).
(13) I nstal l and ti ghten the two l arge screws on
the gl ove box openi ng upper rei nforcement that
secure the top pad to the i nstrument panel structural
duct (Fi g. 24). Ti ghten the screws to 11.8 Nm (105
i n. l bs.).
(14) I nstal l and ti ghten the two smal l screws on
the gl ove box openi ng upper rei nforcement that
secure the panel outl ets to the i nstrument panel
structural duct. Ti ghten the screws to 2.2 Nm (20 i n.
l bs.).
(15) Rei nstal l the gl ove box l amp and swi tch i nto
LAMPS/LI GHTI NG - I NTERI OR/GLOVE BOX
LAMP/SWI TCH - I NSTALLATI ON).
(16) Rei nstal l the l ower ri ght center bezel onto the
- I NSTALLATI ON).
(17) Rei nstal l the end cap onto the i nstrument
I NSTRUMENT PANEL END CAP - I NSTALLA-
TI ON).
BOX ROLL DOWN).
(20) Rei nstal l the i nstrument cl uster i nto the
(21) Rei nstal l the cl uster bezel onto the i nstru-
PANEL/CLUSTER BEZEL - I NSTALLATI ON).
(22) I f the vehi cl e i s so equi pped, posi ti on the
automati c headl amp l i ght sensor/vehi cl e theft secu-
ri ty system i ndi cator uni t to the i nstrument panel
top pad just outboard of the dri ver si de defroster out-
l et. I nstal l and ti ghten the two screws that secure
the sensor/i ndi cator uni t. Ti ghten the screws to 2.2
Nm (20 i n. l bs.).
(23) Engage the retai ner that secures each of the
two i nstrument panel wi re harness speaker take outs
to the mounti ng hol e i n the i nstrument panel top
pad.
(24) Rei nstal l the speakers onto the i nstrument
panel top pad. (Refer to 8 - ELECTRI CAL/AUDI O/
SPEAKER - I NSTALLATI ON - I NSTRUMENT
PANEL SPEAKER).
the i nstrument panel top pad to the studs on the
dash panel near the wi ndshi el d fence l i ne (Fi g. 23).
(26) Rei nstal l the top cover onto the i nstrument
TI ON).
(27) Rei nstal l the tri m onto the ri ght and l eft
A-pi l l ars. (Refer to 23 - BODY/I NTERI OR/A-PI LLAR
INSTRUMENT PANEL C-
CHANNEL COVER BRACKET
REMOVAL
REMOVAL).
(3) Pl ace the i nstrument panel top down on a sui t-
abl e work surface. Be certai n to take the proper pre-
cauti ons to protect the top of the i nstrument panel
from any possi bl e cosmeti c damage.
(4) Di sengage the radi o antenna coaxi al cabl e
retai ner from the mounti ng hol e i n the i nstrument
panel wi re harness mounti ng tab on the passenger
si de outboard end of the i nstrument panel C-channel
cover bracket.
(5) Remove the screw that secures the i nstrument
cover bracket (Fi g. 26).
(6) Remove the screw that secures the passenger
si de courtesy l amp to the l ower tab of i nstrument
panel C-channel cover bracket.
(7) Remove the ei ght screws that secure the
C-channel cover bracket to the i nstrument panel
structural duct.
(8) Remove the C-channel cover bracket from the
INSTALLATION
(1) Posi ti on the C-channel cover bracket to the
(2) I nstal l and ti ghten the ei ght screws that secure
the C-channel cover bracket to the i nstrument panel
structural duct (Fi g. 26). Ti ghten the screws to 2.2
Nm (20 i n. l bs.).
(3) Posi ti on the passenger si de courtesy l amp to
the l ower tab of i nstrument panel C-channel cover
bracket.
passenger si de courtesy l amp to the l ower tab of
i nstrument panel C-channel cover bracket. Ti ghten
the screw to 2.2 Nm (20 i n. l bs.).
(5) Posi ti on the i nstrument panel wi re harness
mounti ng tab to the passenger si de outboard end of
the i nstrument panel C-channel cover bracket.
i nstrument panel wi re harness mounti ng tab to the
passenger si de outboard end of the i nstrument panel
C-channel cover bracket. Ti ghten the screw to 2.2
Nm (20 i n. l bs.).
(7) Engage the radi o antenna coaxi al cabl e
retai ner i n the mounti ng hol e i n the i nstrument
cover bracket.
I NSTALLATI ON).
Fig. 26 Instrument Panel C-Channel Cover Bracket
Remove/Install
1 - C-CHANNEL COVER BRACKET
2 - SCREWS (8)
3 - PASSENGER SIDE COURTESY LAMP
5 - STRUCTURAL DUCT
INSTRUMENT PANEL CENTER
BEZEL - LOWER
REMOVAL
cabl e.
the center l ower bezel away from the i nstrument
panel far enough to di sengage the four snap cl i ps
from thei r receptacl es (Fi g. 27).
(3) Pul l the center l ower bezel away from the
i nstrument panel far enough to access the i nstru-
ment panel wi re harness connectors.
(4) Squeeze the mounti ng l egs of the ash recei ver
l amp hood and remove i t from the rectangul ar hol e
i n the ash recei ver fl ame shi el d.
(5) I f the vehi cl e i s so equi pped, di sconnect the
i nstrument panel wi re harness connectors for the two
heated seat swi tches from the swi tch connector
receptacl es.
connectors for the ci gar l i ghter and accessory power
outl et from the l i ghter and outl et connector recepta-
cl es.
ment panel .
INSTALLATION
INJURY.
(1) Posi ti on the center l ower bezel to the i nstru-
ment panel .
connectors for the ci gar l i ghter and the accessory
power outl et to the l i ghter and outl et connector
receptacl es.
(3) I f the vehi cl e i s so equi pped, reconnect the
i nstrument panel wi re harness connectors for the two
heated seat swi tches to the swi tch connector recepta-
cl es.
(4) Squeeze the mounti ng l egs of the ash recei ver
l amp hood and i nstal l them i nto the rectangul ar hol e
i n the ash recei ver fl ame shi el d.
(5) Al i gn the two l ower snap cl i ps on the center
l ower bezel wi th thei r receptacl es i n the i nstrument
panel top pad.
(6) Usi ng hand pressure, press fi rml y and evenl y
on the center l ower bezel over each of the l ower snap
cl i p l ocati ons unti l each of the snap cl i ps i s ful l y
(7) Al i gn the two upper snap cl i ps on the center
l ower bezel wi th thei r receptacl es i n the i nstrument
panel top pad.
on the center l ower bezel over each of the upper snap
Fig. 27 Instrument Panel Center Lower Bezel
Remove/Install
1 - HEATER AND AIR CONDITIONER CONTROLS
2 - TRIM STICK
BEZEL - UPPER
REMOVAL
INJURY.
cabl e.
the center upper bezel away from the i nstrument
panel far enough to di sengage the four snap cl i ps
(3) Remove the center upper bezel from the i nstru-
ment panel .
INSTALLATION
INJURY.
(1) Posi ti on the center upper bezel onto the i nstru-
ment panel .
(2) Al i gn the four snap cl i ps on the center upper
bezel wi th thei r receptacl es i n the i nstrument panel
top pad.
on the center upper bezel over each of the snap cl i p
l ocati ons unti l each of the snap cl i ps i s ful l y engaged
i n i ts receptacl e.
FLOOR TUNNEL BRACKET
REMOVAL
INJURY.
cabl e.
(2) Remove the front bi n from the fl oor consol e.
REMOVAL).
fl oor consol e to access and di sengage the i nstrument
Fig. 28 Instrument Panel Center Upper Bezel
Remove/Install
1 - CENTER UPPER BEZEL
2 - RADIO
3 - TRIM STICK
panel wi re harness retai ner from the mounti ng hol e
on the dri ver si de of the i nstrument panel center
fl oor tunnel bracket.
(4) Remove the two screws that secure the center
fl oor tunnel bracket to the i nstrument panel (Fi g.
29).
(5) Remove the two nuts that secure the center
fl oor tunnel bracket to the studs on the fl oor panel
(6) Remove the center fl oor tunnel bracket from
the i nstrument panel and the fl oor panel transmi s-
si on tunnel .
INSTALLATION
INJURY.
(1) Posi ti on the center fl oor tunnel bracket over
the fl oor panel transmi ssi on tunnel studs and sl i de i t
up agai nst the i nstrument panel (Fi g. 29).
the center fl oor tunnel bracket to the studs on the
fl oor panel transmi ssi on tunnel . Ti ghten the nuts to
11.3 Nm (100 i n. l bs.).
the center fl oor tunnel bracket to the i nstrument
panel . Ti ghten the screws to 11.3 Nm (100 i n. l bs.).
fl oor consol e to access and engage the i nstrument
panel wi re harness retai ner wi th the mounti ng hol e
on the dri ver si de of the i nstrument panel center
fl oor tunnel bracket.
(5) Rei nstal l the front bi n i nto the fl oor consol e.
I NSTALLATI ON).
INSTRUMENT PANEL
COURTESY LAMP BRACKET
REMOVAL
INJURY.
cabl e.
(2) Remove the i nstrument panel fuse cover from
the bottom of the Juncti on Bl ock (JB) and Body Con-
trol Modul e (BCM) uni t. (Refer to 8 - ELECTRI CAL/
POWER DI STRI BUTI ON/FUSE COVER -
REMOVAL).
(3) Reach under the steeri ng col umn openi ng cover
to access and remove the screw that secures the cour-
tesy l amp uni t to the l ower end of the i nstrument
panel courtesy l amp bracket near the i nboard si de of
the JB (Fi g. 30).
(4) Remove the courtesy l amp from the l ower end
of the courtesy l amp bracket.
Fig. 29 Instrument Panel Center Floor Tunnel
Bracket Remove/Install
1 - SCREW (2)
2 - NUT (2)
3 - STUDS
4 - CENTER FLOOR TUNNEL BRACKET
INSTRUMENT PANEL CENTER FLOOR TUNNEL BRACKET (Continued)
(5) Reach under the steeri ng col umn openi ng cover
to access and remove the screw that secures the cour-
tesy l amp bracket and the i nboard si de of the JB to
bracket.
(6) Remove the courtesy l amp bracket from the
i nboard si de of the JB and the i nstrument panel
INSTALLATION
INJURY.
(1) Reach under the i nstrument panel to posi ti on
the upper end of the courtesy l amp bracket to the
i nboard si de of the Juncti on Bl ock (JB) and the
i nstrument panel steeri ng col umn support bracket
(Fi g. 30).
courtesy l amp bracket and the i nboard si de of the JB
to the i nstrument panel steeri ng col umn support
bracket. Ti ghten the screw to 2.2 Nm (20 i n. l bs.).
(3) Posi ti on the courtesy l amp to the l ower end of
the courtesy l amp bracket.
courtesy l amp to the l ower end of the courtesy l amp
bracket. Ti ghten the screw to 2.2 Nm (20 i n. l bs.).
(5) Rei nstal l the i nstrument panel fuse cover to
the bottom of the JB and Body Control Modul e
(BCM) uni t. (Refer to 8 - ELECTRI CAL/POWER
DI STRI BUTI ON/FUSE COVER - I NSTALLATI ON).
INSTRUMENT PANEL
INTERMEDIATE BRACKET
REMOVAL
INJURY.
cabl e.
(2) Remove the accel erator pedal assembl y from
the shoul der studs on the dash panel . (Refer to 14 -
FUEL SYSTEM/FUEL I NJECTI ON/ACCELERATOR
PEDAL - REMOVAL).
REMOVAL).
(4) Remove the one nut that secures the i nstru-
ment panel i ntermedi ate bracket to the stud on the
dash panel (Fi g. 31).
(5) Remove the i nstrument panel i ntermedi ate
bracket from the two shoul der studs and the one
stud on the dash panel .
Fig. 30 Instrument Panel Courtesy Lamp Bracket
Remove/Install
1 - STEERING COLUMN
2 - SCREW
3 - COURTESY LAMP BRACKET
4 - DRIVER SIDE COURTESY LAMP
5 - JUNCTION BLOCK
6 - SCREW
INSTRUMENT PANEL COURTESY LAMP BRACKET (Continued)
INSTALLATION
INJURY.
(1) Posi ti on the i nstrument panel i ntermedi ate
bracket to the two shoul der studs and the one stud
on the dash panel (Fi g. 31).
(2) Loosel y i nstal l the one nut that secures the
i ntermedi ate bracket to the one stud on the dash
panel .
I NSTALLATI ON).
(4) Rei nstal l the accel erator pedal assembl y onto
the shoul der studs on the dash panel . (Refer to 14 -
FUEL SYSTEM/FUEL I NJECTI ON/ACCELERATOR
PEDAL - I NSTALLATI ON).
INSTRUMENT PANEL LOWER
RIGHT CENTER BEZEL
REMOVAL
INJURY.
cabl e.
(2) Unl atch and open the gl ove box.
(3) Remove the three screws that secure the l ower
ri ght center bezel to the i nstrument panel gl ove box
openi ng (Fi g. 32).
(4) Pul l the l ower ri ght center bezel strai ght back
from the i nstrument panel to di sengage the two snap
cl i ps that secure i t to the receptacl es i n the i nstru-
ment panel top pad.
i nstrument panel .
INSTALLATION
INJURY.
(1) Be certai n that the gl ove box catch bumper i s
i nstal l ed i n the mounti ng hol e nearest the i nboard
Fig. 31 Instrument Panel Intermediate Bracket
Remove/Install
1 - STUD
2 - DASH PANEL
3 - NUT (2)
4 - INTERMEDIATE BRACKET
5 - NUT (2)
7 - SHOULDER STUDS
INSTRUMENT PANEL INTERMEDIATE BRACKET (Continued)
end of the l ower ri ght center bezel extensi on over the
i nstrument panel upper gl ove box openi ng rei nforce-
ment.
(2) Posi ti on the l ower ri ght center bezel to the
i nstrument panel . Be certai n that the end of the
l ower ri ght center bezel extensi on near the center of
the upper gl ove box openi ng rei nforcement i s posi -
ti oned on top of the end of the extensi on from the
end cap (Fi g. 32).
(3) Al i gn the snap cl i ps on the l ower ri ght center
bezel wi th the receptacl es i n the i nstrument panel
top pad.
(4) Usi ng hand pressure, press fi rml y on the l ower
ri ght center bezel over each of the snap cl i p l ocati ons
unti l the snap cl i ps are ful l y engaged i n thei r recep-
tacl es.
the l ower ri ght center bezel to the i nstrument panel
gl ove box openi ng. Ti ghten the screws to 2.2 Nm (20
i n. l bs.).
(6) Cl ose and l atch the gl ove box.
INSTRUMENT PANEL PLENUM
BRACKET
REMOVAL
REMOVAL).
(3) Pl ace the i nstrument panel top down on a sui t-
abl e work surface. Be certai n to take the proper pre-
cauti ons to protect the top of the i nstrument panel
from any possi bl e cosmeti c damage.
(4) Remove the one screw that secures the pl enum
bracket to the i nstrument panel steeri ng col umn sup-
port bracket (Fi g. 33).
(5) Remove the pl enum bracket from the i nstru-
ment panel steeri ng col umn support bracket.
Fig. 32 Instrument Panel Lower Right Center Bezel
Remove/Install
2 - END CAP
3 - SCREWS (3)
4 - BUMPER
5 - LOWER RIGHT CENTER BEZEL
Fig. 33 Instrument Panel Plenum Bracket Remove/
Install
2 - PLENUM BRACKET
3 - STEERING COLUMN SUPPORT BRACKET
4 - SCREW
INSTRUMENT PANEL LOWER RIGHT CENTER BEZEL (Continued)
INSTALLATION
(1) Posi ti on the pl enum bracket to the i nstrument
panel steeri ng col umn support bracket (Fi g. 33).
the pl enum bracket to the i nstrument panel steeri ng
col umn support bracket. Ti ghten the screw to 11.8
Nm (105 i n. l bs.).
I NSTALLATI ON).
INSTRUMENT PANEL
STEERING COLUMN BRACKET
REMOVAL
(3) Remove the four screws that secure the steer-
i ng col umn bracket to the i nstrument panel steeri ng
col umn support bracket (Fi g. 34).
(4) Remove the steeri ng col umn bracket from the
INSTALLATION
(1) Posi ti on the steeri ng col umn bracket to the
i nstrument panel steeri ng col umn support bracket
(Fi g. 34).
the steeri ng col umn bracket to the i nstrument panel
steeri ng col umn support bracket. Ti ghten the screws
to 11.8 Nm (105 i n. l bs.).
(3) Rei nstal l the steeri ng col umn openi ng cover.
I NG COLUMN OPENI NG COVER - I NSTALLATI ON).
Fig. 34 Instrument Panel Steering Column Bracket
Remove/Install
BRACKET
2 - SCREW (4)
3 - INSTRUMENT PANEL STEERING COLUMN BRACKET
INSTRUMENT PANEL PLENUM BRACKET (Continued)
INSTRUMENT PANEL
STEERING COLUMN SUPPORT
BRACKET
REMOVAL
INJURY.
cabl e.
(3) Remove the i nstrument panel pl enum bracket
from the steeri ng col umn support bracket. (Refer to
23 - BODY/I NSTRUMENT PANEL/I P PLENUM
BRACKET - REMOVAL).
i nstrument panel wi re harness mounti ng tabs to the
back of the steeri ng col umn support bracket.
(5) Remove the two screws that secure the 16-way
data l i nk connector to the i nstrument panel steeri ng
col umn support bracket and remove the connector
from the bracket (Fi g. 35).
(6) Remove the Juncti on Bl ock (JB) and Body Con-
trol Modul e (BCM) uni t from the i nstrument panel
steeri ng col umn support bracket, but do not di scon-
nect any of the i nstrument panel wi re harness con-
nectors from the uni t. (Refer to 8 - ELECTRI CAL/
POWER DI STRI BUTI ON/JUNCTI ON BLOCK -
REMOVAL).
(7) From the face of the i nstrument panel , remove
the fi ve screws that secure the steeri ng col umn sup-
port bracket to the i nstrument panel structural duct.
(8) Remove the steeri ng col umn support bracket
from the i nstrument panel structural duct.
INSTALLATION
INJURY.
(1) Posi ti on the steeri ng col umn support bracket to
(2) From the face of the i nstrument panel , i nstal l
and ti ghten the fi ve screws that secure the steeri ng
col umn support bracket to the i nstrument panel
structural duct (Fi g. 35). Ti ghten the screws to 11.8
Nm (105 i n. l bs.).
(3) Posi ti on the i nstrument panel wi re harness
mounti ng tabs to the back of the steeri ng col umn
support bracket.
the i nstrument panel wi re harness mounti ng tabs to
the back of the steeri ng col umn support bracket.
(5) Rei nstal l the i nstrument panel pl enum bracket
onto the steeri ng col umn support bracket. (Refer to
23 - BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL PLENUM BRACKET - I NSTALLATI ON).
(6) Rei nstal l the Juncti on Bl ock (JB) and Body
Control Modul e (BCM) uni t onto the i nstrument
Fig. 35 Instrument Panel Steering Column Support
Bracket Remove/Install
1 - STRUCTURAL DUCT
2 - SCREWS (5)
3 - 16WAY DATA LINK CONNECTOR
4 - STEERING COLUMN SUPPORT BRACKET
panel steeri ng col umn support bracket. (Refer to 8 -
ELECTRI CAL/POWER DI STRI BUTI ON/JUNCTI ON
BLOCK - I NSTALLATI ON).
(7) Posi ti on the 16-way data l i nk connector to the
the 16-way data l i nk connector to the i nstrument
panel steeri ng col umn support bracket. Ti ghten the
INSTRUMENT PANEL TRIM
BEZEL - DRIVER
REMOVAL
INJURY.
cabl e.
fl at-bl aded tool , gentl y pry the edges of the dri ver
si de tri m bezel up and away from the i nstrument
panel far enough to di sengage the two snap cl i ps
(3) Remove the dri ver si de tri m bezel from the
INSTALLATION
INJURY.
(1) Posi ti on the dri ver si de tri m bezel to the
(2) Al i gn the snap cl i ps on the dri ver si de tri m
bezel wi th the receptacl es i n the i nstrument panel
top pad.
on the dri ver si de tri m bezel over the snap cl i p l oca-
ti ons unti l each of the snap cl i ps i s ful l y engaged i n
i ts receptacl e.
Fig. 36 Instrument Panel Driver Side Trim Bezel
Remove/Install
2 - DRIVER SIDE TRIM BEZEL
3 - TRIM STICK
4 - PANEL OUTLET
INSTRUMENT PANEL STEERING COLUMN SUPPORT BRACKET (Continued)
INSTRUMENT PANEL TRIM
BEZEL - PASSENGER
REMOVAL
INJURY.
cabl e.
(2) Remove the top pad from the i nstrument panel .
STRUMENT PANEL TOP PAD - REMOVAL).
(3) From the undersi de of the top pad, remove the
four screws from the top of the passenger ai rbag door
that secure the passenger si de tri m bezel to the
i nstrument panel (Fi g. 37).
(4) Remove the passenger si de tri m bezel from the
INSTALLATION
INJURY.
(1) Posi ti on the passenger si de tri m bezel to the
(2) From the undersi de of the top pad, i nstal l and
ti ghten the four screws through the passenger ai rbag
door that secure the passenger si de tri m bezel to the
i nstrument panel (Fi g. 37). Ti ghten the screws to
11.8 Nm (105 i n. l bs.).
(3) Rei nstal l the top pad onto the i nstrument
I NSTRUMENT PANEL TOP PAD - I NSTALLA-
TI ON).
Fig. 37 Instrument Panel Passenger Side Trim Bezel
Remove/Install
1 - INSTRUMENT PANEL AIRBAG DOOR REINFORCEMENT
2 - PASSENGER AIRBAG DOOR
3 - PASSENGER SIDE TRIM BEZEL SCREWS (4)
POWER OUTLET DOOR
REMOVAL
INJURY.
cabl e.
PANEL/I P CENTER BEZEL - LOWER - REMOVAL).
(3) Wi th the power outl et door i n the open posi -
ti on, careful l y spread the power outl et door hi nge
arms far enough to di sengage the pi vot pi ns from the
pi vots on the back si de of the center l ower bezel (Fi g.
38).
NOTE: The power outlet door is more easily ser-
viced while in the open position. The illustration
shows the door in the closed position for improved
visibility of the assist spring orientation and anchor
point details.
(4) Di sengage the stepped ends of the assi st spri ng
from the anchor hol es i n the i nboard power outl et
door hi nge arm and i n the si de of the ash recei ver
housi ng.
(5) Remove the power outl et door from the i nstru-
ment panel center l ower bezel .
INSTALLATION
INJURY.
(1) Posi ti on the power outl et door to the i nstru-
ment panel center l ower bezel .
(2) Engage the stepped ends of the assi st spri ng
wi th the anchor hol es i n the i nboard power outl et
door hi nge arm and i n the si de of the ash recei ver
(3) Wi th the power outl et door i n the open posi -
ti on, careful l y spread the power outl et door hi nge
arms far enough to engage the pi vot pi ns wi th the
pi vots on the back si de of the l ower center bezel .
(4) Rei nstal l the center l ower bezel i nto the i nstru-
PANEL/I P CENTER BEZEL - LOWER - I NSTALLA-
TI ON).
Fig. 38 Instrument Panel Power Outlet Door
Remove/Install
2 - ASH RECEIVER FLAME SHIELD
3 - ASH RECEIVER HOUSING
4 - PIVOT PINS
5 - ASSIST SPRING
6 - POWER OUTLET DOOR HINGE ARMS
STEERING COLUMN OPENING
COVER
REMOVAL
INJURY.
cabl e.
(2) Remove the fuse cover from the Juncti on Bl ock
(JB) and Body Control Modul e (BCM) uni t under the
dri ver si de outboard end of the i nstrument panel .
(Refer to 8 - ELECTRI CAL/POWER DI STRI BU-
TI ON/FUSE COVER - REMOVAL).
board end of the steeri ng col umn openi ng cover to
the U-nut on the outboard end of the i nstrument
panel top pad (Fi g. 39).
(5) Remove the two screws that secure the l ower
edge of the steeri ng col umn openi ng cover to the
U-nuts on the i nstrument panel steeri ng col umn sup-
port bracket.
(6) Pul l the steeri ng col umn openi ng cover rear-
ward to di sengage the three snap cl i ps (one outboard
and two i nboard) that secure i t to the receptacl es i n
the i nstrument panel .
from the i nstrument panel .
INSTALLATION
INJURY.
(1) Posi ti on the steeri ng col umn openi ng cover
onto the i nstrument panel (Fi g. 39).
(2) Al i gn the three snap cl i ps on the steeri ng col -
umn openi ng cover wi th thei r receptacl es i n the
i nstrument panel .
on the steeri ng col umn openi ng cover over the snap
the l ower edge of the steeri ng col umn openi ng cover
to the i nstrument panel steeri ng col umn support
bracket. Ti ghten the screws to 2.2 Nm (20 i n. l bs.).
the outboard end of the steeri ng col umn openi ng
cover to the U-nut on the outboard end of the i nstru-
ment panel top pad. Ti ghten the screw to 2.2 Nm (20
i n. l bs.).
(6) Rei nstal l the cl uster bezel onto the i nstrument
CLUSTER BEZEL - I NSTALLATI ON).
(7) Rei nstal l the fuse cover onto the Juncti on
Bl ock (JB) and Body Control Modul e (BCM) uni t
under the dri ver si de outboard end of the i nstrument
panel . (Refer to 8 - ELECTRI CAL/POWER DI STRI -
BUTI ON/FUSE COVER - I NSTALLATI ON).
Fig. 39 Steering Column Opening Cover Remove/
Install
3 - SCREW (3)
INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
ASSIST HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
B-PILLAR LOWER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
B-PILLAR UPPER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
CARPETS AND FLOOR MATS
REMOVAL
REMOVAL - FRONT CARPET . . . . . . . . . . . . 71
REMOVAL - CARGO AREA CARPET . . . . . . . 71
INSTALLATION
INSTALLATION - FRONT CARPET . . . . . . . . . 71
INSTALLATION - CARGO AREA CARPET . . . 72
COWL TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
C-PILLAR TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
DOOR SILL SCUFF PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
DOOR SILL TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
D-PILLAR TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 75
FLOOR CONSOLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
HEADLINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
LIFTGATE OPENING UPPER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
QUARTER TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
REAR STORAGE BOX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
REAR VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET. . . . . . . . . . . . . . . . . . . 80
SUN VISOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
A-PILLAR TRIM
REMOVAL
The A-pi l l ar tri m i s attached to the A-pi l l ar wi th
spri ng cl i ps.
(1) Grasp A-pi l l ar tri m and pul l tri m outward from
A-pi l l ar (Fi g. 1).
(2) Separate A-pi l l ar tri m from A-pi l l ar.
INSTALLATION
(1) Posi ti on A-pi l l ar tri m on A-pi l l ar and, starti ng
at the bottom, press i nto pl ace (Fi g. 1).
(2) Usi ng a tri m sti ck or other sui tabl e tool , care-
ful l y cover the edge of the tri m wi th weatherstri p.
Fig. 1 A-Pillar Trim
1 - A-PILLAR TRIM
2 - A-PILLAR
3 - SPRING CLIP
WJ INTERIOR 23 - 69
ASSIST HANDLE
REMOVAL
(1) Remove the screws hol di ng the assi st handl e to
the roof panel .
(2) Remove the assi st handl e from the roof panel .
INSTALLATION
(1) Al i gn the assi st handl e wi th the screw hol es i n
the roof panel .
(2) I nstal l the screws hol di ng the assi st handl e to
the roof panel .
B-PILLAR LOWER TRIM
REMOVAL
(1) Remove front door si l l tri m (Refer to 23 -
BODY/I NTERI OR/DOOR SI LL TRI M - REMOVAL).
(2) Remove front seat shoul der bel t anchor bol t.
(3) Remove front seat shoul der bel t hei ght adjust-
ment knob and turni ng l oop.
(4) Remove screw attachi ng front of quarter panel
tri m to fl oor.
(5) Remove screws attachi ng front and rear of
B-pi l l ar l ower tri m to fl oor.
(6) Remove screw attachi ng B-pi l l ar l ower tri m to
B-pi l l ar (Fi g. 2).
(7) Grasp B-pi l l ar l ower tri m and pul l outward to
separate from B-pi l l ar.
(8) Route seat/shoul der bel t through access sl ot i n
B-pi l l ar l ower tri m.
(9) Separate B-pi l l ar l ower tri m from B-pi l l ar.
INSTALLATION
(1) Posi ti on B-pi l l ar l ower tri m panel at B-pi l l ar
(Fi g. 2).
(2) Route seat/shoul der bel t through access sl ot i n
B-pi l l ar l ower tri m.
(3) Press B-pi l l ar l ower tri m onto B-pi l l ar.
Fig. 2 B-Pillar Trim Panel
1 - B-PILLAR UPPER TRIM
2 - ACCESS COVER
3 - B-PILLAR LOWER TRIM
4 - PLASTIC NUT
5 - COWL LOWER TRIM
6 - CLIP
7 - SCUFF PLATE
8 - SILL TRIM
9 - A-PILLAR TRIM
23 - 70 INTERIOR WJ
(4) I nstal l screw attachi ng B-pi l l ar l ower tri m to
B-pi l l ar.
(5) I nstal l screw attachi ng front of B-pi l l ar l ower
tri m to fl oor.
(6) I nstal l screw attachi ng front of quarter panel
tri m to fl oor.
(7) I nstal l front seat shoul der bel t anchor bol t.
(8) I nstal l front seat shoul der bel t hei ght adjust-
ment knob and turni ng l oop.
(9) I nstal l front door si l l tri m (Refer to 23 - BODY/
I NTERI OR/DOOR SI LL TRI M - I NSTALLATI ON).
B-PILLAR UPPER TRIM
REMOVAL
(1) Remove shoul der bel t hei ght adjustment knob.
(2) Remove front seat bel t turni ng l oop.
(3) Remove the screw attachi ng l ower B pi l l ar
tri m.
(4) Pul l l ower B pi l l ar tri m out far enough to
remove upper tri m panel .
(5) Grasp upper B-pi l l ar tri m and pul l outward to
detach from B-pi l l ar (Fi g. 2).
INSTALLATION
(1) Posi ti on tri m panel on B-pi l l ar (Fi g. 2).
(2) Ensure tri m panel covers i nner edge of door
openi ng weatherstri p and press i nward to seat.
(3) I nstal l screw attachi ng l ower B pi l l ar tri m
panel .
(4) I nstal l front seat bel t turni ng l oop.
(5) I nstal l shoul der bel t hei ght adjustment knob.
CARPETS AND FLOOR MATS
REMOVAL
REMOVAL - FRONT CARPET
(1) Remove door si l l tri m (Refer to 23 - BODY/I N-
TERI OR/DOOR SI LL TRI M - REMOVAL).
(2) Remove the B-pi l l ar l ower tri m, refer to (Refer
to 23 - BODY/I NTERI OR/B-PI LLAR LOWER TRI M -
REMOVAL).
(3) Remove front seats (Refer to 23 - BODY/
SEATS/SEAT - REMOVAL).
(4) Remove the rear seats l ower cushi ons (Refer to
23 - BODY/SEATS/SEAT CUSHI ON - REMOVAL).
(5) Remove center fl oor consol e (Refer to 23 -
BODY/I NTERI OR/FLOOR CONSOLE - REMOVAL).
(6) Remove any other i nterferi ng tri m or mol di ng.
(7) Li ft carpet and mat from fl oor panel .
REMOVAL - CARGO AREA CARPET
(1) Li ft tai l gate.
(2) Fol d rear seat cushi ons forward.
(3) Remove rear seat backs (Refer to 23 - BODY/
SEATS/REAR SEAT BACK - REMOVAL).
(4) Remove the rear shoul der bel ts (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/REAR SEAT BELT &
RETRACTOR - REMOVAL).
(5) Remove the retractabl e securi ty cargo cover
assembl y.
(6) Remove the spare ti re cover.
(7) Remove the rear cargo ti e down footman l oops.
The si de mounted footman l oops are retai ned by
screws. The fl oor footman l oops are ri veted (Fi g. 3).
(8) Remove the C pi l l ar tri m (Refer to 23 - BODY/
I NTERI OR/C-PI LLAR TRI M - REMOVAL).
(9) Remove the CD changer, i f equi pped (Refer to 8
- ELECTRI CAL/AUDI O/CD CHANGER - REMOV-
AL).
(10) Remove the I nfi ni ty amp, i f equi pped (Refer to
8 - ELECTRI CAL/AUDI O/AMPLI FI ER - REMOVAL).
(11) Li ft the carpet.
INSTALLATION
INSTALLATION - FRONT CARPET
(1) Careful l y l ay the carpet and mat on the fl oor
panel . Al i gn the carpet to al l ow i nstal l ati on of the
components fastened to the fl oor panel .
(2) I nstal l the center consol e (Refer to 23 - BODY/
(3) I nstal l the front seats (Refer to 23 - BODY/
SEATS/SEAT - I NSTALLATI ON).
(4) I nstal l the rear seat cushi ons (Refer to 23 -
BODY/SEATS/SEAT CUSHI ON - I NSTALLATI ON).
Fig. 3 Cargo Area Carpet
1 - CARGO AREA CARPET
2 - RIVET
3 - CARGO TIE-DOWN LOOP
WJ INTERIOR 23 - 71
B-PILLAR LOWER TRIM (Continued)
(5) I nstal l the l ower B pi l l ar tri m (Refer to 23 -
BODY/I NTERI OR/B-PI LLAR LOWER TRI M -
I NSTALLATI ON).
(6) I nstal l the door si l l tri m (Refer to 23 - BODY/
(7) I nstal l any other mol di ngs or tri m panel s
removed.
INSTALLATION - CARGO AREA CARPET
(1) Thoroughl y cl ean the area wi th Mopar Super
(2) Lay the new carpet i n.
(3) I nstal l the C pi l l ar tri m (Refer to 23 - BODY/
I NTERI OR/C-PI LLAR TRI M - I NSTALLATI ON).
(4) I nstal l the CD changer, i f equi pped (Refer to 8 -
ELECTRI CAL/AUDI O/CD CHANGER - I NSTALLA-
TI ON).
(5) I nstal l the footman l oops (Fi g. 3).
(6) I nstal l the rear shoul der bel ts (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/REAR SEAT BELT &
RETRACTOR - I NSTALLATI ON).
(7) I nstal l the rear seat backs (Refer to 23 -
BODY/SEATS/REAR SEAT BACK - I NSTALLA-
TI ON).
(8) I nstal l the I nfi ni ty amp, i f equi pped (Refer to 8
- ELECTRI CAL/AUDI O/AMPLI FI ER - I NSTALLA-
TI ON).
(9) I nstal l the spare ti re cover.
(10) I nstal l the retractabl e securi ty cover.
COWL TRIM
REMOVAL
(1) Remove front door si l l tri m (Refer to 23 -
BODY/I NTERI OR/DOOR SI LL TRI M - REMOVAL).
(2) Remove screws attachi ng cowl tri m to fl oor.
(3) Remove pl asti c nut.
(4) Grasp cowl tri m and pul l outward to separate
from cl i p.
(5) Separate cowl tri m from vehi cl e.
INSTALLATION
(1) Posi ti on cowl tri m and press i nto pl ace.
(2) I nstal l screws attachi ng cowl tri m to fl oor.
(3) I nstal l pl asti c nut.
(4) I nstal l front door si l l tri m (Refer to 23 - BODY/
C-PILLAR TRIM
REMOVAL
(1) Remove rear shoul der bel t turni ng l oop.
(2) Remove rear shoul der bel t hei ght adjustment
knob.
(3) Remove screws attachi ng quarter panel tri m.
(4) Pul l quarter panel tri m outward as necessary.
(5) Grasp C-pi l l ar upper tri m and pul l outward to
di sengage from C-pi l l ar (Fi g. 4).
(6) Route rear shoul der bel t through access hol e.
(7) Separate C-pi l l ar upper tri m from vehi cl e.
INSTALLATION
(1) Posi ti on C-pi l l ar upper tri m at C-pi l l ar (Fi g. 4).
(2) Route rear shoul der bel t through access hol e.
(3) Press C-pi l l ar upper tri m onto C-pi l l ar.
(4) Press quarter panel tri m i nto pl ace as neces-
sary.
(5) Ensure front edge of tri m i s covered by weath-
erstri p.
(6) I nstal l screws attachi ng quarter panel tri m.
(7) I nstal l rear shoul der bel t hei ght adjustment
knob.
(8) I nstal l rear shoul der bel t turni ng l oop.
23 - 72 INTERIOR WJ
CARPETS AND FLOOR MATS (Continued)
Fig. 4 Right Side Trim Panel
1 - D-PILLAR TRIM
2 - SNAP-IN NUT
3 - BRACKET
4 - SNAP-IN NUT
5 - QUARTER TRIM PANEL
6 - STORAGE BIN
7 - BRACKET
9 - C-PILLAR UPPER TRIM
10 - SNAP-IN NUT
WJ INTERIOR 23 - 73
C-PILLAR TRIM (Continued)
DOOR SILL SCUFF PLATE
REMOVAL
(1) Usi ng a tri m sti ck or other sui tabl e tool , care-
ful l y pry up the scuff pl ate from the door si l l (Fi g. 5).
(2) Remove the scuff pl ate.
INSTALLATION
(1) I nstal l the scuff pl ate on the door si l l (Fi g. 5).
(2) Press the mol ded i n snap retai ners i nto the
door si l l .
DOOR SILL TRIM
REMOVAL
The si l l tri m mol di ng i s hel d i n pl ace wi th mol ded
i n snap retai ners (Fi g. 6).
(1) Usi ng a tri m sti ck or other sui tabl e devi ce,
careful l y pry up one corner of the si l l tri m.
(2) Grasp the edge of the tri m and pul l up gentl y
to rel ease the snap retai ners.
INSTALLATION
(1) Posi ti on the si l l mol di ng on the door si l l .
(2) Press the snap retai ners i nto pl ace.
Fig. 5 Door Sill Scuff Plates
1 - B-PILLAR
2 - FRONT DOOR SCUFF PLATE
3 - REAR DOOR SCUFF PLATE
23 - 74 INTERIOR WJ
D-PILLAR TRIM
REMOVAL
The D-pi l l ar tri m i s attached to the D-pi l l ar wi th
spri ng cl i ps (Fi g. 7).
(1) Remove l i ftgate openi ng upper tri m panel
(Refer to 23 - BODY/I NTERI OR/LI FTGATE OPEN-
I NG UPPER TRI M - REMOVAL).
(2) Grasp D-pi l l ar tri m and pul l outward from
D-pi l l ar.
(3) Separate D-pi l l ar tri m from D-pi l l ar.
INSTALLATION
(1) Posi ti on D-pi l l ar tri m panel at D-pi l l ar and
press i nto pl ace.
(2) I nstal l upper l i ftgate openi ng tri m panel (Refer
to 23 - BODY/I NTERI OR/LI FTGATE OPENI NG
UPPER TRI M - I NSTALLATI ON).
Fig. 6 Sill Trim Molding
1 - B-PILLAR UPPER TRIM
2 - ACCESS COVER
4 - PLASTIC NUT
5 - COWL LOWER TRIM
6 - CLIP
7 - SCUFF PLATE
8 - SILL TRIM
9 - A-PILLAR TRIM
Fig. 7 D Pillar Upper Trim
1 - D PILLAR UPPER TRIM
WJ INTERIOR 23 - 75
DOOR SILL TRIM (Continued)
FLOOR CONSOLE
REMOVAL
CAUTION: The ACM should be depowered by dis-
connecting the negative battery cable in any opera-
tion requiring the key to be turned ON, while
working in the console area. E.G. console, carpet,
or seat removal or installation; shifter linkage
adjustment or replacement; parking brake cable
replacement or adjustment. Failure to take proper
precautions could result in accidental airbag
deployment and possible personal injury.
(1) Set park brake.
(2) Pl ace transmi ssi on shi ft l ever and transfer case
l ever i n ful l rearward posi ti on.
(3) Remove mat from front bi n and remove screws
attachi ng front of consol e to fl oor (Fi g. 8).
(4) Remove screws attachi ng rear bi n to consol e.
(5) Remove rear bi n.
(6) Pul l rear passenger cuphol der outward to
access screws.
(7) Remove screws attachi ng rear of consol e to fl oor.
(8) Li ft the consol e upward and rearward.
(9) Remove consol e from vehi cl e.
INSTALLATION
CAUTION: The ACM should be depowered by dis-
connecting the negative battery cable in any opera-
tion requiring the key to be turned ON, while
working in the console area. E.G. console, carpet,
or seat removal or installation; shifter linkage
adjustment or replacement; parking brake cable
replacement or adjustment. Failure to take proper
precautions could result in accidental airbag
deployment and possible personal injury.
(1) Posi ti on consol e i n vehi cl e. Ensure rear passen-
ger HEVAC duct i s engaged.
(2) I nstal l screws attachi ng rear of consol e to fl oor.
(3) Posi ti on rear bi n i n consol e.
(4) I nstal l screws attachi ng rear bi n to consol e.
(5) I nstal l screws attachi ng front of consol e to fl oor
and pl ace front bi n mat i n front bi n.
(6) Return transmi ssi on shi ft l ever and transfer
case l ever to ori gi nal posi ti on.
(7) Rel ease park brake.
Fig. 8 Floor Console
1 - REAR BIN
2 - CONSOLE LID
3 - SHIFTER CONSOLE
4 - BRACKET
5 - PARKING BRAKE
6 - FRONT PIN
7 - MAT
23 - 76 INTERIOR WJ
HEADLINER
REMOVAL
CAUTION: The headliner is a one-piece, molded
component. It has limited flexibility and must not be
bent. Damage may possibly result.
(1) Record radi o presets and di sconnect negati ve
battery cabl e.
(2) Remove A pi l l ar tri m mol di ngs (Refer to 23 -
BODY/I NTERI OR/A-PI LLAR TRI M - REMOVAL).
(3) Remove B pi l l ar upper tri m mol di ngs (Refer to
23 - BODY/I NTERI OR/B-PI LLAR UPPER TRI M -
REMOVAL).
(4) Remove C pi l l ar tri m mol di ngs (Refer to 23 -
BODY/I NTERI OR/C-PI LLAR TRI M - REMOVAL).
(5) Remove D pi l l ar tri m mol di ng (Refer to 23 -
BODY/I NTERI OR/D-PI LLAR TRI M - REMOVAL).
(6) Remove the sun vi sors (Refer to 23 - BODY/I N-
TERI OR/SUN VI SOR - REMOVAL).
(7) Di sconnect the vani ty l amp el ectri cal connector.
(8) Remove assi st handl es from roof rai l s (Refer to
23 - BODY/I NTERI OR/ASSI ST HANDLE - REMOV-
AL).
(9) Remove dome l amp and overhead consol e, i f
equi pped.
(10) Remove rear cargo/dome l amp.
(11) Remove sun roof pi nch wel t, i f equi pped.
(12) Di sengage rear washer hose from l i ftgate (Fi g.
9).
(13) Di sengage the wi re harness connectors at rear
of headl i ner.
(14) Di sconnect the rear washer hose at the l eft
A pi l l ar (Fi g. 10).
(15) Di sengage the wi re harness for the sunroof, i f
equi pped.
(16) Fol d down the rear seats, move the front seats
ful l forward, and l ower the front seat backs.
(17) Parti al l y l ower the headl i ner and di sengage
the sunroof drai n hoses, i f equi pped (Fi g. 11).
(18) Wi th the ai d of an assi stant, remove the head-
l i ner through the l i ftgate openi ng.
INSTALLATION
(1) Wi th the ai d of an assi stant, posi ti on the head-
l i ner i n the vehi cl e.
(2) Connect the sunroof drai n hoses, i f equi pped.
(3) Connect the sunroof harness, the rear wi re har-
nesses, and the washer hose at the A pi l l ar and at
the l i ftgate.
(4) I nstal l the sunroof pi nch wel t, i f equi pped.
(5) I nstal l the roof rai l assi st handl es (Refer to 23 -
BODY/I NTERI OR/ASSI ST HANDLE - I NSTALLA-
TI ON).
Fig. 9 Liftgate Washer Hose Routing at Rear of
Headliner
1 - ROOF
2 - REAR WASHER HOSE ROUTING
3 - REAR WASHER HOSE
4 - HEADLINER
Fig. 10 Rear Liftgate Washer Hose Routing at A
Pillar
1 - OVERHEAD CONSOLE WIRE HARNESS
2 - ROOF
4 - REAR WASHER HOSE ROUTING
5 - HEADLINER
WJ INTERIOR 23 - 77
(6) I nstal l the sun vi sors (Refer to 23 - BODY/I N-
TERI OR/SUN VI SOR - I NSTALLATI ON).
(7) I nstal l the overhead consol e, i f equi pped.
(8) I nstal l the rear cargo/dome l amp.
(9) I nstal l the D pi l l ar tri m (Refer to 23 - BODY/
I NTERI OR/D-PI LLAR TRI M - I NSTALLATI ON).
(10) I nstal l the C pi l l ar tri m (Refer to 23 - BODY/
I NTERI OR/C-PI LLAR TRI M - I NSTALLATI ON).
(11) I nstal l the upper B pi l l ar tri m (Refer to 23 -
BODY/I NTERI OR/B-PI LLAR UPPER TRI M -
I NSTALLATI ON).
(12) I nstal l the A pi l l ar tri m (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - I NSTALLATI ON).
Fig. 11 Headliner
1 - SUNROOF PINCH WELT
2 - ROOF
4 - HEADLINER
5 - SUNROOF
23 - 78 INTERIOR WJ
HEADLINER (Continued)
LIFTGATE OPENING UPPER
TRIM
REMOVAL
The upper l i ftgate openi ng tri m i s hel d on wi th
spri ng cl i ps.
(1) Grasp the rear of the tri m pi ece and pul l down
and back to di sengage cl i ps (Fi g. 12).
(2) Sl i de the tri m pi ece to the rear to di sengage
headl i ner l ocati ng hooks.
INSTALLATION
The l i ftgate upper openi ng tri m pi ece i s equi pped
wi th headl i ner l ocati ng hooks (Fi g. 13).
(1) Al i gn the l ocati ng hooks wi th the sl ots i n the
headl i ner.
(2) Engage the spri ng cl i ps and press the l i ftgate
upper openi ng tri m panel i nto pl ace.
QUARTER TRIM PANEL
REMOVAL
(1) Move rear seat to cargo posi ti on.
(2) I f equi pped, remove sunshade cover.
(3) Open l i ftgate.
(4) Remove upper and l ower l i ftgate openi ng tri m
panel s (Refer to 23 - BODY/I NTERI OR/LI FTGATE
OPENI NG UPPER TRI M - REMOVAL).
(5) Remove D-pi l l ar upper tri m (Refer to 23 -
BODY/I NTERI OR/D-PI LLAR TRI M - REMOVAL).
(6) Remove storage bi n (ri ght si de onl y) (Refer to
23 - BODY/I NTERI OR/REAR STORAGE BOX -
REMOVAL).
(7) Remove C-pi l l ar upper tri m panel (Refer to 23 -
BODY/I NTERI OR/C-PI LLAR TRI M - REMOVAL).
(8) Remove mounti ng screws.
(9) Pul l quarter tri m panel forward and di sengage
connectors for CD pl ayer and power outl et, i f
equi pped.
(10) Pul l quarter tri m panel extensi on i n the rear
door openi ng upward.
(11) Remove rear quarter tri m panel .
INSTALLATION
(1) Posi ti on quarter tri m panel , engage connectors
for CD pl ayer and power outl et, i f equi pped, and
al i gn screw hol es.
(2) I nstal l quarter tri m panel .
(3) I nstal l C-pi l l ar upper tri m panel (Refer to 23 -
BODY/I NTERI OR/C-PI LLAR TRI M - I NSTALLA-
TI ON).
(4) I nstal l storage bi n (Refer to 23 - BODY/I NTE-
RI OR/REAR STORAGE BOX - I NSTALLATI ON).
(5) I nstal l D-pi l l ar upper tri m panel (Refer to 23 -
BODY/I NTERI OR/D-PI LLAR TRI M - I NSTALLA-
TI ON).
(6) I nstal l upper and l ower l i ftgate openi ng tri m
panel s (Refer to 23 - BODY/I NTERI OR/LI FTGATE
OPENI NG UPPER TRI M - I NSTALLATI ON).
(7) I f equi pped, i nstal l sunshade cover.
(8) I nstal l cargo l oops.
(9) Move the rear seat to the upri ght posi ti on.
REAR STORAGE BOX
REMOVAL
(1) Open the storage bi n l i d and remove screws on
each si de of the l i d hi nge.
(2) Pul l upward sharpl y on the bottom of the bi n
to di sengage hooks.
(3) Rai se bi n and move i nboard to di sengage the
quarter tri m panel .
Fig. 12 Upper Liftgate Opening Trim
1 - UPPER LIFTGATE OPENING TRIM
Fig. 13 Headliner Locating Hooks
1 - UPPER LIFTGATE OPENING TRIM
2 - HEADLINER
WJ INTERIOR 23 - 79
INSTALLATION
(1) Posi ti on the bi n hooks hi gh i n the sl ots on the
quarter tri m panel .
(2) Push downward unti l the bi n snaps i nto pl ace.
(3) I nstal l the hi nge screws.
REAR VIEW MIRROR
REMOVAL
(1) I f equi pped, di sconnect mi rror harness connector.
(2) Loosen the mi rror base setscrew (Fi g. 14).
(3) Sl i de the mi rror base upward and off the
bracket.
INSTALLATION
INSTALLATION
(1) Posi ti on the mi rror base at the bracket and
sl i de i t downward onto the support bracket (Fi g. 14).
(2) Ti ghten the setscrew 1 Nm (15 i n. l bs.) torque.
(3) I f equi pped, connect mi rror harness connector.
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
(a) Crush the vi al to saturate the fel t appl i cator.
(b) Remove the paper sl eeve.
(c) Appl y accel erator to the contact surface on
the bracket.
(d) Al l ow the accel erator to dry for fi ve mi nutes.
(e) Do not touch the bracket contact surface
after the accel erator has been appl i ed.
(5) Appl y adhesi ve accel erator to the bracket contact
surface on the wi ndshi el d gl ass. Al l ow the accel erator to
dry for one mi nute. Do not touch the gl ass contact sur-
face after the accel erator has been appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
(a) Appl y one drop of adhesi ve at the center of the
bracket contact-surface on the wi ndshi el d gl ass.
(b) Appl y an even coat of adhesi ve to the contact
surface on the bracket.
(c) Al i gn the bracket wi th the marked posi ti on
on the wi ndshi el d gl ass.
(d) Press and hol d the bracket i n pl ace for at
l east one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
SUN VISOR
REMOVAL
(1) Remove screws attachi ng sunvi sor arm support
bracket to headl i ner and roof panel .
(2) Di sengage el ectri cal connecti ons for vani ty mi r-
ror, i f equi pped.
(3) Detach sunvi sor from support bracket.
(4) Remove sunvi sor from vehi cl e.
(5) Remove retai ni ng screw and support bracket.
INSTALLATION
(1) I nstal l the retai ni ng screw and support
bracket.
(2) Posi ti on the sunvi sor i n the vehi cl e.
(3) Connect the el ectri cal harness for the l i ghted
vani ty mi rror, i f equi pped.
(4) Attach the sunvi sor to the support bracket.
(5) I nstal l the support bracket w/sunvi sor onto the
headl i ner and roof panel .
Fig. 14 Rear View Mirror
1 - CONNECTOR
2 - SCREW
3 - REAR VIEW MIRROR
4 - SUPPORT BUTTON
5 - WINDSHIELD
23 - 80 INTERIOR WJ
REAR STORAGE BOX (Continued)
PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES . . . . . . . . . . 81
PAINT CODE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 81
BASE COAT/CLEAR COAT FINISH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 81
PAINT TOUCH-UP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 82
FINESSE SANDING/BUFFING & POLISHING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 82
PAINT
SPECIFICATIONS - PAINT CODES
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
CODE
Dark Garnet Red
Pearlcoat
XRV
Inferno Red Tinted
Pearlcoat
WEL
Woodland Brown Satin
Glow
YUB
Onyx Green Pearlcoat YJR
Steel Blue Pearlcoat XBQ
Patriot Blue Pearlcoat WBT
Silverstone Metallic
Clearcoat
XS5
Graphite Metallic
Clearcoat
ZDR
Black Clearcoat DX8
Stone White Clearcoat SW1
INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
CODE
Dark Slate Grey DV
Taupe L5
Sandstone T5
Dark Slate/Light Slate DB
LAREDO FASCIA/CLADDING COLORS
COLOR DAIMLERCHRYSLER
CODE
Dark Grey Metallic XS9
PAINT CODE
DESCRIPTION
Exteri or vehi cl e body col ors are i denti fi ed on the
Body Code pl ate. The pl ate i s l ocated on the i n the
engi ne compartment and attached to the top of the
ri ght frame rai l . Refer to the I ntroducti on secti on at
the front of thi s manual for body code pl ate descri p-
ti on. The pai nt code i s al so i denti fi ed on the Vehi cl e
Safety Certi fi cati on Label whi ch i s l ocated on the
dri vers door shut face. The fi rst di gi t of the pai nt
code l i sted on the vehi cl e i ndi cates the sequence of
appl i cati on, i .e.: P = pri mary coat, Q = secondary
coat.
BASE COAT/CLEAR COAT
FINISH
DESCRIPTION
The ori gi nal equi pment fi ni sh i s a mul ti -step pro-
cess that i nvol ves cl eani ng, el ectrodeposi ti on (e-coat),
base coat, and cl ear coat steps. Addi ti onal l y, sel ected
areas of the vehi cl e may be coated wi th an anti -chi p
fi ni sh.
WJ PAINT 23 - 81
PAINT TOUCH-UP
DESCRIPTION
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. Refer to I ntroducti on group of thi s manual for
Body Code Pl ate i nformati on.
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
OPERATION
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the defect wi thout runni ng. Do
not stroke brush appl i cator on body surface. Al l ow
the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up
col or can be l i ghtl y fi nesse sanded (1500 gri t) and
pol i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, appl y cl ear top coat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
CAUTION: Do not remove more than .5 mils of
clearcoat finish, if equipped. Base coat paint must
retain clear coat for durability.
Use a Paint Thickness Gauge #PR-ETG-2X or equiv-
alent to determine film thickness before and after
the repair.
Mi nor aci d etchi ng, orange peel , or smudgi ng i n
cl earcoat or si ngl e-stage fi ni shes can be reduced wi th
l i ght fi nesse sandi ng, hand buffi ng, and pol i shi ng. If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
23 - 82 PAINT WJ
SEATS
TABLE OF CONTENTS
page page
FRONT HEADREST
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
FRONT HEADREST SLEEVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
FRONT SEAT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
FRONT SEAT BACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
FRONT SEAT BACK COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
FRONT SEAT CUSHION/COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86
FRONT SEAT SIDE SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86
SEAT TRACK & RECLINER ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86
SEAT TRACK ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87
REAR HEADREST
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 88
REAR HEADREST RELEASE KNOB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 88
REAR HEADREST FOLDING MECHANISM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 88
REAR HEADREST SLEEVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 89
REAR SEAT BACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 89
REAR SEAT BACK COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 90
REAR SEAT CUSHION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 90
REAR SEAT CUSHION COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91
REAR SEAT CUSHION RELEASE LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91
FOLDING REAR SEAT BACK LATCH HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92
FOLDING REAR SEAT BACK LATCH/HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92
FRONT HEADREST
REMOVAL
(1) Depress head restrai nt rel ease button and l i ft
head restrai nt to ful l up posi ti on.
(2) Usi ng a smal l fl at bl ade, depress tab on ri ght
si de head restrai nt rel ease button and usi ng your
hand, si mul taneousl y press tab on l eft si de head
restrai nt rel ease button (Fi g. 1) and pul l head
restrai nt up to separate from seat back.
INSTALLATION
(1) Posi ti on head restrai nt i n seat back, press tab
on l eft si de head restrai nt rel ease button and push
down head restrai nt to secure.
Fig. 1 Head Restraint
1 - HEAD RESTRAINT
2 - FLAT BLADE
WJ SEATS 23 - 83
FRONT HEADREST SLEEVE
REMOVAL
(1) Remove head restrai nt (Refer to 23 - BODY/
SEATS/FRONT HEADREST - REMOVAL).
(2) Remove seat back cover (Refer to 23 - BODY/
SEATS/FRONT SEAT BACK COVER - REMOVAL).
(3) Remove hog ri ngs attachi ng cushi on pad to
seat back frame (Fi g. 2).
(4) Remove cushi on pad from seat back frame.
(5) Rotate head restrai nt sl eeve 1/4 turn counter-
cl ockwi se to rel ease retai ni ng tab.
(6) Pul l sl eeve from seat back frame (Fi g. 3).
INSTALLATION
(1) Posi ti on sl eeve i n seat back frame.
(2) Rotate head restrai nt sl eeve 1/4 turn cl ockwi se
to engage retai ni ng tab.
(3) I nstal l cushi on pad onto seat back frame.
(4) I nstal l hog ri ngs attachi ng cushi on pad to seat
back frame.
(5) I nstal l seat back cover (Refer to 23 - BODY/
SEATS/FRONT SEAT BACK COVER - I NSTALLATI ON).
(6) I nstal l head restrai nt (Refer to 23 - BODY/
SEATS/FRONT HEADREST - I NSTALLATI ON).
FRONT SEAT
REMOVAL
(1) Move seat to ful l rearward posi ti on.
(2) Remove front bol ts attachi ng seat to fl oor pan
(Fi g. 4).
(3) Move seat to ful l forward posi ti on.
(4) Usi ng a tri m sti ck, pry cover from seat track
(power seat onl y).
(5) Remove rear bol ts attachi ng seat to fl oor pan.
(6) I f equi pped, di sconnect power seat wi re har-
ness connector.
(7) Remove seat from vehi cl e.
Fig. 2 Cushion Pad
1 - HOG RING
2 - SEAT BACK CUSHION PAD
Fig. 3 Head Restraint Sleeve
1 - HEAD RESTRAINT SLEEVE
2 - SEAT BACK FRAME
3 - RETAINING TAB
Fig. 4 Front Bucket Seat
1 - POWER BUCKET SEAT
2 - FLOOR PAN
3 - SEAT TRACK COVER
23 - 84 SEATS WJ
INSTALLATION
(1) Posi ti on seat on fl oor pan.
(2) I f equi pped, connect power seat wi re harness
connector.
(3) I nstal l rear bol ts attachi ng seat to fl oor pan.
(4) I f equi pped, i nstal l cover on seat track.
(6) I nstal l front bol ts attachi ng seat to fl oor pan.
FRONT SEAT BACK
REMOVAL
(2) Remove i nboard bol t attachi ng seat back frame
to seat cushi on frame.
(3) Move seat to ful l forward posi ti on.
(4) Move seat back to ful l recl i ne posi ti on.
(5) Remove screws attachi ng seat si de shi el d to
seat frame.
(6) Di sconnect wi re harness connector from
recl i ner motor, i f equi pped.
(7) From the undersi de of the seat, di sconnect the
wi re harness connector for the power l umber and/or
heated seat, i f equi pped.
(8) Remove outboard bol ts attachi ng recl i ner to
seat cushi on frame.
(9) Route the power l umber and/or heated seat
harness through the seat cushi on cover, i f equi pped.
(10) Separate seat back from seat cushi on.
INSTALLATION
(1) Posi ti on seat back on seat cushi on.
(2) Route the power l umber and heater harness
through the seat cushi on cover, i f equi pped.
(3) I nstal l recl i ner bol ts attachi ng seat back frame
to seat cushi on frame. Ti ghten bol ts to 28 Nm (20 ft.
l bs.) torque.
(4) I nstal l the i nboard bol t attachi ng seat back
frame to seat cushi on frame. Ti ghten bol t to 47Nm
(35 ft.l bs.).
(5) Connect wi re harness connector to recl i ner
motor and/or heated seat, i f equi pped.
(6) From the undersi de of the seat, connect the
power l umber and/or heated seat wi re harness con-
nector to the seat harness, i f equi pped.
(7) I nstal l screws attachi ng seat si de shi el d to seat
frame.
FRONT SEAT BACK COVER
REMOVAL
SEATS/FRONT HEADREST - REMOVAL).
(2) Usi ng a tri m sti ck, careful l y pry head restrai nt
rel ease button caps from the top of seat back.
(3) Remove seat back (Refer to 23 - BODY/SEATS/
FRONT SEAT BACK - REMOVAL).
(4) Di sengage J-strap at base of seat back.
(5) Sl i de hand between the face of the seat back
pad and the cushi on cover and careful l y separate
hook and l oop fastener (Fi g. 5).
(6) Rol l cover upward and di sengage hog ri ngs.
(7) Rol l cover upward to top of seat back.
(8) Separate cover from seat back.
INSTALLATION
(1) Posi ti on cover i nsi de-out at the top of seat
back.
(2) Rol l cover downward.
(3) Engage hog ri ngs.
(4) Al i gn seat back cover wi th hook and l oop fas-
teners and secure.
(5) Rol l cover downward.
(6) Engage J-strap at base of seat back.
(7) I nstal l seat back (Refer to 23 - BODY/SEATS/
FRONT SEAT BACK - I NSTALLATI ON).
NOTE: The taller head restraint release button cap
is positioned on the left hand side and the head
restraint button cap with the hidden button is posi-
tioned on the right hand side.
Fig. 5 Seat Back Cover
1 - SEAT BACK COVER
2 - HOOK AND LOOP FASTENER
3 - SEAT BACK PAD
WJ SEATS 23 - 85
FRONT SEAT (Continued)
(8) Posi ti on head restrai nt rel ease button caps on
head restrai nt sl eeves and press to secure.
SEATS/FRONT HEADREST - I NSTALLATI ON).
FRONT SEAT CUSHION/COVER
REMOVAL
(1) Remove seat from vehi cl e (Refer to 23 - BODY/
SEATS/FRONT SEAT - REMOVAL).
(3) Di sengage J-straps attachi ng cushi on cover to
seat cushi on frame.
(4) Di sengage hog ri ngs attachi ng cushi on cover to
cushi on frame at rear of seat al ong bottom of cushi on
cover (Fi g. 6).
(5) Rol l up edges of cover and route seat functi on
swi tches through access hol e on outboard si de of seat
cushi on, i f equi pped.
(6) Di sengage seat cushi on heater el ement connec-
tor, i f equi pped.
(7) Di sengage hog ri ngs attachi ng cover to cushi on
al ong cover i nsert.
(8) Separate seat cushi on cover from seat cushi on.
INSTALLATION
(1) Posi ti on seat cover on cushi on.
(2) Engage hog ri ngs attachi ng cushi on cover to
cushi on al ong i nsert.
(3) Engage seat cushi on heater el ement connector,
i f equi pped.
(4) Route seat functi on swi tches through access
hol e on outboard si de of seat cushi on, i f equi pped.
(5) Engage J-straps attachi ng cushi on cover to seat
cushi on frame.
cushi on frame.
(8) I nstal l seat (Refer to 23 - BODY/SEATS/
FRONT SEAT - I NSTALLATI ON).
FRONT SEAT SIDE SHIELD
REMOVAL
(1) Remove screws attachi ng si de shi el d to seat
frame.
(2) Di sconnect wi re harness connectors from power
seat and power l umbar swi tches, i f equi pped.
(3) Separate si de shi el d from seat.
INSTALLATION
(1) Posi ti on si de shi el d on seat.
(2) Connect wi re harness connectors to power seat
and power l umbar swi tches, i f equi pped.
(3) I nstal l screws attachi ng si de shi el d to seat
frame.
SEAT TRACK & RECLINER
ASSEMBLY
REMOVAL
(2) Di sengage J-strap at base of seat back.
(3) Rol l seat back cover upward to access bol ts
attachi ng recl i ner to seat back frame.
(4) Remove bol ts attachi ng recl i ner to seat back
frame.
(5) Separate recl i ner from seat back.
INSTALLATION
(1) Posi ti on recl i ner on seat back.
(2) I nstal l bol ts attachi ng recl i ner to seat back
(3) Rol l seat back cover downward.
(4) Engage J-strap at base of seat back.
Fig. 6 Seat Cushion Cover
1 - HOG RING
2 - CUSHION COVER
23 - 86 SEATS WJ
FRONT SEAT BACK COVER (Continued)
SEAT TRACK ADJ USTER
REMOVAL
(1) Remove seat (Refer to 23 - BODY/SEATS/
FRONT SEAT - REMOVAL).
(2) Remove si de shi el d (Refer to 23 - BODY/
SEATS/FRONT SEAT SI DE SHI ELD - REMOVAL).
(3) Remove nuts attachi ng seat track adjuster to
seat cushi on frame (Fi g. 7) and (Fi g. 8). Rol l cushi on
tri m cover up to access the two front nuts.
(4) Di sengage cl i ps attachi ng wi re harness to
adjuster.
(5) Di sengage seat memory modul e connector, i f
equi pped.
(6) Separate seat track from seat cushi on frame.
INSTALLATION
(1) Transfer seat memory modul e, i f equi pped.
(2) Posi ti on seat track on seat cushi on frame.
(3) Route harness through frame and engage cl i ps
attachi ng wi re harness to adjuster.
(4) Engage seat memory modul e connector, i f
equi pped.
(5) I nstal l nuts attachi ng seat track adjuster to
seat cushi on frame. Ti ghten nuts to 28 Nm (20 ft.
l bs.) torque.
(6) I nstal l the si de shi el d (Refer to 23 - BODY/
SEATS/FRONT SEAT SI DE SHI ELD - I NSTALLA-
TI ON).
(7) I nstal l seat (Refer to 23 - BODY/SEATS/
FRONT SEAT - I NSTALLATI ON).
Fig. 7 Seat Track AdjusterPower
1 - BACK PANEL
2 - LUMBAR ASSEMBLY
4 - POWER SEAT TRACK ADJUSTER
5 - POWER RECLINER
7 - SEAT BACK FRAME
Fig. 8 Seat Track Adjuster Manual
1 - MANUAL RECLINER
3 - SEAT BACK FRAME
5 - MANUAL SEAT TRACK ADJUSTER
WJ SEATS 23 - 87
REAR HEADREST
REMOVAL
(1) Depress head rest rel ease button and l i ft head
rest to ful l up posi ti on.
(2) Usi ng a smal l fl at bl ade, depress tab on out-
board si de head rest rel ease button and usi ng your
hand, si mul taneousl y press tab on i nboard si de head
rest rel ease button (Fi g. 9) and pul l head rest up to
separate from seat back.
INSTALLATION
(1) Posi ti on head rest i n seat back, press tab on
i nboard si de head rest rel ease button cap and push
down head restrai nt to secure.
REAR HEADREST RELEASE
KNOB
REMOVAL
(1) Usi ng a razor kni fe or equi val ent, cut the
rel ease knob from the rel ease l ever.
(2) Pul l the rel ease knob from the l ever (Fi g. 10).
INSTALLATION
(1) Posi ti on the rel ease knob on the l ever and
press to snap i n pl ace.
REAR HEADREST FOLDING
MECHANISM
REMOVAL
(1) Remove the head rest (Refer to 23 - BODY/
SEATS/REAR HEADREST - REMOVAL).
(2) Remove fol di ng mechani sm cover (Fi g. 10).
(3) Remove the screws that secure the head rest
bun to the fol di ng mechani sm.
NOTE: The folding release knob is always located
on the outboard side.
INSTALLATION
(1) Posi ti on the head rest bun on the fol di ng mech-
ani sm and i nstal l the screws.
(2) I nstal l the fol di ng mechani sm cover.
(3) I nstal l the head restrai nt (Refer to 23 - BODY/
SEATS/REAR HEADREST - I NSTALLATI ON).
Fig. 9 Head Rest
1 - HEAD RESTRAINT
2 - FLAT BLADE
Fig. 10 Rear Seat Head Rest Folding Mechanism
1 - REAR SEAT HEAD REST FOLDING MECHANISM
2 - RELEASE KNOB
3 - FOLDING MECHANISM COVER
23 - 88 SEATS WJ
REAR HEADREST SLEEVE
REMOVAL
REAR SEAT BACK - REMOVAL).
(2) Remove head rest (Refer to 23 - BODY/SEATS/
REAR HEADREST - REMOVAL).
(3) Remove head rest caps.
(4) Remove seat back cover (Refer to 23 - BODY/
SEATS/REAR SEAT BACK COVER - REMOVAL).
(5) Rotate head rest sl eeve 1/4 turn counter-cl ock-
wi se to rel ease retai ni ng tab.
(6) Pul l sl eeve from seat back frame.
INSTALLATION
(1) Posi ti on sl eeve i n seat back frame.
(2) Rotate head rest sl eeve 1/4 turn cl ockwi se to
engage retai ni ng tab.
(3) I nstal l seat back cover (Refer to 23 - BODY/
SEATS/REAR SEAT BACK COVER - I NSTALLA-
TI ON).
(4) I nstal l head rest caps.
NOTE: The head rest cap with the taller button is
always on the inboard side of the seat back.
(5) I nstal l the head rest (Refer to 23 - BODY/
NOTE: The folding head rest release knob is always
on the outboard side.
(6) I nstal l the seat back (Refer to 23 - BODY/
SEATS/REAR SEAT BACK - I NSTALLATI ON).
REAR SEAT BACK
REMOVAL
(1) Move rear seat cushi ons to forward cargo posi -
ti on.
(2) Remove bol ts attachi ng seatback si de support
bracket to fl oor pan (ri ght si de) (Fi g. 11).
(3) Ti l t seatback forward, and sl i de i t outboard to
detach i t from pi n on center pi vot bracket.
(4) Remove ri ght si de (60%) seatback from vehi cl e.
(5) Remove bol ts attachi ng seatback si de support
bracket and center pi vot bracket to fl oor pan (l eft
si de).
(6) Remove l eft si de (40%) seatback from vehi cl e.
INSTALLATION
(1) Posi ti on l eft si de (40%) seatback i n vehi cl e.
(2) Posi ti on l eft si de support bracket and center
pi vot bracket wi th bol t hol es al i gned and i nstal l
bol ts. Ti ghten bol ts to 28 Nm (20 ft. l bs.) torque.
(3) Posi ti on ri ght si de (60%) seatback i n vehi cl e.
(4) I nstal l seatback onto center pi vot bracket pi n.
Ensure seat back i s properl y engaged on the center
pi vot pi n.
(5) Posi ti on ri ght si de support bracket wi th bol t
hol es al i gned and i nstal l bol ts. Ti ghten bol ts to 28
(6) Return seat cushi ons to seati ng posi ti on.
Fig. 11 Rear Seat Back
1 - SEAT BACK
2 - FLOOR PAN
3 - CENTER PIVOT BRACKET
4 - SIDE SUPPORT BRACKET
WJ SEATS 23 - 89
REAR SEAT BACK COVER
REMOVAL
SEATS/REAR HEADREST - REMOVAL).
(3) Remove head restrai nt caps.
(4) Di sengage J-straps on outboard si de of seat
back.
(5) Di sengage J-straps at base of seat back.
(6) Remove screws attachi ng l atch rel ease handl e
to seat back frame.
(7) Rol l seat back cover upward.
(8) Di sengage hook and l oop fasteners attachi ng
seat back cover to seat back pad (Fi g. 12).
(9) Rol l seat back cover upward and route l atch
rel ease handl e through seat back cover.
(10) Separate seat back cover from seat back.
(11) Separate seat back pad from seat back frame.
INSTALLATION
(1) Posi ti on seat back cover and pad on seat back
frame.
(2) Route l atch rel ease handl e through seat back
cover.
(3) Rol l seat back cover parti al l y downward al i gn-
i ng hol es i n seat back cover for head restrai nt and
l atch rel ease handl e.
(4) Rol l seat back cover downward al i gn and
engage hook and l oop fasteners to seat back pad.
(5) Engage J-straps at base of seat back.
(6) Engage J-straps on outboard si de of seat back.
(7) I nstal l screws attachi ng l atch rel ease handl e to
seat back frame.
REAR SEAT BACK - I NSTALLATI ON).
REAR SEAT CUSHION
REMOVAL
(1) Di sengage seat cushi on at rear by pul l i ng
upward on rel ease strap.
(2) Remove bol ts attachi ng seat cushi on to fl oor
pan (Fi g. 13).
(3) Remove seat cushi on from vehi cl e.
INSTALLATION
(1) Posi ti on seat cushi on i n vehi cl e.
(2) I nstal l bol ts attachi ng seat cushi on to fl oor
pan. Ti ghten bol ts to 11 Nm (8 ft. l bs.) torque.
(3) Lock seat cushi on down by pressi ng fi rml y on
center of cushi on unti l l atch engages.
Fig. 12 Rear Seat Back Cover
1 - SEAT BACK COVER
2 - SEAT BACK PAD
3 - HOOK AND LOOP FASTENER
Fig. 13 Rear Seat Cushion
1 - SEAT CUSHION
2 - FLOOR PAN
23 - 90 SEATS WJ
REAR SEAT CUSHION COVER
REMOVAL
(1) Remove rear seat cushi on (Refer to 23 - BODY/
SEATS/REAR SEAT CUSHI ON - REMOVAL).
(2) From the undersi de of the seat, di sengage
J-straps attachi ng cover to seat cushi on base panel .
(3) Remove push-i n fasteners attachi ng cushi on
cover to seat cushi on base panel (Fi g. 14).
(4) Rol l back cover.
(5) Di sengage hog ri ngs attachi ng cushi on cover to
seat cushi on foam pad.
(6) Separate cushi on cover from seat cushi on foam
pad.
INSTALLATION
(1) Posi ti on cushi on cover on seat cushi on foam
pad.
seat cushi on foam pad.
(3) Al i gn cushi on cover and engage J-straps
attachi ng cushi on cover to seat cushi on base panel .
(4) I nstal l push-i n fasteners attachi ng cushi on
cover to seat cushi on base panel .
(5) I nstal l rear seat cushi on (Refer to 23 - BODY/
SEATS/REAR SEAT CUSHI ON - I NSTALLATI ON).
REAR SEAT CUSHION
RELEASE LATCH
REMOVAL
(1) Unl atch seat and pi vot seat upward.
(2) Di sengage J-strap at seat cushi on base panel .
(3) Rol l back cushi on cover.
(4) Remove screws attachi ng l atch to base panel .
(5) Separate l atch from base panel .
INSTALLATION
(1) Posi ti on l atch on base panel .
(2) I nstal l screws attachi ng l atch to base panel .
(3) Route the cushi on rel ease strap from the l oop
on the l atch through the sl ot i n the tri m cover.
(4) Engage J-strap at seat cushi on base panel .
(5) l atch seat.
FOLDING REAR SEAT BACK
LATCH HANDLE
REMOVAL
(1) Pul l handl e to rel ease l atch.
(2) Remove screws attachi ng rel ease handl e to seat
back frame.
(3) Usi ng a smal l fl at bl ade, di sengage retai ners
securi ng l atch rel ease cabl e housi ng to l atch rel ease
handl e.
(4) Rotate cabl e end unti l barrel end al i gns wi th
key hol e sl ot i n l atch rel ease handl e.
(5) Di sengage cabl e barrel end from rel ease han-
dl e.
(6) Separate l atch rel ease handl e from seat back
(Fi g. 15).
Fig. 14 Push-in Fasteners
1 - CUSHION COVER
2 - SEAT CUSHION BASE PANEL
3 - PUSH-IN FASTENER
Fig. 15 Rear Seat Release Handle
1 - REAR SEAT FOLDING RELEASE HANDLE
WJ SEATS 23 - 91
INSTALLATION
(1) Route cabl e end i nto l atch rel ease handl e.
(2) Rotate cabl e end unti l barrel end al i gns wi th
key hol e sl ot i n l atch rel ease handl e and i nsert i nto
handl e.
(3) Engage retai ners securi ng l atch rel ease cabl e
housi ng to l atch rel ease handl e.
(4) Posi ti on l atch rel ease handl e i n seat back.
Ensure seat back cover i s properl y al i gned.
(5) I nstal l screws attachi ng rel ease handl e to seat
back frame.
FOLDING REAR SEAT BACK
LATCH/HINGE
REMOVAL
(2) Di sengage J-straps on outboard si de of seat
back.
(3) Di sengage rel ease cabl e from l atch.
(4) Remove bol ts attachi ng l atch/hi nge to seat back
frame.
(5) Separate l atch/hi nge from seat back frame.
INSTALLATION
(1) Posi ti on l atch/hi nge on seat back frame.
(2) I nstal l bol ts attachi ng l atch/hi nge to seat back
(3) Engage l atch rel ease cabl e.
(4) Engage J-straps on outboard si de of seat back.
REAR SEAT BACK - I NSTALLATI ON).
23 - 92 SEATS WJ
FOLDING REAR SEAT BACK LATCH HANDLE (Continued)
STATIONARY GLASS
TABLE OF CONTENTS
page page
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93
QUARTER WINDOW
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93
WINDSHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95
DOOR GLASS
REMOVAL
(1) Remove door tri m panel .
(2) Remove waterdam.
(3) Remove i nner bel t weatherstri p.
(4) Remove bol t attachi ng bottom of rear gl ass run
channel to door.
(5) Pul l run channel downward and separate from
door.
(6) Remove screws attachi ng stati onary door gl ass
frame to door (Fi g. 1) and (Fi g. 2).
(7) Separate stati onary door gl ass from door.
INSTALLATION
(1) Posi ti on stati onary door gl ass i n door.
(2) I nstal l screws attachi ng stati onary door gl ass
frame to door.
(3) I nstal l gl ass run channel .
(4) I nstal l i nner bel t weatherstri p.
(5) I nstal l waterdam.
(6) I nstal l door tri m panel .
QUARTER WINDOW
REMOVAL
(1) Cut urethane bondi ng from around quarter
wi ndow gl ass usi ng a sui tabl e sharp col d kni fe. A
pneumati c cutti ng devi ce can be used i f avai l abl e.
(2) Separate gl ass from vehi cl e.
INSTALLATION
CAUTION: Open a window before installing glass.
This will avoid pressurizing the passenger compart-
ment. If a door or liftgate is slammed before ure-
thane is cured, water leaks can result.
The wi ndow openi ng fence shoul d be cl eaned of ol d
urethane bondi ng materi al .
(1) Cl ean i nsi de of gl ass wi th Mopar Gl ass Cl eaner
and l i nt-free cl oth.
(2) Appl y PVC (vi nyl ) pri mer 25 mm (1 i n.) wi de
around edge of gl ass. Wi pe wi th cl ean/dry l i nt-free
cl oth.
Fig. 1 Stationary Door Glass
1 - DOOR
2 - STATIONARY DOOR GLASS
Fig. 2 Stationary Door Glass
1 - STATIONARY DOOR GLASS
2 - DOOR
WJ STATIONARY GLASS 23 - 93
(3) Appl y fence pri mer around edge of fence. Al l ow
at l east ei ghteen mi nutes dryi ng ti me.
(4) Appl y a 10 mm (0.4 i n.) bead of urethane
around wi ndow vi nyl border l ocati on.
(5)
Posi ti on gl ass i nto wi ndow openi ng and l ock cl i ps
i nto pl ace (Fi g. 3).
WINDSHIELD
REMOVAL
(1) Remove i nsi de rear vi ew mi rror.
(2) Remove cowl cover.
(3) Remove screws attachi ng wi ndshi el d si de mol d-
i ng to A-pi l l ar (Fi g. 4).
(4) Remove upper wi ndshi el d mol di ng.
(5) Cut urethane bondi ng from around wi ndshi el d
usi ng a sui tabl e sharp col d kni fe. A pneumati c cut-
ti ng devi ce can be used i f avai l abl e (Fi g. 5).
(6) Separate wi ndshi el d from vehi cl e.
Fig. 3 Quarter Window Glass
1 - CLIP
2 - ROOF PANEL
3 - QUARTER WINDOW GLASS
Fig. 4 Windshield
1 - SIDE MOLDING
2 - SUPPORT SPACER
3 - UPPER MOLDING
4 - SIDE MOLDING
5 - ROOF PANEL
6 - SUPPORT SPACER
7 - BLOCKER
8 - STUD
9 - SUPPORT SPACER
10 - WINDSHIELD
11 - ALIGNMENT SPACER
23 - 94 STATIONARY GLASS WJ
QUARTER WINDOW (Continued)
INSTALLATION
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
CAUTION: Open a window before installing wind-
shield. This will avoid pressurizing the passenger
compartment. If a door or liftgate is slammed before
urethane is cured, water leaks can result.
The wi ndshi el d fence shoul d be cl eaned of ol d ure-
thane bondi ng materi al . Support spacers shoul d be
cl eaned and properl y i nstal l ed on wel d studs or
repai r screws at bottom of wi ndshi el d openi ng.
(1) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng. Posi ti on gl ass i n the center of the openi ng
agai nst the support spacers. Mark the gl ass at the sup-
port spacers wi th a grease penci l or maski ng tape and
i nk pen to use as a reference for i nstal l ati on. Remove
repl acement wi ndshi el d from wi ndshi el d openi ng (Fi g. 6).
(2) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 7).
(3) Cl ean i nsi de of wi ndshi el d wi th Mopar Gl ass
Cl eaner and l i nt-free cl oth.
(4) Appl y cl ear gl ass pri mer 25 mm (1 i n.) wi de
around edge of wi ndshi el d. Wi pe wi th cl ean/dry l i nt-
free cl oth.
(5) Appl y bl ack-out pri mer 15 mm (.75 i n.) wi de on
top and si des of wi ndshi el d and 25 mm (1 i n.) on bottom
of wi ndshi el d. Al l ow at l east three mi nutes dryi ng ti me.
(6) Posi ti on wi ndshi el d spacers on l ower fence
above support spacers at the edge of the wi ndshi el d
openi ng (Fi g. 4).
(7) Appl y a 10 mm (0.4 i n.) bead of urethane around
peri meter of wi ndshi el d al ong the i nsi de of the mol d-
i ngs. Appl y two beads al ong the bottom edge.
(8) I nstal l upper mol di ng onto wi ndshi el d.
(9) Appl y fence pri mer around the peri meter of the
wi ndshi el d openi ng fence. Al l ow at l east 18 mi nutes
dryi ng ti me.
(10) Wi th ai d of a hel per, posi ti on wi ndshi el d over
wi ndshi el d openi ng. Al i gn reference marks at bottom
of wi ndshi el d to support spacers.
(11) Sl owl y l ower wi ndshi el d gl ass to wi ndshi el d
openi ng fence. Gui de top mol di ng i nto proper posi ti on
i f necessary. Push wi ndshi el d i nward to fence spacers
at bottom and unti l top mol di ng i s fl ush to roof l i ne.
(12) Cl ean excess urethane from exteri or wi th
Mopar Super Cl ean or equi val ent.
(13) I nstal l wi ndshi el d si de mol di ngs.
(14) I nstal l cowl cover and wi pers.
(15) I nstal l i nsi de rear vi ew mi rror.
(16) After urethane has cured, water test wi nd-
shi el d to veri fy repai r.
Fig. 6 Center Windshield and Mark at Support Spacers
1 - A-PILLAR
2 - WINDSHIELD
3 - MARKS
4 - SUPPORT SPACER
5 - COWL
Fig. 7 Work Surface Set up and Molding Installation
1 - WINDSHIELD AND MOULDINGS
2 - URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM EDGE
3 - BLOCKS
Fig. 5 Cut Urethane Around WindshieldTypical
1 - COLD KNIFE
2 - WINDSHIELD
WJ STATIONARY GLASS 23 - 95
WINDSHIELD (Continued)
SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 96
DIAGNOSIS AND TESTING - SUNROOF . . . . . . 96
DRAIN TUBE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 100
CONTROL MODULE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101
DRIVE MOTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101
WIND DEFLECTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
GLASS PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103
ADJUSTMENTS
ADJUSTMENTS - FIT . . . . . . . . . . . . . . . . . 103
ADJUSTMENT - TIMING . . . . . . . . . . . . . . . 103
SUNSHADE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103
HOUSING ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 104
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sunroof features a power sl i di ng gl ass panel
and a sunshade whi ch can be manual l y posi ti oned
anywhere al ong i ts travel , rearward of gl ass panel
front edge.
The sunroof i s el ectri cal l y operated from a swi tch
l ocated on the mi ni overhead consol e. To operate the
sunroof the i gni ti on swi tch must be i n the On/Run
posi ti on. The sunroof has both manual and Express
Open modes of operati on when openi ng. To open the
sunroof i n the Express Open mode, the swi tch i s
pressed rearward for l ess than 1 second. Thi s causes
the sunroof gl ass to automati cal l y retract and stop at
a posi ti on sl i ghtl y forward of ful l open that reduces
l ow speed wi nd buffeti ng. The sunroof can al so be
opened manual l y by pressi ng and hol di ng the swi tch
rearward. Once the swi tch i s hel d reward for more
than 1 second, the gl ass wi l l retract i n the manual
mode. Rel easi ng the swi tch at any ti me duri ng travel
wi l l cause the sunroof to stop at the current posi ti on.
To cl ose the sunroof from an open posi ti on, the
swi tch must be pushed forward and hel d unti l the
sunroof gl ass comes to a compl ete stop. Rel easi ng the
swi tch at any ti me i n thi s mode wi l l cause the sun-
roof to stop at the current posi ti on.
To vent the sunroof from the cl osed posi ti on, the
swi tch i s pushed forward and hel d. Rel easi ng the
swi tch at any ti me duri ng travel wi l l cause the sun-
roof to stop at the current vent posi ti on. To reach the
ful l y vented posi ti on, conti nue to hol d the swi tch for-
ward unti l vent moti on stops. To cl ose the sunroof
from the vent posi ti on, push and hol d the swi tch
rearward unti l the gl ass comes to a compl ete stop.
DIAGNOSIS AND TESTING - SUNROOF
CAUTION: The sunroof motor is only to be powered
through the vehicle battery and vehicle wire har-
ness. Applying power to the sunroof motor leads
will cause failure of the sunroof control unit.
Before begi nni ng sunroof di agnosti cs veri fy that al l
other power accessori es are i n proper operati ng con-
di ti on. Refer to Sunroof Di agnosti c Chart for possi bl e
causes. I f not, a common el ectri cal probl em may
exi st. Refer to Group 8W, Wi ri ng Di agrams, of thi s
publ i cati on for ci rcui t, spl i ce and component descri p-
ti ons. Check the condi ti on of the ci rcui t protecti on
(20 amp hi gh current fuse (battery feed) l ocated i n
the Power Di stri buti on Center (PDC). Check the
cover of the PDC for l ocati on of the fuse. Check for
correct operati on of the sunroof del ay rel ay. I nspect
al l wi ri ng connector pi ns for proper engagement and
conti nui ty. Check for battery vol tage at battery and
i gni ti on pi ns of the power sunroof express modul e
wi ri ng connector. Refer to Group 8W, Wi ri ng Di a-
grams, for ci rcui t i nformati on. The control l er wi l l not
operate at l ess than 10 vol ts. Check the ground at
the sunroof express modul e.
Before begi nni ng di agnosi s for wi nd noi se or water
l eaks, veri fy that the probl em was not caused by
23 - 96 SUNROOF WJ
rel easi ng the control swi tch before the sunroof was
ful l y cl osed. The sunroof modul e has a water-man-
agement system. Duri ng washi ng hi gh-pressure
water may be forced between the gl ass panel seal
and the roof openi ng. Normal l y thi s water wi l l drai n.
However, when some type of dryi ng bl ower system i s
used, l i ke those found i n automati c car washes, the
water may not have a chance to drai n before the
bl ower forces ai r between the seal and the roof open-
i ng. Thi s causes the water to bl ow over the edge of
the modul e and onto the headl i ni ng.
Refer to (Fi g. 1) Sunroof Assembl y for expl oded
vi ew of the sunroof.
SYMPTOM STEP POSSIBLE CAUSE
Sunroof squeaks when
opening/closing.
1 Identify if the cause is a seal squeak. If seal is worn, replace the
seal.
2 Check seal compression for uniformity in opening, If not uniform,
glass is not centered in opening.
3 Re-center glass by repositioning module in opening.
4 Identify if mechanism squeaks.
5 Check for lubrication, re-lube if necessary.
6 Check for dirt/debris in tracks, clean and re-lube.
7 Identify if motor squeaks, replace the motor.
Water leaks into the vehicle. 1 Check for a good connection at the drain tubes, re-connect where
needed.
2 Check for plugged/pinched hoses throughout.
3 Adjust the glass panel. Refer to glass panel adjustments in this
section.
4 Check seal for wear/damage, replace glass as necessary.
Motor inoperative. 1 Check connectors at the motor, switch, control module and power
source.
2 Check for defective control module, replace if necessary.
3 Replace the motor.
Motor noise when opening/
closing.
1 Identify if motor noise, replace motor.
2 Insure noise is from the motor and not cables, (cable ratcheting).
Grinding noise when opening/
closing.
1 Identify if the motor is grinding, replace motor.
(Mechanism noise, scraping.) 2 Check for lubrication in tracks and mechanism, re-lube if
necessary.
3 Check for dirt/debris in tracks, clean and re-lube.
(Cable ratcheting.) 4 Cables ratchet at the motor pinion; mechanism jammed, fix
mechanism and replace cables and motor bracket.
Wind noise when sunroof fully
closed.
1 Check seal compression for uniformity in opening, If not uniform,
glass is not centered in opening.
2 Glass not adjusted flush to roof. Refer to glass panel adjustments
in this section.
3 Mechanism not fully closed.
A) Motor out of time, re-time motor/mechanism. Refer to glass
panel adjustments in this section.
B) Cable ratcheting, replace cables and motor bracket.
4 Seal worn, replace glass.
Sunroof will not open/close. 1 Check switch and switch connection.
WJ SUNROOF 23 - 97
SUNROOF (Continued)
SYMPTOM STEP POSSIBLE CAUSE
2 Check mechanism for binding (result of forcing the glass closed/
broken components).
3 See motor inoperative above.
Sunroof rattles, anytime,
closed/open.
1 Loose attachment screws (module), re-fasten and adjust module.
2 Loose glass panel, re-fasten and adjust glass panel.
3 Loose drain channel, refasten/secure to repair.
4 Broken mechanism, replace the sunroof assembly module.
5 Mechanism not fully closed.
A) Motor out of time, re-time motor/mechanism. Refer to glass
panel adjustments in this section.
B) Cable ratcheting, replace cables and motor bracket.
6 Check for sunshade out of track or for sunshade broken slide
block.
7 Loose wind deflector. Replace if broken.
8 Loose wind deflector spring. Replace if loose.
Sunshade squeaks/rattles,
anytime.
1 Sunshade slide blocks out of track(s), put back in tracks.
-OR- 2 Missing felt pads on the drain channel, add felt pads.
Sunshade force high/low or
binding during operation.
3 Felt on the drain channel rolling off, (sunshade rubs on adhesive),
replace felt pads.
4 Slide block binding in sunshade, free-up slide block by actuating a
couple times, grease slide block(s) and spring(s).
5 Broken slide block in sunshade, replace slide block.
6 Slide block spring missing, replace spring and slide block.
7 Sunshade interference with drain channel or trim welt, replace trim
welt and/or sunshade.
Motor/sunroof control module
operation: Auto open doesnt
work, or doesnt stop at closed
position.
1 After power disconnect or replacement, sunroof module has to
complete on full cycle to program the sunroof control module. Full
cycle = close > open > close > vent > close.
23 - 98 SUNROOF WJ
SUNROOF (Continued)
Fig. 1 Sunroof Assembly
1 - SUNSHADE
2 - EXPRESS MODULE
3 - DRIVE MOTOR
4 - FRAME ASSEMBLY
5 - WIND DEFLECTOR
6 - GLASS PANEL
7 - DRAIN CHANNEL
WJ SUNROOF 23 - 99
SUNROOF (Continued)
DRAIN TUBE
REMOVAL
(1) Remove the headl i ner. (Refer to 23 - BODY/I N-
TERI OR/HEADLI NER - REMOVAL)
(2) Di sengage cl amps attachi ng drai n tube to sun-
roof (Fi g. 2).
(3) Tape the end of the ol d drai n tube to the new
drai n tube. Ensure that the tape bui l d up on the tube
ends i s not excessi ve.
(4) Remove front/rear tri m panel s as necessary to
di sengage cl amps securi ng drai n tube to body.
(5) Remove the drai n tube pl ug from the undersi de
of the vehi cl e.
(6) From the undersi de of the vehi cl e careful l y,
pul l /route the drai n tube through the body panel .
Appl yi ng a soapy water sol uti on to the new tube may
ai d i n thi s procedure.
INSTALLATION
(1) I nstal l the pl ug adapter to the bottom of the
drai n tube.
(2) Engage cl amps securi ng drai n tube to body
(Fi g. 2).
(3) I nstal l front/rear tri m panel s as necessary.
(4) I nstal l drai n tube to sunroof and engage cl amp.
(5) I nstal l the headl i ner. (Refer to 23 - BODY/I N-
TERI OR/HEADLI NER - I NSTALLATI ON)
Fig. 2 Sunroof Drain Hose Routing
1 - DRAIN HOSE
2 - CLAMPS
3 - PLUG
4 - FLOOR
5 - CLAMPS
6 - DRAIN HOSE
23 - 100 SUNROOF WJ
CONTROL MODULE
REMOVAL
(1) Move the gl ass panel to the ful l y cl osed posi -
ti on.
(2) Remove the A-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - REMOVAL)
(3) Remove the sun vi sors. (Refer to 23 - BODY/
I NTERI OR/SUN VI SOR - REMOVAL)
(4) Remove the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - REMOVAL)
(5) Lower headl i ner as necessary to gai n access to
the sunroof express modul e.
(6) Di sconnect the express modul e wi re harness
connectors.
(7) Remove express modul e screw.
(8) Remove express modul e from the keyway by
sl i di ng modul e towards the center of the vehi cl e.
INSTALLATION
(1) I nsert sunroof express modul e i n the keyway
l ocated i n the sunroof modul e and sl i de the modul e
outward to l ock i t i nto posi ti on.
(2) I nstal l the sunroof express modul e screw.
(3) Connect the wi re connectors to the sunroof
express modul e.
(4) I nstal l the headl i ner i nto posi ti on.
(5) I nstal l the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - I NSTALLA-
TI ON)
(6) I nstal l the sun vi sors. (Refer to 23 - BODY/I N-
TERI OR/SUN VI SOR - I NSTALLATI ON)
(7) I nstal l the A-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - I NSTALLATI ON)
(8) Test sunroof operati on, adjust i f necessary.
(Refer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS)
DRIVE MOTOR
REMOVAL
CAUTION: The sunroof system is timed from the
factory so that the motor shuts off automatically
when the sunroof window reaches a certain posi-
tion. Extreme care must be taken when removing
the motor, timing may be thrown off causing possi-
ble damage to the sunroof system. Anytime the
motor is removed from the sunroof assembly the
sunroof glass panel must be in the FULLY CLOSED
POSITION or the unit will be out of timing. The drive
motor cannot be reset to the park position after
being removed.
CAUTION: The sunroof motor should only be pow-
ered through the vehicle battery and sunroof wire
harness. Applying power to the sunroof motor leads
will cause failure of the control module.
(1) Move gl ass panel to the ful l y cl osed posi ti on.
(2) Remove the A-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - REMOVAL)
(3) Remove the B-pi l l ar upper tri m. (Refer to 23 -
REMOVAL)
(4) Remove the C-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/C-PI LLAR TRI M - REMOVAL)
(5) Remove the D-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/D-PI LLAR TRI M - REMOVAL)
(6) Remove the sunvi sors. (Refer to 23 - BODY/I N-
TERI OR/SUN VI SOR - REMOVAL)
(7) Remove the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - REMOVAL)
(8) Di sconnect the control swi tch wi re connector.
(9) Remove headl i ner as necessary to gai n access
to sunroof dri ve motor. Refer to Headl i ner Removal
and I nstal l ati on for proper procedures.
(10) Di sconnect the dri ve motor wi re harness con-
nectors (Fi g. 3).
(11) Remove dri ve motor fasteners and remove
motor from the sunroof housi ng.
INSTALLATION
(1) Ensure that the wi ndow i s i n the ful l y cl osed
posi ti on before mounti ng the motor. I f motor fai l s
wi th the wi ndow i n the open posi ti on the sunroof
gl ass panel ti mi ng wi l l have to be ti med. The new
motor comes i n the ful l y cl osed posi ti on and wi th a
gage for setti ng cabl e ti mi ng. (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - ADJUSTMENTS - TI M-
I NG)
(2) Pl ace dri ve motor i nto posi ti on on the sunroof
housi ng and i nstal l fasteners.
Fig. 3 Sunroof Drive Motor and Express Module
1 - EXPRESS MODULE
2 - SCREW
WJ SUNROOF 23 - 101
(3) Connect express modul e, dri ve motor, and con-
trol swi tch wi re connectors.
(4) Set headl i ner i nto posi ti on.
(5) Test sunroof operati on, adjust as necessary.
(Refer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS)
(6) Fi ni sh i nstal l i ng the headl i ner.
(7) Connect the control swi tch wi re connector.
(8) I nstal l the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - I NSTALLA-
TI ON)
(9) I nstal l the sunvi sors. (Refer to 23 - BODY/I N-
TERI OR/SUN VI SOR - I NSTALLATI ON)
(10) I nstal l the D-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/D-PI LLAR TRI M - I NSTALLATI ON)
(11) I nstal l the C-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/C-PI LLAR TRI M - I NSTALLATI ON)
(12) I nstal l the B-pi l l ar upper tri m. (Refer to 23 -
I NSTALLATI ON)
(13) I nstal l the A-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - I NSTALLATI ON)
WIND DEFLECTOR
REMOVAL
(1) Open sunroof gl ass panel .
(2) Push down one corner of the wi nd defl ector and
l et the other corner ri se up (Fi g. 4).
(3) Push the l ow corner towards the opposi te si de
of the vehi cl e unti l tab on sunshade cl ears the body.
Then rai se the corner up.
(4) Repeat the procedure to the other corner.
(5) Li ft wi nd defl ector to 90% of the way.
(6) Push the attachi ng ends of the defl ector to the
rear of the vehi cl e to di sengage the defl ector.
INSTALLATION
(1) Pl ace wi nd defl ector at 90% i n the verti cal posi -
ti on to the sunroof. Wi th the sunroof open.
(2) Push ends of the defl ector towards the front of
the vehi cl e to engage ends.
(3) Lower wi nd defl ector to normal posi ti on.
(4) Push one corner to the opposi te si de of the
vehi cl e unti l tab cl ears vehi cl e body and l ower defl ec-
tor for that corner.
(5) Push the si de that was just i nstal l ed com-
pl etel y down.
(6) Push the opposi te corner cross vehi cl e unti l tab
cl ears the body. Then l ower defl ector to posi ti on.
(7) Test sunroof operati on.
GLASS PANEL
REMOVAL
(1) Sl i de sunshade rearward to the open posi ti on.
(2) Move the gl ass panel to the ful l y cl osed posi -
ti on.
(3) Remove the four attachi ng screws (Fi g. 5).
(4) Li ft off gl ass panel and remove from vehi cl e.
Fig. 4 Wind Deflector
1 - WIND DEFLECTOR
2 - TAB
Fig. 5 Sunroof Glass Panel Removal
1 - ATTACHING SCREW
23 - 102 SUNROOF WJ
DRIVE MOTOR (Continued)
INSTALLATION
NOTE: Sunroof glass must be set in place and
attached as close as possible to flush with the roof
surface. For wind noise reasons, care must be
taken to ensure that the glass is not remounted
either a) Overflush to the roof surface at the front
edge of the glass, or b) Underflush to the roof sur-
face at the rear edge of the glass.
(1) Posi ti on gl ass panel i n to openi ng.
(2) Start the four attachi ng screws.
(3) Ti ghten screws.
(4) Veri fy sunroof operati on and al i gnment. Check
fi t and adjust as necessary. (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - ADJUSTMENTS - FI T)
ADJ USTMENTS
ADJUSTMENTS - FIT
(1) Move the sunshade rearward to the open posi -
ti on.
(2) Move the sunroof gl ass panel to the ful l y cl osed
posi ti on.
(3) Loosen the forward screws on each si de enough
to make the front adjustment.
(4) Adjust the front of the sunroof gl ass panel 1
mm (1/32 i nch) bel ow the top surface of the roof
panel .
(5) Ti ghten the front two screws.
(6) Loosen the rear screws on each si de enough to
make the rear adjustment.
(7) Adjust the rear of the sunroof gl ass panel 1
mm (1/32 i nch) above the top surface of the roof
panel .
(8) Ti ghten the rear two screws.
(9) Check for proper fi t. I f not OK, repeat gl ass
panel adjustment.
ADJUSTMENT - TIMING
NOTE: A gage comes with the new motor.
(1) I f the gl ass panel was not i n the ful l y cl osed
posi ti on, when the motor was removed, the sunroof
gl ass panel needs to be ti med, before the new motor
i s i nstal l ed.
(2) Remove sunroof gl ass panel .
(3) Set gage i nto the track near the rear of the
openi ng between the dri ver sl i de and the bracket
(Fi g. 6).
(4) Move the dri ver sl i de forward or aft to get
proper setti ng.
(5) Repeat the operati on on the other si de.
(6) I nstal l dri ve motor.
SUNSHADE
REMOVAL
(1) Open sunroof approxi matel y 50% of the way.
(2) Push sunshade down unti l tabs cl ear gl ass.
(3) Move sunshade forward of gl ass panel .
(4) Compress the spri ng l oaded pl ungers hol di ng
the gui de bl ocks i n the track.
(5) Sl i de the sunshade forward whi l e l i fti ng the
front through the openi ng unti l the rear gui de bl ocks
are accessi bl e.
CAUTION: Use care not to crease the sunshade
when removing or installing.
(6) Di sengage rear gui de bl ocks from track.
INSTALLATION
(1) I nstal l the sunshade from outsi de of the vehi cl e
wi th the sunroof ful l y open.
(2) Put rear gui de bl ocks i nto sunshade gui de
track.
(3) Push sunshade back and down through the
sunroof openi ng.
(4) Usi ng a fl at bl ade tool , put front gui de bl ocks
i nto the sunshade track. By pushi ng the bl ock
towards the center of the vehi cl e.
(5) Move the gl ass panel to approxi matel y hal fway
to the ful l y cl osed posi ti on.
Fig. 6 Sunroof Drive Cable Timing
1 - MOVE DRIVER SLIDE FORWARD/AFT
2 - GAGE
WJ SUNROOF 23 - 103
GLASS PANEL (Continued)
(6) Push sunshade down unti l the sunshade cl ears
the gl ass then move sunshade rearward behi nd the
gl ass panel .
HOUSING ASSEMBLY
REMOVAL
(1) Move gl ass panel to the ful l y cl osed posi ti on.
(3) Recl i ne both front seats.
(4) Remove headl i ner. (Refer to 23 - BODY/I NTE-
RI OR/HEADLI NER - REMOVAL)
(5) Di sconnect the drai n tubes from sunroof hous-
i ng (Fi g. 7).
(6) Loosen fasteners attachi ng sunroof housi ng
assembl y.
(7) Wi th the ai d of a hel per, remove fasteners
attachi ng sunroof housi ng assembl y to roof panel .
INSTALLATION
(1) Rai se the sunroof housi ng assembl y and gui de
i nto posi ti on and start fasteners (Fi g. 7).
(2) Ti ghten the fasteners, front to rear, attachi ng
the sunroof modul e to roof panel . Ti ghten the fasten-
ers, front to rear, to 11 Nm (97 i n. l bs.) torque.
(3) Connect the drai n tubes to the sunroof housi ng.
(4) Set headl i ner i nto posi ti on.
(5) Connect express modul e, dri ve motor, and con-
trol swi tch wi re connectors.
(6) Test sunroof operati on, adjust as necessary.
(7) Fi ni sh i nstal l i ng the headl i ner. (Refer to 23 -
BODY/I NTERI OR/HEADLI NER - I NSTALLATI ON)
(8) Connect battery negati ve cabl e.
Fig. 7 SUNROOF ASSEMBLY
1 - ROOF
2 - DRAIN HOSE
3 - CLAMP
4 - SUNROOF ASSEMBLY
5 - CLAMP
6 - DRAIN HOSE
23 - 104 SUNROOF WJ
SUNSHADE (Continued)
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
B-PILLAR DOOR SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 105
COWL WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
FDR OUTER BELT WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
FLIP-UP GLASS WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
FRONT DOOR 2ND WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
FRONT DOOR WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 108
HOOD SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 108
LIFTGATE OPENING WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
RDR INNER BELT WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
RDR OUTER BELT WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
RDR SECONDARY WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110
REAR DOOR WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110
ROOF RAIL WEATHERSTRIP / RETAINR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110
B-PILLAR DOOR SEAL
REMOVAL
The B-pi l l ar seal i s attached to the rear door wi th
adhesi ve tape.
(1) Peel seal from the door (Fi g. 1).
INSTALLATION
(1) Cl ean contact area wi th Mopar Super Kl een
or equi val ent.
(2) Remove carri er from seal .
(3) Al i gn seal on door and press i nto pl ace.
Fig. 1 B-Pillar Seal
1 - B-PILLAR SEAL
WJ WEATHERSTRIP/SEALS 23 - 105
COWL WEATHERSTRIP
REMOVAL
(1) Rai se hood.
(2) Pul l cowl pl enum seal from cowl .
(3) Separate cowl pl enum seal from cowl (Fi g. 2).
INSTALLATION
(1) Posi ti on cowl pl enum seal on cowl .
(2) Press cowl pl enum seal to seat.
FRONT DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(1) Remove i nner bel t weatherstri p (Refer to 23 -
WEATHERSTRI P - REMOVAL).
(2) Remove outer bel t weatherstri p (Refer to 23 -
WEATHERSTRI P - REMOVAL).
(3) Grasp seal from upper run channel corner and
fi rml y pul l weatherstri p from fl ange and run channel
(Fi g. 3).
INSTALLATION
NOTE: Soapy water may be used to aid in installation.
(1) Remove front door speaker.
(2) Posi ti on weatherstri p on fl ange al i gni ng each
corner.
(3) Press weatherstri p i nto posi ti on.
(4) Careful l y move door gl ass for and aft and press
weatherstri p i nto gl ass run channel s.
(5) I nstal l front door speaker.
(6) I nstal l outer bel t weatherstri p (Refer to 23 -
(7) I nstal l i nner bel t weatherstri p (Refer to 23 -
FRONT DOOR INNER BELT
WEATHERSTRIP
REMOVAL
(1) Remove door tri m panel (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - REMOVAL).
(2) Usi ng a tri m sti ck or other sui tabl e devi ce,
careful l y pry up i nner edge of seal (Fi g. 4).
(3) Grasp the edge of the seal and pul l upward to
remove seal from door fl ange.
Fig. 2 Cowl Plenum Seal
1 - PLENUM SEAL
Fig. 3 Front Door Glass Run Channel Weatherstrip
1 - GLASS RUN CHANNEL WEATHERSTRIP
2 - DOOR
Fig. 4 Inner/Outer Belt Weather Strip
1 - INNER BELT WEATHERSTRIP
2 - OUTER BELT WEATHERSTRIP
23 - 106 WEATHERSTRIP/SEALS WJ
INSTALLATION
(1) Posi ti on the seal on the door fl ange.
(2) Fi rml y press downward to seat seal on the door
fl ange.
(3) I nstal l the door tri m panel (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - I NSTALLATI ON).
FDR OUTER BELT
WEATHERSTRIP
REMOVAL
(1) Lower the door gl ass.
(2) Remove the screw from the i nner door panel
attachi ng the seal to outer door panel (Fi g. 4).
(3) Pul l the seal rearward to rel ease from the si de
vi ew mi rror bezel .
(4) Li ft seal and separate from door panel .
INSTALLATION
(1) Posi ti on seal on the door panel .
(2) Push the seal forward to i nstal l under the si de
vi ew mi rror bezel .
(3) I nstal l the screw from the i nner door panel
attachi ng the seal to outer door panel .
(4) Rai se the door gl ass.
FLIP-UP GLASS
WEATHERSTRIP
REMOVAL
(1) Rai se fl i p up gl ass.
(2) Careful l y pul l the seal away from the fl ange
around the edge of the gl ass openi ng (Fi g. 5).
(3) Remove i t from the vehi cl e.
INSTALLATION
(1) Thoroughl y cl ean the surface of the fl ange as
necessary.
(2) Al i gn the weather stri p seal wi th the wi ndow
openi ng corners.
(3) Fi rml y seat the seal around the enti re fl ange.
But the seal ends together and smooth out any
remai ni ng l ength.
(4) Weatherstri p break shoul d be 120mm l eft of l atch
openi ng. Cut any surpl us from non-pl ug end onl y.
FRONT DOOR 2ND
WEATHERSTRIP
REMOVAL
The front door secondary weatherstri p i s attached
to the door shutface wi th push-i n fasteners.
(1) Open door.
(2) Usi ng a tri m panel removal tool , remove
push-i n fasteners attachi ng secondary weatherstri p
to door shutface (Fi g. 6).
(3) Separate secondary weatherstri p from door.
INSTALLATION
(1) Cl ean contact area as necessary.
(2) Posi ti on secondary weatherstri p on door shut-
face.
(3) I nstal l push-i n fasteners attachi ng secondary
weatherstri p to door shutface.
Fig. 5 Flip-up Glass Weatherstrip
1 - WEATHERSTRIP
2 - LIFTGATE W/FLIP-UP GLASS
Fig. 6 Front Door Secondary Weatherstrip
1 - SECONDARY WEATHERSTRIP
FRONT DOOR INNER BELT WEATHERSTRIP (Continued)
FRONT DOOR WEATHERSTRIP
REMOVAL
(1) Remove A-pi l l ar tri m (Refer to 23 - BODY/I N-
TERI OR/A-PI LLAR TRI M - REMOVAL).
(2) Remove B-pi l l ar upper tri m (Refer to 23 -
REMOVAL).
(3) Remove B-pi l l ar l ower tri m (Refer to 23 -
REMOVAL).
(4) Pul l weatherstri p from door openi ng fl ange.
INSTALLATION
(1) Posi ti on weatherstri p at corners.
(2) Move upward and around edge of door openi ng
seati ng weatherstri p onto fl ange (Fi g. 7).
(3) Engage connector pl ug wi th each end of weath-
erstri p at bottom of door openi ng.
(4) I nstal l B-pi l l ar l ower tri m (Refer to 23 - BODY/
I NTERI OR/B-PI LLAR LOWER TRI M - I NSTALLA-
TI ON).
(5) I nstal l B-pi l l ar upper tri m (Refer to 23 -
I NSTALLATI ON).
(6) I nstal l A-pi l l ar tri m (Refer to 23 - BODY/I NTE-
RI OR/A-PI LLAR TRI M - I NSTALLATI ON).
HOOD SEAL
REMOVAL
(1) Rai se hood.
(2) Pul l hood seal from upper radi ator crossmem-
ber.
(3) Separate seal from upper radi ator crossmember
(Fi g. 8).
INSTALLATION
(1) Posi ti on seal on upper radi ator crossmember.
(2) Press seal onto upper radi ator crossmember to
seat.
Fig. 7 Door Opening
1 - REAR DOOR OPENING WEATHERSTRIP
2 - FRONT DOOR OPENING WEATHERSTRIP
Fig. 8 Hood Seal
1 - HOOD SEAL
LIFTGATE OPENING
WEATHERSTRIP
REMOVAL
(1) Pul l seal away from fl ange around edge of l i ft-
gate openi ng.
(2) Separate weatherstri p from openi ng (Fi g. 9).
(3) Cl ean weatherstri p fl ange as necessary.
INSTALLATION
(1) Posi ti on weatherstri p i n openi ng wi th l eft end
of seal at openi ng centerl i ne.
(2) Press weatherstri p onto fl ange i n a cl ockwi se
di recti on.
(3) Center and butt weatherstri p ends together at
centerl i ne.
(4) I f necessary, cut surpl us from weatherstri p
(non-pl ug end onl y).
RDR INNER BELT
WEATHERSTRIP
REMOVAL
(1) Remove door tri m panel (Refer to 23 - BODY/
DOORS - REAR/TRI M PANEL - REMOVAL).
(2) Usi ng a tri m sti ck, careful l y pry rear i nner
edge of i nner bel t weatherstri p upward.
(3) Grasp weatherstri p and pul l upward to sepa-
rate from door fl ange (Fi g. 10).
INSTALLATION
(1) Posi ti on weatherstri p on door fl ange.
(2) Fi rml y press downward to seat weatherstri p on
fl ange.
(3) I nstal l tri m panel (Refer to 23 - BODY/DOORS
- REAR/TRI M PANEL - I NSTALLATI ON).
RDR OUTER BELT
WEATHERSTRIP
REMOVAL
(1) Remove tri m panel (Refer to 23 - BODY/
DOORS - REAR/TRI M PANEL - REMOVAL).
(2) Usi ng a smal l fl at bl ade, di sengage tangs
attachi ng outer bel t weatherstri p to i nner door panel .
(3) Li ft weatherstri p upward and separate from
door (Fi g. 10).
INSTALLATION
(1) Posi ti on the weatherstri p onto the door fl ange.
(2) Force the weatherstri p onto door fl ange and
engage tangs. Conti nue rearward unti l i t i s seated on
fl ange.
(3) I nstal tri m panel (Refer to 23 - BODY/DOORS
- REAR/TRI M PANEL - I NSTALLATI ON).
Fig. 9 Liftgate Opening Weatherstrip
1 - LIFTGATE
2 - WEATHERSTRIP
Fig. 10 Rear Door Inner/Outer Belt Weatherstrip
1 - INNER BELT WEATHERSTRIP
2 - OUTER BELT WEATHERSTRIP
RDR SECONDARY
WEATHERSTRIP
REMOVAL
The rear door secondary weatherstri p i s attached
to the door shutface wi th push-i n fasteners.
(1) Open door.
(2) Usi ng a tri m panel removal tool , remove
push-i n fasteners attachi ng secondary weatherstri p
to door shutface.
(3) Separate secondary weatherstri p from door
(Fi g. 11).
INSTALLATION
(1) Cl ean contact area as necessary.
(2) Posi ti on secondary weatherstri p on door shutface.
(3) I nstal l push-i n fasteners attachi ng secondary
weatherstri p to door shutface.
REAR DOOR WEATHERSTRIP
REMOVAL
(1) Remove C-pi l l ar tri m (Refer to 23 - BODY/I N-
TERI OR/C-PI LLAR TRI M - REMOVAL).
(2) Remove B-pi l l ar upper tri m (Refer to 23 -
REMOVAL).
(3) Remove B-pi l l ar l ower tri m(Refer to 23 -
REMOVAL).
(4) Remove screws at front of quarter tri m panel .
(5) Pul l weatherstri p from door openi ng fl ange.
INSTALLATION
(1) Posi ti on weatherstri p at corners.
(2) Move upward and around edge of door openi ng
seati ng weatherstri p onto fl ange (Fi g. 7).
(3) Engage connector pl ug wi th each end of weath-
erstri p at bottom of door openi ng.
(4) I nstal l screws at front of quarter tri m panel .
(5) I nstal l B-pi l l ar l ower tri m (Refer to 23 - BODY/I N-
TERI OR/B-PI LLAR LOWER TRI M - I NSTALLATI ON).
(6) I nstal l B-pi l l ar upper tri m (Refer to 23 -
I NSTALLATI ON).
(7) I nstal l C-pi l l ar tri m (Refer to 23 - BODY/I NTE-
RI OR/C-PI LLAR TRI M - I NSTALLATI ON).
ROOF RAIL WEATHERSTRIP /
RETAINR
REMOVAL
(1) Open front and rear doors.
(2) Remove secondary seal from retai ner to access
the screws hol di ng the retai ner to the A pi l l ar and
roof panel .
(3) Remove the screws hol di ng the retai ner i n
pl ace (Fi g. 12).
(4) Remove the retai ner.
INSTALLATION
(1) Posi ti on the retai ner on the A pi l l ar and roof
panel .
(2) Al i gn the screw hol es and i nstal l the screws.
(3) I nstal l secondary seal .
Fig. 11 Rear Door Secondary Weatherstrip
1 - SECONDARY WEATHERSTRIP
Fig. 12 Upper Body Seal With Retainer
1 - ROOF RAIL WEATHERSTRIP
2 - RETAINER
3 - SCREW
4 - BLOCKER
BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS - GAP AND FLUSH . . . . . . . 112
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . 114
SEALER LOCATIONS
SPECIFICATIONS
SEALER LOCATIONS . . . . . . . . . . . . . . . . . 118
STUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS - STRUCTURAL ADHESIVE
LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 137
WELD LOCATIONS
SPECIFICATIONS
WELD LOCATIONS . . . . . . . . . . . . . . . . . . . 153
GAP AND FLUSH
SPECIFICATIONS - GAP AND FLUSH
DESCIPTION FIGURE
FRONT VIEW 1
REAR VIEW 2
23 - 112 BODY STRUCTURE WJ
NOTE:
All measurements are in mm.
LOCATION DESCRIPTION GAP FLUSH
A Front Door to Windshield Pillar N/A 3.0 +/- 1.0
B Front Door Header to Aperture 6.0 +/- 1.0 1.0 +/- 1.5
C Front Door to Rear Door 5.0 +/- 1.0 0.0 +/- 1.0
D Front Door to Aperture at Sill 7.0 +/- 1.5 N/A
E Front Door to Fender 5.0 +/- 1.0 0.5 +/- 1.0
F Hood to Fender 5.0 +/- 1.0 0.0 +/- 1.0
G Headlamp to Fender 5.0 +/- 2.0 3.0 +/- 2.0
H Headlamp to Grille 5.5 +/- 2.0 0.0 +/- 2.0
I Grille to Headlamp N/A 0.0 +/- 1.0
J Grille to Hood 10.0 +/- 2.0 0.8 +/- 2.0
K Front Fascia to Fender Net + 1.0 - 0.0 3.0 +/- 3.0
L Fuel Filler Door to Bodyside 3.0 +/- 0.75 0.5 +/- 0.75
Fig. 1 FRONT VIEW
WJ BODY STRUCTURE 23 - 113
GAP AND FLUSH (Continued)
NOTE:
All measurements are in mm.
LOCATION DESCRIPTION GAP FLUSH
M Rear Door to Quarter Panel 5.0 +/- 1.0 0.0 +/- 1.0
N Aperture to Rear Fascia Net to 1.0 3.0 +/- 2.0
O Taillamp to Quarter Panel 2.0 +/- 1.0 3.0 +/- 1.5
Q Liftgate to Fascia 10.0 +/- 3.0 N/A
R Liftgate to Aperture 5.0 +/- 1.5 1.0 +/- 1.0
S Liftgate to Roof 11.0 +/- 1.5 1.0 +/- 1.0
T Rear Door Header to Aperture 6.0 +/- 1.0 1.0 +/- 1.5
Fig. 2 REAR VIEW
GAP AND FLUSH (Continued)
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS
DESCRIPTION FIGURE
WINDSHIELD AND
FRONT DOOR
OPENING
3
REAR DOOR AND
QUARTER GLASS
OPENING
4
LIFTGATE OPENING
AND ENGINE
COMPARTMENT
5
Fig. 3 WINDSHIELD AND FRONT DOOR OPENING
OPENING DIMENSIONS (Continued)
TSB 26-11-01 November 2001
Fig. 4 REAR DOOR AND QUARTER GLASS OPENING
Fig. 5 LIFTGATE OPENING AND ENGINE COMPARTMENT
SEALER LOCATIONS
SPECIFICATIONS
SEALER LOCATIONS
INDEX
DESCRIPTION FIGURE
APPLICATION METHODS 6
COWL PLENUM AND DASH PANEL 7
DASH, COWL AND PLENUM 8
INNER FENDER AND COWL 9
LOWER PLENUM AND BAFFLE 10
A-PILLAR 11
COWL SIDE ATTACHMENT 12
BODYSIDE ATTACHMENT 13
BODYSIDE INNER AND OUTER TO COWL 14
FENDER ATTACHMENT 15
DOOR HINGE BOLT HOLES 16
A-PILLAR AND B-PILLAR HINGE AREA 17
B-PILLAR AND SILL 18
SILL AND B-PILLAR 19
BODYSIDE APERTURE AND REAR WHEELHOUSE 20
FUEL FILLER GUSSET 21
OUTER WHEELHOUSE FLANGE 22
LIFTGATE OPENING 23
INNER WHEELHOUSE FLANGE TO BODYSIDE APERTURE 24
WHEELHOUSE LOWER 25
REAR INNER CROSSMEMBER 26
ROOF TO BODY SIDE APERTURE 27
Fig. 6 APPLICATION METHODS
SEALER LOCATIONS (Continued)
Fig. 7 COWL PLENUM AND DASH PANEL
Fig. 8 DASH, COWL AND PLENUM
Fig. 9 INNER FENDER AND COWL
Fig. 10 LOWER PLENUM AND BAFFLE
Fig. 11 A-PILLAR
Fig. 12 COWL SIDE ATTACHMENT
Fig. 13 BODYSIDE ATTACHMENT
Fig. 14 BODYSIDE INNER AND OUTER TO COWL
Fig. 15 FENDER ATTACHMENT
Fig. 16 DOOR HINGE BOLT HOLES
Fig. 17 A-PILLAR AND B-PILLAR HINGE AREA
Fig. 18 B-PILLAR AND SILL
Fig. 19 SILL AND B-PILLAR
Fig. 20 BODYSIDE APERTURE AND REAR WHEELHOUSE
Fig. 21 FUEL FILLER GUSSET
Fig. 22 OUTER WHEELHOUSE FLANGE
Fig. 23 LIFTGATE OPENING
Fig. 24 INNER WHEELHOUSE FLANGE TO BODYSIDE APERTURE
Fig. 25 WHEELHOUSE LOWER
Fig. 26 REAR INNER CROSSMEMBER
Fig. 27 ROOF TO BODY SIDE APERTURE
STUCTURAL ADHESIVE
LOCATIONS
SPECIFICATIONS - STRUCTURAL ADHESIVE
LOCATIONS
INDEX
DESCRIPTION FIGURE
COWL PLENUM 28
DASH PANEL AND FRONT FLOOR PAN 29
PLENUM AND WINDSHIELD WIPER MOUNTING 30
FRONT FLOOR PAN AND SILLS 31
FRONT AND CENTER FLOOR PAN 32
FRONT PAN AND INNER BODY SIDE APERTURE 33
REAR SEAT CROSSMEMBER 34
REAR INNER WHEELHOUSE 35
FLOOR PAN AND SILL ASSEMBLY 36
FLOOR PAN 37
REAR INNER WHEELHOUSE AND REAR FLOOR PAN 38
RIGHT INNER BODYSIDE APERTURE 39
BODY SIDE INNER PANEL AND WHEELHOUSE 40
BODY SIDE OUTER PANEL AND REAR WHEELHOUSE OUTER PANEL 41
D-PILLAR AND FUEL FILLER GUSSETS 42
LIFTGATE 43
TAILLAMP MOUNTING PANEL 44
TAILLAMP 45
REAR INNER CROSSMEMBER 46
ROOF BOWS 47
REAR LOWER HEADER 48
Fig. 28 COWL PLENUM
Fig. 29 DASH PANEL AND FRONT FLOOR PAN
STUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 30 PLENUM AND WINDSHIELD WIPER MOUNTING
Fig. 31 FRONT FLOOR PAN AND SILLS
Fig. 32 FRONT AND CENTER FLOOR PAN
Fig. 33 FRONT PAN AND INNER BODY SIDE APERTURE
Fig. 34 REAR SEAT CROSSMEMBER
Fig. 35 REAR INNER WHEELHOUSE
Fig. 36 FLOOR PAN AND SILL ASSEMBLY
Fig. 37 FLOOR PAN
Fig. 38 REAR INNER WHEELHOUSE AND REAR FLOOR PAN
Fig. 39 RIGHT INNER BODYSIDE APERTURE
Fig. 40 BODY SIDE INNER PANEL AND WHEELHOUSE
Fig. 41 BODY SIDE OUTER PANEL AND REAR WHEELHOUSE OUTER PANEL
Fig. 42 D-PILLAR AND FUEL FILLER GUSSETS
Fig. 43 LIFTGATE
Fig. 44 TAILLAMP MOUNTING PANEL
Fig. 45 TAILLAMP
Fig. 46 REAR INNER CROSSMEMBER
Fig. 47 ROOF BOWS
Fig. 48 REAR LOWER HEADER
WELD LOCATIONS
SPECIFICATIONS
WELD LOCATIONS
INDEX
DESCRIPTION FIGURE
RADIATOR SUPPORT BRACKETS 49
FRONT SUSPENSION SUPPORT REINFORCEMENT 50
FRONT LOWER CROSSMEMBER TO COWL SIDE PANEL 51
FRONT SILL TO LOWER CROSSMEMBER 52
FRONT FENDER MOUNTING BRACKET AND REINFORCEMENT 53
FRONT SUSPENSION SUPPORT TO SILLS AND COWL SIDE PANEL 54
LEFT INSTRUMENT PANEL BRACKET TO COWL SIDE PANEL 55
COWL SIDE UPPER REINFORCEMENT TO COWL SIDE AND FRONT SUSPENSION
SUPPORT
56
COWL SIDE PANEL TO DASH PANEL AND INNER BODYSIDE PANEL AND SILL 57
PLENUM ASSEMBLY TO COWL SIDE PANEL 58
FRONT LOWER CROSSMEMBER 59
FRONT SUSPENSION SUPPORT TO DASH 60
WIPER MOUNTING BRACKETS TO PLENUM ASSEMBLY 61
COWL TOP AND PLENUM ASSEMBLY 62
LOWER PLENUM REINFORCEMENT TO LOWER PLENUM PANEL 63
DASH PANEL TO LOWER PLENUM PANEL 64
PLENUM ASSEMBLY TO COWL 65
COWL PANEL TO BODYSIDE SILL 66
COWL PANEL TO FRONT FLOOR PAN 67
FRONT SILLS TO DASH AND FRONT FLOOR PAN 68
COWL SIDE PANEL DASH INNER BODYSIDE AND OUTER BODYSIDE PANELS 69
UPPER FRONT INNER PILLAR TO ROOF AND COWL 70
DOOR OPENINGS 71
B-PILLAR REINFORCEMENT TO INNER BODYSIDE APERTURE 72
REAR QUARTER WINDOW TO BODYSIDE APERTURE INNER AND OUTER 73
LOWER REAR QUARTER TO BODYSIDE APERTURE INNER AND OUTER 74
INNER TRACK BAR, LOWER CONTROL ARM AND TRANSMISSION CROSSMEMBER
BRACKETS TO FRONT SILLS
75
TRANSMISSION CROSSMEMBER BRACKET AND REINFORCEMENT TO FRONT
SILLS
76
UPPER SILLS AND UPPER CONTROL ARM REINFORCEMENT AND BRACKETS TO
FRONT SILLS
77
REINFORCEMENT TO FRONT OUTER SILLS 78
FRONT INNER SILL TO FRONT OUTER SILL 79
OUTER TRACK BAR BRACKET TO FRONT OUTER SILL 80
DESCRIPTION FIGURE
REINFORCEMENT FOR FRONT ENGINE MOUNTING AND STEERING GEAR TO
FRONT INNER SILL
81
LARGE AND SMALL SWAY BAR TAPPING PLATES TO FRONT INNER SILLS 82
FRONT AND REAR DOOR HINGE TAPPING PLATES 83
REAR DOOR STRIKER REINFORCEMENT 84
TAIL LAMP MOUNTING PANELS 85
ROOF PANEL TO BODYSIDE APERTURE 86
ROOF PANEL TO REAR HEADER 87
UPPER REAR HEADER TO LOWER HEADER 88
FRONT HEADER AND ROOF BOWS TO INNER PANEL 89
FRONT SEAT/SHOULDER BELT TO INNER PANEL REINFORCEMENT 90
REAR SEAT/SHOULDER BELT TO INNER PANEL REINFORCEMENT 91
FUEL FILLER GUSSET TO INNER QUARTER PANEL 92
FRONT FLOOR PAN TO SILL REINFORCEMENT 93
CENTER FLOOR PAN TO REAR SEAT CROSSMEMBER 94
FRONT FLOOR PAN TO FRONT SEAT REINFORCEMENT AND RAILS 95
CENTER FLOOR PAN TO UPPER CONTROL ARM CROSSMEMBER AND RAILS 96
REAR FLOOR PAN TO RAILS AND SPRING GUIDE CROSSMEMBER 97
REAR RAILS 98
UPPER CONTROL ARM CROSSMEMBER TO REAR RAIL 99
REAR RAIL REINFORCEMENT TO REAR RAILS 100
UPPER CONTROL ARM REINFORCEMENTS TO REAR RAIL 101
OUTER TRANSMISSION CROSSMEMBER REINFORCEMENT TO RAIL AND
BODYSIDE SILL
102
BODYSIDE SILL TO FLOOR PAN 103
REAR RAILS TO REAR CROSSMEMBER 104
INNER WHEELHOUSE TO FLOOR PAN 105
INNER WHEELHOUSE TO INNER BODYSIDE APERTURE AND FLOOR PAN 106
OUTER WHEELHOUSE TO OUTER BODYSIDE APERTURE 107
OUTER WHEELHOUSE TO INNER BODYSIDE APERTURE 108
INNER BODYSIDE APERTURE TO OUTER BODYSIDE APERTURE 109
REAR INBOARD SEAT BELT REINFORCEMENT TO FLOOR PAN 110
WELD LOCATIONS (Continued)
Fig. 49 RADIATOR SUPPORT BRACKETS
Fig. 50 FRONT SUSPENSION SUPPORT REINFORCEMENT
Fig. 51 FRONT LOWER CROSSMEMBER TO COWL SIDE PANEL
Fig. 52 FRONT SILL TO LOWER CROSSMEMBER
Fig. 53 FRONT FENDER MOUNTING BRACKET AND REINFORCEMENT
Fig. 54 FRONT SUSPENSION SUPPORT TO SILLS AND COWL SIDE PANEL
Fig. 55 LEFT INSTRUMENT PANEL BRACKET TO COWL SIDE PANEL
Fig. 56 COWL SIDE UPPER REINFORCEMENT TO COWL SIDE AND FRONT SUSPENSION SUPPORT
Fig. 57 COWL SIDE PANEL TO DASH PANEL AND INNER BODYSIDE PANEL AND SILL
Fig. 58 PLENUM ASSEMBLY TO COWL SIDE PANEL
Fig. 59 FRONT LOWER CROSSMEMBER
Fig. 60 FRONT SUSPENSION SUPPORT TO DASH
Fig. 61 WIPER MOUNTING BRACKETS TO PLENUM ASSEMBLY
Fig. 62 COWL TOP AND PLENUM ASSEMBLY
Fig. 63 LOWER PLENUM REINFORCEMENT TO LOWER PLENUM PANEL
Fig. 64 DASH PANEL TO LOWER PLENUM PANEL
Fig. 65 PLENUM ASSEMBLY TO COWL
Fig. 66 COWL PANEL TO BODYSIDE SILL
Fig. 67 COWL PANEL TO FRONT FLOOR PAN
Fig. 68 FRONT SILLS TO DASH AND FRONT FLOOR PAN
Fig. 69 COWL SIDE PANEL DASH INNER BODYSIDE AND OUTER BODYSIDE PANELS
Fig. 70 UPPER FRONT INNER PILLAR TO ROOF AND COWL
Fig. 71 DOOR OPENINGS
Fig. 72 B-PILLAR REINFORCEMENT TO INNER BODYSIDE APERTURE
Fig. 73 REAR QUARTER WINDOW TO BODYSIDE APERTURE INNER AND OUTER
Fig. 74 LOWER REAR QUARTER TO BODYSIDE APERTURE INNER AND OUTER
Fig. 75 INNER TRACK BAR, LOWER CONTROL ARM AND TRANSMISSION CROSSMEMBER
BRACKETS TO FRONT SILLS
Fig. 76 TRANSMISSION CROSSMEMBER BRACKET AND REINFORCEMENT TO FRONT SILLS
Fig. 77 UPPER SILLS AND UPPER CONTROL ARM REINFORCEMENT AND BRACKETS TO FRONT SILLS
Fig. 78 REINFORCEMENT TO FRONT OUTER SILLS
Fig. 79 FRONT INNER SILL TO FRONT OUTER SILL
Fig. 80 OUTER TRACK BAR BRACKET TO FRONT OUTER SILL
Fig. 81 REINFORCEMENT FOR FRONT ENGINE MOUNTING AND STEERING GEAR TO FRONT INNER SILL
Fig. 82 LARGE AND SMALL SWAY BAR TAPPING PLATES TO FRONT INNER SILLS
Fig. 83 FRONT AND REAR DOOR HINGE TAPPING PLATES
Fig. 84 REAR DOOR STRIKER REINFORCEMENT
Fig. 85 TAIL LAMP MOUNTING PANELS
Fig. 86 ROOF PANEL TO BODYSIDE APERTURE
Fig. 87 ROOF PANEL TO REAR HEADER
Fig. 88 UPPER REAR HEADER TO LOWER HEADER
Fig. 89 FRONT HEADER AND ROOF BOWS TO INNER PANEL
Fig. 90 FRONT SEAT/SHOULDER BELT TO INNER PANEL REINFORCEMENT
Fig. 91 REAR SEAT/SHOULDER BELT TO INNER PANEL REINFORCEMENT
Fig. 92 FUEL FILLER GUSSET TO INNER QUARTER PANEL
Fig. 93 FRONT FLOOR PAN TO SILL REINFORCEMENT
Fig. 94 CENTER FLOOR PAN TO REAR SEAT CROSSMEMBER
Fig. 95 FRONT FLOOR PAN TO FRONT SEAT REINFORCEMENT AND RAILS
Fig. 96 CENTER FLOOR PAN TO UPPER CONTROL ARM CROSSMEMBER AND RAILS
Fig. 97 REAR FLOOR PAN TO RAILS AND SPRING GUIDE CROSSMEMBER
Fig. 98 REAR RAILS
Fig. 99 UPPER CONTROL ARM CROSSMEMBER TO REAR RAIL
Fig. 100 REAR RAIL REINFORCEMENT TO REAR RAILS
Fig. 101 UPPER CONTROL ARM REINFORCEMENTS TO REAR RAIL
Fig. 102 OUTER TRANSMISSION CROSSMEMBER REINFORCEMENT TO RAIL AND BODYSIDE SILL
Fig. 103 BODYSIDE SILL TO FLOOR PAN
Fig. 104 REAR RAILS TO REAR CROSSMEMBER
Fig. 105 INNER WHEELHOUSE TO FLOOR PAN
Fig. 106 INNER WHEELHOUSE TO INNER BODYSIDE APERTURE AND FLOOR PAN
Fig. 107 OUTER WHEELHOUSE TO OUTER BODYSIDE APERTURE
Fig. 108 OUTER WHEELHOUSE TO INNER BODYSIDE APERTURE
Fig. 109 INNER BODYSIDE APERTURE TO OUTER BODYSIDE APERTURE
Fig. 110 REAR INBOARD SEAT BELT REINFORCEMENT TO FLOOR PAN
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - HEATER AND AIR
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT. . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT. . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - A/C
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - DIODE
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
A/C APPLICATION TABLE . . . . . . . . . . . . . . . . 7
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 8
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
HEATING & AIR
CONDITIONING
DESCRIPTION
REQUIREMENTS
To mai ntai n the performance l evel of the heati ng-
ai r condi ti oni ng system, the engi ne cool i ng system
must be properl y mai ntai ned. The use of a bug
screen i s not recommended. Any obstructi ons i n front
of the radi ator or condenser wi l l reduce the perfor-
mance of the ai r condi ti oni ng and engi ne cool i ng sys-
tems.
The engi ne cool i ng system i ncl udes the heater core
and the heater hoses. Refer to Cool i ng for more i nfor-
mati on before openi ng, or attempti ng any servi ce to
the engi ne cool i ng system.
DESCRIPTION - HEATER AND AIR
CONDITIONER
A manual temperature control type heati ng-ai r
condi ti oni ng system i s standard factory-i nstal l ed
equi pment on thi s model . An el ectroni cal l y control l ed
Automati c Zone Control (AZC) type heati ng-ai r con-
di ti oni ng system i s an avai l abl e factory-i nstal l ed
opti on.
Al l vehi cl es are equi pped wi th a common HVAC
housi ng assembl y (Fi g. 1). The system combi nes ai r
condi ti oni ng, heati ng, and venti l ati ng capabi l i ti es i n
a si ngl e uni t housi ng mounted under the i nstrument
panel .
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refri gerant system servi ce ports are used
to charge, recover/recycl e, evacuate, and test the ai r
condi ti oni ng refri gerant system. Uni que servi ce port
coupl er si zes are used on the R-134a system to
ensure that the refri gerant system i s not acci dental l y
contami nated by the use of the wrong refri gerant
(R-12), or refri gerant system servi ce equi pment.
Fig. 1 Blend-Air HVAC System - (typical)
1 - Blend Door
2 - Expansion Valve
3 - Evaporator Core
4 - Blower Assembly
5 - Recirculation Door
6 - Evaporator Probe
7 - Heater Core
8 - Heat/Defrost Door
9 - Panel/Defrost Door
WJ HEATING & AIR CONDITIONING 24 - 1
OPERATION
OPERATION - HEATER AND AIR CONDITIONER
Outsi de fresh ai r enters the vehi cl e through the
cowl top openi ng at the base of the wi ndshi el d, and
passes through a pl enum chamber to the HVAC sys-
tem bl ower housi ng. Ai r fl ow vel oci ty can then be
adjusted wi th the bl ower motor speed sel ector swi tch
on the a/c heater control panel . The ai r i ntake open-
i ngs must be kept free of snow, i ce, l eaves, and other
obstructi ons for the HVAC system to recei ve a suffi -
ci ent vol ume of outsi de ai r.
I t i s al so i mportant to keep the ai r i ntake openi ngs
cl ear of debri s because l eaf parti cl es and other debri s
that i s smal l enough to pass through the cowl pl e-
num screen can accumul ate wi thi n the HVAC hous-
i ng. The cl osed, warm, damp and dark envi ronment
created wi thi n the HVAC housi ng i s i deal for the
growth of certai n mol ds, mi l dews and other fungi .
Any accumul ati on of decayi ng pl ant matter provi des
an addi ti onal food source for fungal spores, whi ch
enter the housi ng wi th the fresh ai r. Excess debri s,
as wel l as objecti onabl e odors created by decayi ng
pl ant matter and growi ng fungi can be di scharged
i nto the passenger compartment duri ng HVAC sys-
tem operati on.
Both the manual and AZC heater and ai r condi -
ti oner are bl end-ai r type systems. I n a bl end-ai r sys-
tem, a bl end door control s the amount of
uncondi ti oned ai r (or cool ed ai r from the evaporator)
that i s al l owed to fl ow through, or around, the heater
core. A temperature control knob on the a/c heater
control panel determi nes the di scharge ai r tempera-
ture by energi zi ng the bl end door actuator, whi ch
operates the bl end door. Thi s al l ows an al most i mme-
di ate control of the output ai r temperature of the sys-
tem. The AZC system wi l l have separate bl end doors
and temperature control s for each front seat occu-
pant.
The mode control knob on the a/c heater control
panel i s used to di rect the condi ti oned ai r to the
sel ected system outl ets. On manual temperature con-
trol systems, the mode control knob swi tches engi ne
vacuum to control the mode doors, whi ch are oper-
ated by vacuum actuators. On AZC systems, the
mode control knob swi tches el ectri cal current to con-
trol the mode doors, whi ch are operated by el ectroni c
actuators.
The outsi de ai r i ntake can be shut off on manual
temperature control systems by sel ecti ng the Reci rcu-
l ati on Mode wi th the mode control knob. The outsi de
ai r i ntake can be shut off on Automati c Zone Control
(AZC) type system by pushi ng the Reci rcul ati on
Mode button. Thi s wi l l operate the reci rcul ati on door
that cl oses off the outsi de fresh ai r i ntake and reci r-
cul ates the ai r that i s al ready i nsi de the vehi cl e.
The ai r condi ti oner for al l model s i s desi gned for
the use of non-CFC, R-134a refri gerant. The ai r con-
di ti oni ng system has an evaporator to cool and dehu-
mi di fy the i ncomi ng ai r pri or to bl endi ng i t wi th the
heated ai r. Thi s ai r condi ti oni ng system uses a ther-
mal expansi on val ve to meter refri gerant fl ow to the
evaporator coi l . To mai ntai n mi ni mum evaporator
temperature and prevent evaporator freezi ng, the
system uti l i zes an evaporator thermi ster probe wi th
the appropri ate operati ng l ogi c l ocated i n the body
control modul e (BCM).
OPERATION - REFRIGERANT SYSTEM SERVICE
PORT
The hi gh pressure servi ce port i s l ocated on the l i q-
ui d l i ne near the recei ver/dri er. The l ow pressure ser-
vi ce port i s l ocated on the sucti on l i ne near the
evaporator at the rear of the engi ne compartment.
Each of the servi ce ports has a threaded pl asti c
protecti ve cap i nstal l ed over i t from the factory. After
servi ci ng the refri gerant system, al ways rei nstal l
both of the servi ce port caps.
PERFORMANCE
The ai r condi ti oni ng system i s desi gned to provi de
the passenger compartment wi th l ow temperature
and l ow speci fi c humi di ty ai r. The evaporator, l ocated
i n the HVAC housi ng on the dash panel bel ow the
i nstrument panel , i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes through the
cool ed evaporator, the ai r transfers i ts heat to the
refri gerant i n the evaporator and the moi sture i n the
ai r condenses on the evaporator fi ns. Duri ng peri ods
of hi gh heat and humi di ty, an ai r condi ti oni ng sys-
tem wi l l be more effecti ve i n the Reci rcul ati on Mode.
Wi th the system i n the Reci rcul ati on Mode, onl y ai r
from the passenger compartment passes through the
evaporator. As the passenger compartment ai r dehu-
mi di fi es, the ai r condi ti oni ng system performance
l evel s i mprove.
Humi di ty has an i mportant beari ng on the tempera-
ture of the ai r del i vered to the i nteri or of the vehi cl e. I t
i s i mportant to understand the effect that humi di ty has
on the performance of the ai r condi ti oni ng system.
When humi di ty i s hi gh, the evaporator has to perform a
doubl e duty. I t must l ower the ai r temperature, and i t
must l ower the temperature of the moi sture i n the ai r
that condenses on the evaporator fi ns. Condensi ng the
moi sture i n the ai r transfers heat energy i nto the evap-
orator fi ns and tubi ng. Thi s reduces the amount of heat
the evaporator can absorb from the ai r. Hi gh humi di ty
greatl y reduces the abi l i ty of the evaporator to l ower
the temperature of the ai r.
24 - 2 HEATING & AIR CONDITIONING WJ
HEATING & AIR CONDITIONING (Continued)
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Wri ng-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from thei r
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
I f the vehi cl e has the opti onal Automati c Zone Control
(AZC) system, and has i ntermi ttent operati onal prob-
l ems or faul t codes, be certai n that the wi re harness
connectors on the HVAC housi ng are properl y seated
(Fi g. 2). To check thi s condi ti on, unpl ug the two wi re
harness connector hal ves, then pl ug them i n agai n.
Before performi ng the fol l owi ng procedure, (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/PLUMB-
I NG - CAUTI ON) (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - WARNI NG). The ai r
temperature i n the test room and i n the vehi cl e must
be a mi ni mum of 21 C (70 F) for thi s test.
(1) Connect a tachometer and a mani fol d gauge set.
(2) I f the vehi cl e has the standard manual temper-
ature control , set the A/C Heater mode control swi tch
knob i n the Panel posi ti on, the temperature control
knob i n the ful l cool (Fresh Ai r Mode) posi ti on, the
A/C button i n the On posi ti on, and the bl ower motor
swi tch knob i n the hi ghest speed posi ti on. I f the vehi -
cl e has the opti onal AZC, set the A/C Heater mode
control swi tch knob i n the Panel posi ti on, the tem-
perature control knob i n the ful l cool posi ti on, the
A/C button i n the On posi ti on, and the bl ower motor
swi tch knob i n the hi ghest (manual ) speed posi ti on.
(3) Start the engi ne and hol d the i dl e at 1,300 rpm
wi th the compressor cl utch engaged.
(4) The engi ne shoul d be at operati ng temperature.
The doors and wi ndows must be open.
(5) I nsert a thermometer i n the dri ver si de center
A/C (panel ) outl et. Operate the engi ne for fi ve mi nutes.
(6) The compressor cl utch may cycl e, dependi ng
upon the ambi ent temperature and humi di ty.
(7) Wi th the compressor cl utch engaged, record the
di scharge ai r temperature and the compressor di s-
charge pressure.
(8) Compare the di scharge ai r temperature to the
Performance Temperature and Pressure chart. I f the
di scharge ai r temperature i s hi gh, (Refer to 24 -
DI AGNOSI S AND TESTI NG - REFRI GERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - STANDARD PRO-
CEDURE - REFRI GERANT SYSTEM CHARGE).
Performance Temperature and Pressure
Ambient Air Temperature
and Humidity
21C
(70F @ 80%
humidity)
27C
(80F @ 80%
humidity)
32C
(90F @ 80%
humidity)
38C
(100F @ 50%
humidity)
43C
110F @ 20%
humidity)
Air Temperature at Center
Panel Outlet
10 to 13C
(50 to 55F)
14 to 17C
(58 to 63F)
15 to 18C
(60 to 65F)
17 to 20C
(63 to 68F)
14 to 17C
(58 to 63F)
Evaporator Inlet Pressure
at Charge Port
241 to 276 kPa
(35 to 40 psi)
262 to 290 kPa
(38 to 42 psi)
269 to 296 kPa
(39 to 43 psi)
275 to 303 kPa
(40 to 44 psi)
262 to 290 kPa
(38 to 42 psi)
Compressor Discharge
Pressure
1241 to 1792
kPa
(180 to 260 psi)
1380 to 1930
kPa
(200 to 280 psi)
1380 to 1930
kPa
(200 to 280 psi)
1655 to 2206
kPa
(240 to 320 psi)
1567 to 2068
kPa
(220 to 300 psi)
Note: The discharge air temperatures will be lower if the humidity is less than the percentages shown.
Fig. 2 HVAC Housing - (rear view)
1 - Instrument Panel
2 - Air Intake
3 - Expansion Valve
4 - HVAC Housing
5 - Heater Core Input/Output Ports
6 - Instrument Panel Wiring Harness
7 - Blower Motor
(9) Compare the compressor di scharge pressure to
the Performance Temperature and Pressure chart. I f
the compressor di scharge pressure i s hi gh, see the
Pressure Di agnosi s chart.
Pressure Diagnosis
Rapid compressor clutch
cycling (ten or more cycles
per minute).
1. Low refrigerant system
charge.
1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the
refrigerant system.
2. Faulty fuse. 2. Check the fuses in the Power Distribution
Center and the junction block. Repair the shorted
circuit or component and replace the fuses, if
required.
3. Faulty a/c compressor
clutch coil.
3. See A/C Compressor/Diagnosis and Testing -
Compressor Clutch Coil in this group. Test the
compressor clutch coil and replace, if required.
4. Faulty compressor clutch
relay.
4. See A/C Compressor Clutch Relay/Diagnosis
and Testing - Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
6. Faulty a/c high pressure
transducer.
6. See A/C High Pressure Transducer/Diagnosis
and Testing in this group. Test the a/c high
pressure transducer and replace, if required.
7. Faulty Fin Probe. 7. Check for open circuit.
8. Faulty Powertrain Control
Module (PCM).
8. Refer to the proper Diagnostic Procedures
manual for testing of the PCM. Test the PCM and
replace, if required.
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.
1. Excessive refrigerant oil in
system.
1. See Refrigerant Oil/Standard Procedure -
Refrigerant Oil Level in this group. Recover the
refrigerant from the refrigerant system and
inspect the refrigerant oil content. Restore the
refrigerant oil to the proper level, if required.
2. Blend door inoperative or
sealing improperly.
2. See Blend Door in this group. Inspect the
blend door for proper operation and sealing and
correct, if required.
3. Blend door actuator faulty
or inoperative.
3. Perform blend door actuator diagnosis, replace
if faulty.
Pressure Diagnosis
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.
1. Low refrigerant system
charge.
2. Refrigerant flow through
the accumulator is restricted.
2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. Refrigerant flow through
the evaporator coil is
restricted.
3. See A/C Evaporator in this group. Replace the
restricted evaporator coil, if required.
4. Faulty compressor. 4. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.
1. Condenser air flow
restricted.
1. Check the condenser for damaged fins, foreign
objects obstructing air flow through the condenser
fins, and missing or improperly installed air seals.
Refer to Cooling for more information on air
seals. Clean, repair, or replace components as
required.
2. Inoperative cooling fan. 2. Refer to Cooling for more information. Test the
cooling fan and replace, if required.
3. Refrigerant system
overcharged.
3. See Plumbing/Standard Procedure -
Refrigerant System Charge in this group. Recover
the refrigerant from the refrigerant system.
Charge the refrigerant system to the proper level,
if required.
4. Air in the refrigerant
system.
5. Engine overheating. 5. Refer to Cooling for more information. Test the
cooling system and repair, if required.
The low side pressure is too
high, and the high side
pressure is too low.
1. Accessory drive belt
slipping.
1. Refer to Cooling for more information. Inspect
the accessory drive belt condition and tension.
Tighten or replace the accessory drive belt, if
required.
2. Faulty compressor. 2. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is too
low, and the high side
pressure is too high.
1. Restricted refrigerant flow
through the refrigerant lines.
1. See Liquid, Suction, and Discharge Line in this
group. Inspect the refrigerant lines for kinks, tight
bends or improper routing. Correct the routing or
replace the refrigerant line, if required.
through the a/c expansion
valve.
2. See A/C Expansion Valve in this group.
Replace the Expansion Valve if restricted.
through the condenser.
3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE
Before performi ng the fol l owi ng tests, refer to Cool -
i ng for the procedures to check the radi ator cool ant
l evel , serpenti ne dri ve bel t tensi on, radi ator ai r fl ow
and the radi ator fan operati on. Al so be certai n that
the accessory vacuum suppl y l i ne i s connected at the
engi ne i ntake mani fol d for the manual temperature
control system.
MAXIMUM HEATER OUTPUT
Engi ne cool ant i s del i vered to the heater core
through two heater hoses. Wi th the engi ne i dl i ng at
normal operati ng temperature, set the temperature
control knob i n the ful l hot posi ti on, the mode control
swi tch knob i n the fl oor heat posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
Usi ng a test thermometer, check the temperature of
the ai r bei ng di scharged at the HVAC housi ng fl oor
outl ets. Compare the test thermometer readi ng to the
Temperature Reference chart.
Temperature Reference
Ambient Air Temperature
15.5C
(60F)
21.1C
(70F)
26.6C
(80F)
32.2C
(90F)
Minimum Air Temperature at
Floor Outlet
62.2C
(144F)
63.8C
(147F)
65.5C
(150F)
67.2C
(153F)
I f the fl oor outl et ai r temperature i s too l ow, refer
to Cool i ng to check the engi ne cool ant temperature
speci fi cati ons. Both of the heater hoses shoul d be hot
to the touch. The cool ant return heater hose shoul d
be sl i ghtl y cool er than the cool ant suppl y heater
hose. I f the return hose i s much cool er than the sup-
pl y hose, l ocate and repai r the engi ne cool ant fl ow
obstructi on i n the cool i ng system. Refer to Cool i ng
for the procedures.
OBSTRUCTED COOLANT FLOW
Possi bl e l ocati ons or causes of obstructed cool ant
fl ow:
Pi nched or ki nked heater hoses.
I mproper heater hose routi ng.
Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons.
A pl ugged heater core.
I f proper cool ant fl ow through the cool i ng system i s
veri fi ed, and heater outl et ai r temperature i s sti l l
l ow, a mechani cal probl em may exi st.
MECHANICAL PROBLEMS
Possi bl e l ocati ons or causes of i nsuffi ci ent heat:
An obstructed cowl ai r i ntake.
Obstructed heater system outl ets.
A bl end door not functi oni ng properl y.
TEMPERATURE CONTROL
I f the heater outl et ai r temperature cannot be
adjusted wi th the temperature control knob(s) on the
A/C Heater control panel , the fol l owi ng coul d requi re
servi ce:
The A/C heater control .
The bl end door actuator(s).
The wi re harness ci rcui ts for the A/C heater con-
trol or the bl end door actuator(s).
The bl end door(s).
I mproper engi ne cool ant temperature.
STANDARD PROCEDURE - DIODE
REPLACEMENT
cabl e.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 3).
(4) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
Fig. 3 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
(5) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary refer to the
appropri ate wi ri ng di agram for current fl ow.
type sol der onl y. Do not use acid core solder.
(7) Tape the di ode to the harness usi ng el ectri cal
tape maki ng, sure the di ode i s compl etel y seal ed
from the el ements.
(8) Re-connect the battery, and test affected sys-
tems.
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
VEHICLE WJ - Grand
Cherokee
SYSTEM R134a w/
expansion valve
COMPRESSOR Nippondenso
10PA17
ND-8 PAG oil
Freezeup
Control
Evaporator Probe Evaporator
mounted
Low psi Control opens < 22 psi -
resets > 34-38 psi
High psi Control opens > 450-490
psi - resets <
270-330 psi
line mounted
CONTROL
HEAD
Manual type manual
controls
Automatic Zone
Control (AZC)
Automatic
Zone Control
(AZC) with
dual infrared
sensing
Mode Doors Vacuum actuators
(manual)
electric
actuator
(AZC)
Blend Door Electric actuator (manual and
AZC)
Blend Door
(passenger)
Electric actuator (AZC only)
Recirculation
Door
Vacuum actuator
(manual)
electric
actuator
(AZC)
Blower Motor Hardwired to
control head
resistor block
(manual),
blower
controller (AZC)
COOLING FAN Hybrid - viscous
clutch/electric
PCM output
CLUTCH
Control Relay PCM
controlled
Draw 2.0-3.9 amps @ 12 V 0.5V@ 70F
Gap 0.016-0.031
DRB III
Reads TPS, RPM, A/C
switch
Actuators Clutch relay
A/C COMPRESSOR
SHAFT BOLT
13 9.6 115
A/C COMPRESOR LINE
MANIFOLD FASTENERS
4.0L/4.7L
25.4 18.75 225
A/C COMPRESOR LINE
MANIFOLD FASTENERS
2.7L DIESEL
22 16.2 195
A/C COMPRESSOR TO
ENGINE BLOCK BOLTS -
4.0L/4.7L
45-65 33-48 398-575
A/C COMPRESSOR TO
ENGINE BLOCK BOLTS -
2.7L DIESEL
30 22 266
A/C COMPRESSOR REAR
BRACE BOLTS - 4.0L
40-55 30-41 354-487
A/C COMPRESSOR REAR
BRACE BOLTS - 4.7L
35-45 26-33 310-398
A/C CONDENSER TO
REFRIG. LINE
FASTENERS
28 21 248
A/C EVAPORATOR LINE to
TXV FASTENERS
28 21 247
ACCUMULATOR
RETAINING BAND
(4.0L/4.7L)
12 9.0 106
ACCUMULATOR
RETAINING BAND (3.1L
DIESEL)
5 3.7 44
BLOWER MOTOR
SCREWS
2.2 1.7 20
DOOR ACTUATOR
SCREWS
2.2 1.7 20
HVAC HOUSING SCREWS 2.2 1.7 20
HVAC HOUSING TO DASH
PANEL NUTS (ENGINE
COMP. SIDE)
7 5 62
HVAC HOUSING TO DASH
PANEL NUTS
(PASSENGER COMP.
SIDE)
4.5 3.3 40
EXPANSION VALVE TO
HVAC FASTENERS
20 15 177
SUCTION LINE TO
ACCUMULATOR FITTING
28 20.7 248
CONTROLS
TABLE OF CONTENTS
page page
CONTROLS
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A/C COMPRESSOR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH COIL . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
COMPRESSOR CLUTCH RELAY . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
A/C HEATER CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ZONE CONTROL SYSTEM . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
A/C PRESSURE TRANSDUCER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
BLOWER MOTOR CONTROLLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR BLOCK . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
BLOWER MOTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MOTOR SWITCH-MANUAL TEMPERATURE
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
IN-CAR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BLEND DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
MODE DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL
REMOVAL - HEAT/DEFROST - PANEL/
DEFROST DOOR ELECTRIC ACTUATOR . . . 31
REMOVAL - HEAT/DEFROST DOOR
VACUUM ACTUATOR . . . . . . . . . . . . . . . . . . 31
REMOVAL - PANEL/DEFROST DOOR
VACUUM ACTUATOR . . . . . . . . . . . . . . . . . . 32
INSTALLATION
INSTALLATION - HEAT/DEFROST -
PANEL/DEFROST DOOR ELECTRIC
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION - HEAT/DEFROST DOOR
VACUUM ACTUATOR . . . . . . . . . . . . . . . . . . 33
INSTALLATION - PANEL/DEFROST DOOR
VACUUM ACTUATOR . . . . . . . . . . . . . . . . . . 33
RECIRCULATION DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL
REMOVAL - RECIRCULATION DOOR
VACUUM ACTUATOR . . . . . . . . . . . . . . . . . . 33
REMOVAL - RECIRCULATION DOOR
ELECTRIC ACTUATOR . . . . . . . . . . . . . . . . . 33
INSTALLATION
INSTALLATION - RECIRCULATION DOOR
VACUUM ACTUATOR . . . . . . . . . . . . . . . . . . 34
ELECTRIC ACTUATOR . . . . . . . . . . . . . . . . . 34
VACUUM CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
WJ CONTROLS 24 - 9
VACUUM RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
CONTROLS
DIAGNOSIS AND TESTING - VACUUM SYSTEM
Vacuum control i s used to operate the mode doors
i n the standard equi pment manual temperature con-
trol system HVAC housi ng. Testi ng of the A/C Heater
mode control swi tch operati on wi l l determi ne i f the
vacuum and el ectri cal control s are functi oni ng. How-
ever, i t i s possi bl e that a vacuum control system that
operates perfectl y at engi ne i dl e (hi gh engi ne vac-
uum) may not functi on properl y at hi gh engi ne
speeds or l oads (l ow engi ne vacuum). Thi s can be
caused by l eaks i n the vacuum system, or a faul ty
vacuum check val ve.
A vacuum system test wi l l hel p to i denti fy the
source of poor vacuum system performance or vac-
uum system l eaks. Before starti ng thi s test, stop the
engi ne and make certai n that the probl em i snt a di s-
connected vacuum suppl y tube at the engi ne i ntake
mani fol d vacuum tap or the vacuum reservoi r.
Use an adjustabl e vacuum test set (Speci al Tool
C-3707-B) and a sui tabl e vacuum pump to test the
HVAC vacuum control system. Wi th a fi nger pl aced
over the end of the vacuum test hose probe (Fi g. 1),
adjust the bl eed val ve on the test set gauge to obtai n
a vacuum of exactl y 27 kPa (8 i n. Hg.). Rel ease and
bl ock the end of the probe several ti mes to veri fy that
the vacuum readi ng returns to the exact 27 kPa (8
i n. Hg.) setti ng. Otherwi se, a fal se readi ng wi l l be
obtai ned duri ng testi ng.
VACUUM CHECK VALVES
(1) Remove the vacuum check val ve to be tested.
The val ves are l ocated i n the (bl ack) vacuum suppl y
tubes at ei ther the engi ne i ntake mani fol d vacuum
tap, or on the bottom of the HVAC uni t behi nd the
passenger front fl oor duct.
(2) Connect the test set vacuum suppl y hose to the
A/C Heater control si de of the val ve. When connected
to thi s si de of the check val ve, no vacuum shoul d
pass and the test set gauge shoul d return to the 27
kPa (8 i n. Hg.) setti ng. I f OK, go to Step 3. I f not OK,
repl ace the faul ty val ve.
(3) Connect the test set vacuum suppl y hose to the
engi ne vacuum si de of the val ve. When connected to
thi s si de of the check val ve, vacuum shoul d fl ow
through the val ve wi thout restri cti on. I f not OK,
repl ace the faul ty val ve.
A/C HEATER CONTROL
(1) Connect the test set vacuum probe to the
HVAC vacuum suppl y (bl ack) tube i n the engi ne com-
partment. Posi ti on the test set gauge so that i t can
be vi ewed from the passenger compartment.
(2) Pl ace the A/C Heater mode control swi tch knob
i n each mode posi ti on, one posi ti on at a ti me, and
pause after each sel ecti on. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each sel ecti on i s made. I f not OK, a component or
vacuum l i ne i n the vacuum ci rcui t of the sel ected
mode has a l eak. See the procedure i n Locati ng Vac-
uum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
Fig. 1 ADJUST VACUUM TEST BLEED VALVE -
TYPICAL
1 - VACUUM PUMP TOOL C-4289
2 - VACUUM TEST SET C-3707
3 - BLEED VALVE
4 - PROBE
24 - 10 CONTROLS WJ
LOCATING VACUUM LEAKS
INJURY.
(1) Di sconnect the vacuum harness connector from
the back of the A/C Heater mode control swi tch on
the control panel .
(2) Connect the test set vacuum hose probe to each
port i n the vacuum harness connector, one at a ti me,
and pause after each connecti on (Fi g. 2). The test set
gauge shoul d return to the 27 kPa (8 i n. Hg.) setti ng
shortl y after each connecti on i s made. I f OK, repl ace
the faul ty mode control swi tch. I f not OK, go to Step
3.
(3) Determi ne the vacuum l i ne col or of the vacuum
ci rcui t that i s l eaki ng. To determi ne the vacuum l i ne
col ors, refer to the Vacuum Ci rcui ts chart (Fi g. 3).
(4) Di sconnect and pl ug the vacuum l i ne from the
component (fi tti ng, actuator, val ve, swi tch, or reser-
voi r) on the other end of the l eaki ng ci rcui t. I nstru-
ment panel di sassembl y or removal may be necessary
to gai n access to some components.
(5) Connect the test set hose or probe to the open
end of the l eaki ng ci rcui t. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each connecti on i s made. I f OK, repl ace the faul ty
di sconnected component. I f not OK, go to Step 6.
(6) To l ocate a l eak i n a vacuum l i ne, l eave one
end of the l i ne pl ugged and connect the test set hose
or probe to the other end. Run your fi ngers sl owl y
al ong the l i ne whi l e watchi ng the test set gauge. The
vacuum readi ng wi l l fl uctuate when your fi ngers con-
tact the source of the l eak. To repai r the vacuum
l i ne, cut out the l eaki ng secti on of the l i ne. Then,
i nsert the l oose ends of the l i ne i nto a sui tabl e l ength
of 3 mi l l i meter (1/8-i nch) i nsi de di ameter rubber
hose.
Fig. 2 VACUUM CIRCUIT TEST
WJ CONTROLS 24 - 11
CONTROLS (Continued)
Fig. 3 VACUUM CIRCUITS
24 - 12 CONTROLS WJ
CONTROLS (Continued)
DESCRIPTION
The compressor cl utch assembl y consi sts of a sta-
ti onary el ectromagneti c coi l , a hub beari ng and pul -
l ey assembl y, and a cl utch pl ate (Fi g. 4). The
el ectromagneti c coi l uni t and the hub beari ng and
pul l ey assembl y are each retai ned on the nose of the
compressor front housi ng wi th snap ri ngs. The cl utch
pl ate i s keyed to the compressor shaft and secured
wi th a bol t.
OPERATION
The compressor cl utch components provi de the
means to engage and di sengage the compressor from
the engi ne serpenti ne accessory dri ve bel t. When the
cl utch coi l i s energi zed, i t magneti cal l y draws the
cl utch i nto contact wi th the pul l ey and dri ves the
compressor shaft. When the coi l i s not energi zed, the
pul l ey freewheel s on the cl utch hub beari ng, whi ch i s
part of the pul l ey. The compressor cl utch and coi l are
the onl y servi ced parts on the compressor.
The compressor cl utch engagement i s control l ed by
several components: the a/c swi tch on the a/c heater
control panel , the Automati c Zone Control (AZC) con-
trol modul e (i f the vehi cl e i s so equi pped), the evap-
orator probe, the a/c hi gh pressure transducer, the
a/c compressor cl utch rel ay, the body control modul e
(BCM) and the Powertrai n Control Modul e (PCM).
The PCM may del ay compressor cl utch engagement
for up to thi rty seconds. Refer to El ectroni c Control
Modul es for more i nformati on on the PCM control s.
CLUTCH COIL
For ci rcui t descri pti ons and di agrams, refer to the
appropri ate wi ri ng di agrams. The battery must be
ful l y-charged before performi ng the fol l owi ng tests.
Refer to Battery for more i nformati on.
(1) Connect an ammeter (0 to 10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0 to 20 vol t scal e) wi th cl i p-type l eads for measuri ng
the vol tage across the battery and the compressor
cl utch coi l .
(2) Wi th the a/c heater mode control swi tch i n any
a/c mode, the a/c heater control a/c swi tch i n the ON
posi ti on, and the bl ower motor swi tch i n the l owest
speed posi ti on, start the engi ne and run i t at normal
i dl e.
(3) The compressor cl utch coi l vol tage shoul d read
wi thi n 0.2 vol ts of the battery vol tage. I f there i s
vol tage at the cl utch coi l , but the readi ng i s not
wi thi n 0.2 vol ts of the battery vol tage, test the cl utch
coi l feed ci rcui t for excessi ve vol tage drop and repai r
as requi red. I f there i s no vol tage readi ng at the
cl utch coi l , use a DRBI I I scan tool and the appro-
pri ate di agnosti c i nformati on for testi ng of the com-
pressor cl utch ci rcui t. The fol l owi ng components
must be checked and repai red as requi red before you
can compl ete testi ng of the cl utch coi l :
Fuses i n the juncti on bl ock and the Power Di s-
tri buti on Center (PDC)
A/C heater mode control swi tch
A/C compressor cl utch rel ay
A/C hi gh pressure transducer
A/C evaporator probe
Powertrai n Control Modul e (PCM)
(4) The compressor cl utch coi l i s acceptabl e i f the
current draw measured at the cl utch coi l i s 2.0 to 3.9
amperes wi th the el ectri cal system vol tage at 11.5 to
12.5 vol ts. Thi s shoul d onl y be checked wi th the work
area temperature at 21 C (70 F). I f system vol tage
i s more than 12.5 vol ts, add el ectri cal l oads by turn-
i ng on el ectri cal accessori es unti l the system vol tage
drops bel ow 12.5 vol ts.
(a) I f the cl utch coi l current readi ng i s four
amperes or more, the coi l i s shorted and shoul d be
repl aced.
(b) I f the cl utch coi l current readi ng i s zero, the
coi l i s open and shoul d be repl aced.
Fig. 4 COMPRESSOR CLUTCH - TYPICAL
1 - CLUTCH PLATE
2 - SHAFT KEY
3 - PULLEY
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
WJ CONTROLS 24 - 13
STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the A/C Heater control i n the
Reci rcul ati on Mode, the A/C button i n the on posi -
ti on, the bl ower motor swi tch i n the hi ghest speed
posi ti on, and the engi ne speed at 1500 to 2000 rpm.
Thi s procedure (burni shi ng) wi l l seat the opposi ng
fri cti on surfaces and provi de a hi gher compressor
cl utch torque capabi l i ty.
REMOVAL
The refri gerant system can remai n ful l y-charged
duri ng compressor cl utch, pul l ey, or coi l repl acement.
The compressor cl utch can be servi ced i n the vehi cl e.
cabl e.
(2) Remove the serpenti ne dri ve bel t. Refer to
Cool i ng for the procedures.
(3) Remove the bol t that secures the compressor
cl utch to the compressor shaft (Fi g. 5). A band-type
oi l fi l ter wrench may be used to secure the cl utch
duri ng bol t removal .
(4) Tap the cl utch pl ate wi th a pl asti c mal l et to
rel ease i t from the spl i nes on the compressor shaft.
Remove the cl utch pl ate and shi m(s) from the com-
pressor shaft (Fi g. 6).
CAUTION: Do not pry between the clutch plate
assembly and the pulley to remove it from the com-
pressor shaft. Prying may damage the clutch plate
assembly.
(5) Remove the external snap ri ng that secures the
compressor cl utch pul l ey to the nose of the compres-
sor front housi ng wi th snap ri ng pl i ers (Speci al Tool
C-4574) and sl i de the pul l ey assembl y off of the com-
pressor (Fi g. 7).
(6) Remove the screw and retai ner from the cl utch
coi l l ead wi re harness on the compressor front hous-
i ng.
Fig. 5 COMPRESSOR SHAFT BOLT
1 - COMPRESSOR CLUTCH PLATE
2 - COMPRESSOR SHAFT BOLT
Fig. 6 CLUTCH PLATE AND SHIM(S)
1 - COMPRESSOR SHAFT
2 - CLUTCH PLATE
3 - CLUTCH PLATE SHIM
Fig. 7 PULLEY SNAP RING
1 - SNAP RING
24 - 14 CONTROLS WJ
A/C COMPRESSOR CLUTCH (Continued)
(7) Remove the external snap ri ng that secures the
compressor cl utch coi l to the nose of the compressor
front housi ng wi th snap ri ng pl i ers and sl i de the coi l
assembl y off of the compressor (Fi g. 8).
INSPECTION
Exami ne the fri cti on surfaces of the cl utch pul l ey
and the cl utch pl ate for wear. The pul l ey and pl ate
shoul d be repl aced i f there i s excessi ve wear or scor-
i ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for refri gerant oi l .
Remove the fel t wi ck from around the shaft i nsi de
the nose of the compressor front housi ng. I f the fel t
i s saturated wi th refri gerant oi l , the compressor
shaft seal i s l eaki ng and the compressor must be
repl aced.
Check the cl utch pul l ey beari ng for roughness or
excessi ve l eakage of grease. Repl ace the beari ng, i f
requi red.
INSTALLATION
(1) Al i gn the dowel pi n on the back of the cl utch
fi el d coi l wi th the hol e i n the compressor front hous-
i ng and press the fi el d coi l i nto pl ace over the nose of
the compressor.
(2) I nstal l the cl utch coi l l ead wi re harness retai n-
i ng cl i p on the compressor front housi ng and ti ghten
the retai ni ng screw.
(3) I nstal l the cl utch fi el d coi l and snap ri ng wi th
snap ri ng pl i ers (Speci al Tool C-4574). The bevel si de
of the snap ri ng must be faci ng outward. Al so, both
eyel ets of the snap ri ng must be to the ri ght or l eft of
the pi n on the compressor. Press i n on the snap ri ng
to be certai n that i t i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(4) I nstal l the pul l ey assembl y onto the compres-
sor. I f necessary, pl ace a bl ock of wood on the fri cti on
surface and tap gentl y wi th a hammer (Fi g. 9).
CAUTION: Do not mar the pulley friction surface.
(5) I nstal l the pul l ey assembl y retai ni ng snap ri ng
(bevel si de outward) wi th snap ri ng pl i ers (Speci al
Tool C-4574). Press i n on the snap ri ng to be certai n
that i t i s properl y seated i n the groove.
(6) I f the ori gi nal cl utch pl ate assembl y and pul l ey
assembl y are to be reused, the ol d shi m(s) can be
used. I f not, pl ace a stack of shi m(s) equal to the ol d
shi m(s) on the shaft agai nst the shoul der.
(7) I nstal l the cl utch pl ate assembl y onto the
shaft.
(8) Wi th the cl utch pl ate assembl y ti ght agai nst
the shi m(s), measure the ai r gap between the cl utch
pl ate and the pul l ey face wi th feel er gauges. The ai r
Fig. 8 CLUTCH COIL SNAP RING
2 - CLUTCH COIL
3 - SNAP RING
4 - COMPRESSOR
Fig. 9 PULLEY ASSEMBLY INSTALL
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
WJ CONTROLS 24 - 15
gap shoul d be between 0.35 to 0.65 mi l l i meter (0.014
to 0.026 i nch). I f the proper ai r gap i s not obtai ned,
add or subtract shi ms as needed unti l the desi red ai r
gap i s obtai ned.
(9) I nstal l the compressor shaft bol t. Ti ghten the
bol t to 13 Nm (115 i n. l bs.).
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is still correct. Spin the
pulley before performing a final check of the air
gap.
(10) To compl ete the i nstal l ati on, (Refer to 24 -
COMPRESSOR - I NSTALLATI ON)
RELAY
DESCRIPTION
The compressor cl utch rel ay i s a I nternati onal
Standards Organi zati on (I SO) mi cro-rel ay. The termi -
nal desi gnati ons and functi ons are the same as a con-
venti onal I SO rel ay. However, the mi cro-rel ay
termi nal ori entati on (footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the rel ay case di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
OPERATION
The compressor cl utch rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the compres-
sor cl utch coi l when the Powertrai n Control Modul e
(PCM) grounds the coi l si de of the rel ay. The PCM
responds to i nputs from the a/c compressor swi tch on
the a/c heater control panel , the Automati c Zone Con-
trol (AZC) control modul e (i f the vehi cl e i s so
equi pped), the a/c fi n probe, and the a/c hi gh pres-
sure transducer. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/CONTROLS/A/C COMPRESSOR
CLUTCH RELAY - DI AGNOSI S AND TESTI NG)
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment. Refer to the PDC l abel for rel ay i denti fi cati on
and l ocati on.
The compressor cl utch rel ay cannot be repai red
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH RELAY
The compressor cl utch rel ay (Fi g. 10) i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
PDC l abel for rel ay i denti fi cati on and l ocati on.
Remove the rel ay from the PDC to perform the fol -
l owi ng tests:
and 30. I f OK, see the Rel ay Ci rcui t Test procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
appropri ate wi ri ng i nformati on..
connected to fused battery feed. There shoul d be bat-
tery vol tage at the cavi ty for rel ay termi nal 30 at al l
(2) The rel ay normal l y cl osed termi nal (87A) i s not
used i n thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the compressor cl utch coi l . There shoul d
be conti nui ty between thi s cavi ty and the A/C com-
pressor cl utch rel ay output ci rcui t cavi ty of the com-
pressor cl utch coi l wi re harness connector. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t as
requi red.
(4) The rel ay coi l battery termi nal (86) i s con-
nected to the fused i gni ti on swi tch output (run/start)
ci rcui t. There shoul d be battery vol tage at the cavi ty
for rel ay termi nal 86 wi th the i gni ti on swi tch i n the
On posi ti on. I f OK, go to Step 5. I f not OK, repai r the
Fig. 10 A/C COMPRESSOR CLUTCH RELAY
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
24 - 16 CONTROLS WJ
open ci rcui t to the fuse i n the juncti on bl ock as
requi red.
(5) The coi l ground termi nal cavi ty (85) i s swi tched
to ground through the Powertrai n Control Modul e
(PCM). There shoul d be conti nui ty between thi s cav-
i ty and the A/C compressor cl utch rel ay control ci r-
cui t cavi ty of the PCM wi re harness connector C
(gray) at al l ti mes. I f not OK, repai r the open ci rcui t
as requi red.
REMOVAL
cabl e.
(3) Refer to the l abel on the PDC for compressor
cl utch rel ay i denti fi cati on and l ocati on.
(4) Unpl ug the compressor cl utch rel ay from the
PDC.
INSTALLATION
(1) I nstal l the compressor cl utch rel ay by al i gni ng
the rel ay termi nal s wi th the cavi ti es i n the PDC and
pushi ng the rel ay fi rml y i nto pl ace.
(2) I nstal l the PDC cover.
(4) Test the rel ay operati on.
A/C HEATER CONTROL
DESCRIPTION
The manual temperature control HVAC system
uses a combi nati on of el ectri cal , and vacuum con-
trol s. The Automati c Zone Control (AZC) HVAC sys-
tem uses onl y el ectri cal control s. These control s
provi de the vehi cl e operator wi th a number of setti ng
opti ons to hel p control the cl i mate and comfort
wi thi n the vehi cl e. Refer to the owners manual i n
suggested operati on and use of these control s.
Both a/c heater control panel s are l ocated on the
i nstrument panel i nboard of the steeri ng col umn and
bel ow the radi o (Fi g. 12). Both control panel s contai n
rotary-type temperature control knob(s), a rotary-
type mode control swi tch knob, a rotary-type bl ower
motor speed swi tch knob and an ai r condi ti oni ng
compressor push button swi tch. The rear wi ndow
defogger push button swi tch i s al so l ocated on a/c
heater control panel . The AZC control panel al so fea-
tures a reci rcul ati on push button swi tch and a vac-
uum fl uorescent di spl ay area.
OPERATION
The AZC control modul e uses i nfrared sensi ng
technol ogy to control occupant comfort l evel s, not the
actual passenger compartment ai r temperature. Dual
i nfrared sensors mounted i n the face of the control
uni t i ndependentl y measure the surface temperature
to mai ntai n customer-percei ved comfort temperature
under changi ng condi ti ons. Dual Zone temperature
control provi des wi de si de-to-si de vari ati on i n comfort
temperature to exceed the needs of ei ther front seat
occupant. Thi s sensi ng system repl aces i nteri or ai r
temperature and sol ar sensors used to approxi mate
di rect sensi ng control through compl ex control pro-
grams.
Fig. 11 POWER DISTRIBUTION CENTER (PDC)
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - NEGATIVE CABLE
3 - POSITIVE CABLE
4 - POWER DISTRIBUTION CENTER (PDC)
Fig. 12 A/C HEATER CONTROL PANELS
WJ CONTROLS 24 - 17
A/C COMPRESSOR CLUTCH RELAY (Continued)
Both the manual A/C Heater control panel and the
AZC control panel are servi ced onl y as compl ete
uni ts and cannot be repai red. I f faul ty or damaged,
the enti re control panel uni t must be repl aced.
DIAGNOSIS AND TESTING - AUTOMATIC ZONE
CONTROL SYSTEM
The Automati c Zone Control (AZC) control modul e
has a system sel f-di agnosti c mode whi ch conti nuousl y
moni tors vari ous parameters duri ng normal system
operati on. I f a system faul t i s detected, a current and
hi stori cal faul t i s recorded. When the current faul t i s
cl eared, the hi stori cal faul t remai ns unti l reset (man-
ual l y or automati cal l y). Both the current and hi stor-
i cal faul t codes can be accessed through ei ther the
front panel , or over the Programmabl e Communi ca-
ti ons I nterface (PCI ) bus usi ng a DRBI I I scan tool ,
and the appropri ate di agnosti c i nformati on.
The AZC control modul e i s capabl e of three di ffer-
ent types of sel f-di agnosti c tests, as fol l ows:
Faul t Code Tests
I nput Ci rcui t Tests
Output Ci rcui t/Actuator Tests
The i nformati on that fol l ows descri bes:
How to read the sel f-di agnosti c di spl ay
How to enter the AZC control modul e sel f-di ag-
nosti c test mode
How to sel ect the sel f-di agnosti c test types
How to perform the di fferent tests
ENTERING THE AZC SELF-DIAGNOSTIC MODE
To enter the AZC sel f-di agnosti c mode, perform the
fol l owi ng:
(1) Depress the a/c and reci rc buttons at the same
ti me and hol d. Rotate the l eft temperature control
knob cl ockwi se (CW) one detent.
(2) I f you conti nue to keep the a/c and reci rc but-
tons depressed, the AZC control modul e wi l l perform
a Segment Test of the Vacuum Fl uorescent (VF) di s-
pl ay. I n the Segment Test you shoul d see al l of the
di spl ay segments i l l umi nate as l ong as both buttons
are hel d. I f a di spl ay segment fai l s to i l l umi nate, the
vacuum fl uorescent di spl ay i s faul ty and the a/c
heater control must be repl aced.
(3) After vi ewi ng the Segment Test, rel ease the
A/C and Reci rc buttons and the di spl ay wi l l cl ear
momentari l y. If a 0 is displayed, then no faults
are set in the system. Shoul d there be any faul ts,
ei ther current or hi stori cal , al l faul t codes wi l l be
di spl ayed i n ascendi ng numeri cal sequence (note no
effort i s made to di spl ay faul t codes i n chronol ogi cal
order). Each faul t code i s di spl ayed for one second
before the next code i s di spl ayed. Once al l faul t codes
have been di spl ayed, the system wi l l then repeat the
faul t code numbers. Thi s wi l l conti nue unti l the l eft
si de set temperature control i s moved at l east one
detent posi ti on i n the CW di recti on or the i gni ti on i s
turned OFF.
FAULT CODE TESTS
Faul t codes are two-di gi t numbers that i denti fy a
ci rcui t that i s mal functi oni ng. There are two di ffer-
ent ki nds of faul t codes.
1. Current Fault Codes - Current means the
faul t i s present ri ght now. There are two types of cur-
rent faul ts: i nput faul ts, and system faul ts.
2. Historical Fault Codes - Hi stori cal or stored
means that the faul t occurred previ ousl y, but i s not
present ri ght now. A majori ty of hi stori cal faul t codes
are caused by i ntermi ttent wi re harness or wi re har-
ness connector probl ems.
CURRENT FAULT CODES
Input faults 01 = IR thermister circuit
open
02 = IR thermister circuit
shorted
03 = Fan pot shorted
04 = Fan pot open
05 = Mode pot shorted
06 = Mode pot open
07 = IR sensor delta too
large
08 = Reserved
09 = Reserved
10 = One of four motor
drivers has drive A
shorted to ground
11 = Engine air intake
temperature Buss
message missing
12 = Country code Buss
message missing
24 - 18 CONTROLS WJ
A/C HEATER CONTROL (Continued)
CURRENT FAULT CODES
System Faults 13 = Mode motor not
responding
14 = AI (Recirc) motor
not responding
15 = Left temperature
door not responding
16 = Right temperature
door not responding
17 = Mode door travel
range too small
18 = Mode door travel
range too large
19 = AI (Recirc) door
travel too small
20 = AI (Recirc) door
travel too large
door travel too small
door travel too large
door travel too small
door travel too large
25 = Calibration check
sum error
26 = Engine coolant temp
bus message missing
27 = Vehicle speed bus
message missing
28 = Engine RPM bus
message missing
29 = OAT bus message
missing
30 = Display intensity bus
message missing
31 = VIN number bus
message missing
32 = Raw OAT bus
message missing
WJ CONTROLS 24 - 19
HISTORICAL FAULT CODES
Input faults 33 = IR thermister circuit was open
34 = IR thermister circuit was shorted
35 = Fan pot was shorted
36 = Fan pot was open
37 = Mode pot was shorted
38 = Mode pot was open
39 = IR sensor delta was too large
40 = Reserved
41 = Reserved
42 = One of four motor drivers had drive A shorted to
ground
43 = Engine air intake temperature Buss message
missing
44 = Country code Buss message missing
System Faults 45 = Mode motor was not responding
46 = AI (Recirc) motor was not responding
47 = Left temperature door was not responding
48 = Right temperature door was not responding
49 = Mode door travel range too small
50 = Mode door travel range too large
51 = AI (Recirc) door travel range too small
52 = AI (Recirc) door travel range too large
53 = Left temperature door travel too small
54 = Left temperature door travel too large
55 = Right temperature door travel too small
56 = Right temperature door travel too large
57 = Calibration check sum error
58 = Engine coolant temp bus message missing
59 = Vehicle speed bus message missing
60 = Engine RPM bus message missing
61 = OAT bus message missing
62 = Display intensity bus message missing
63 = VIN number bus message missing
64 = Raw OAT bus message was missing
65 = Reserved
66 = Reserved
67 = Reserved
NOTE: A battery disconnect will erase all faults
stored in Random Access Memory (RAM) of the
AZC control module. It is recommended that all
faults be recorded before they are erased.
RETRIEVING FAULT CODES
(1) To begi n the faul t code tests, depress the A/C
and Reci rc buttons at the same ti me and rotate the
l eft temperature control knob cl ockwi se (CW) one
detent, then rel ease the push-button.
24 - 20 CONTROLS WJ
(2) If there are no fault codes, the 00 dis-
play value will remain in the VF window. Shoul d
there be any codes, each wi l l be di spl ayed for one
second i n ascendi ng numeri cal sequence (note: no
effort i s made to di spl ay faul ts i n the order they
occurred). The l eft si de set temperature di spl ay wi l l
be bl anked and the ri ght si de set temperature di s-
pl ay wi l l i ndi cate current and hi stori cal codes (8 hi s-
tori cal max) presentl y acti ve. Once al l codes have
been di spl ayed, the system wi l l repeat the faul t code
numbers. Thi s wi l l conti nue unti l the l eft si de set
temperature control i s moved at l east one detent
posi ti on i n ei ther di recti on, by pressi ng both the A/C
and Reci rc buttons at the same ti me, or the i gni ti on
i s turned off. Record al l of the faul t codes, then see
the Current and Hi stori cal Faul t Code charts for the
descri pti ons.
CLEARING FAULT CODES
Current faul ts cannot be el ectroni cal l y cl eared.
Repai r must be made to the system to el i mi nate the
faul t causi ng code. Hi stori cal faul t codes can be
cl eared manual l y, or automati cal l y. To cl ear a hi stor-
i cal faul t manual l y, depress and hol d ei ther the A/C
or Reci rc button for at l east three seconds whi l e the
di spl ay i s i n the faul t code mode of operati on. Hi stor-
i cal faul t codes are cl eared automati cal l y when the
correspondi ng current faul t code has been cl eared,
and has remai ned cl eared for a number of i gni ti on
cycl es. The faul ts have been cl eared when two hori -
zontal bars appear i n the Test Sel ector di spl ay.
EXITING SELF-DIAGNOSTIC MODE
The sel f-di agnosti c mode can be exi ted by pressi ng
both the A/C and Reci rc buttons at the same ti me, or
turni ng off the i gni ti on.
MONITOR CURRENT PARAMETERS
Whi l e i n the di spl ay faul t code mode of operati on,
current system parameters can al so be moni tored
and/or forced. Rotati ng the l eft si de set temperature
control cl ockwi se wi l l i ncrease the poi nter number
whi l e rotati ng the control counter cl ockwi se wi l l
decrease the poi nter number. Rotati ng the ri ght set
temperature control wi l l have no i mpact on poi nter
val ue or the val ue of the parameter bei ng moni tored.
Once the desi red poi nter number has been sel ected,
pressi ng ei ther the AC or Reci rc buttons wi l l di spl ay
the current val ue of the sel ected parameter. The
right side set temperature display is only capa-
ble of displaying only values ranging from 0 to
99, the left side set temperature display is used
for values greater than 99. If the value is less
than 99, the left side set temperature display
remains blanked. Whi l e a parameter i s bei ng over-
ri dden, the system wi l l conti nue to functi on normal l y
except for the parameter whi ch i s bei ng manual l y
control l ed.
For val ues < 0, the G segment i n the l eft si de set
temperature Most Si gni fi cant Di gi t (MSD)(or l eft-
most number i n the pai r) wi l l be used to i ndi cate a
negati ve number. For val ues between -01 to -99 the
Least Si gni fi cant Di gi t (LSD)(or ri ght-most number
of the pai r) i n the l eft si de set temperature wi l l
remai n bl ank. System control of parameter bei ng di s-
pl ayed can be overri dden by rotati ng the ri ght set
temperature control i n ei ther di recti on. Rotati ng the
ri ght temperature control i n the CW di recti on, the
sel ected parameter val ue i s overri dden and i ncre-
mented begi nni ng at the val ue whi ch was bei ng di s-
pl ayed. Rotati ng the ri ght temperature control i n the
CCW di recti on, the sel ected parameter val ue i s over-
ri dden and decremented begi nni ng at the val ue
whi ch was bei ng di spl ayed. The rate at whi ch i ncre-
menti ng and decrement occurs i s one uni t val ue per
set temperature detent posi ti on.
HVAC SYSTEM POINTER
Pointer
Number
DESCRIPTION Value
Displayed
01 A/C Enable 0 or 1
0 =
disabled
1 =
enabled
02 Final fan PWM duty cycle 0 to 255
While the value of this pointer
is being displayed, turning the
right set temperature control
either direction will manually
control the value. CW =
increase; CCW = decrease
03 Left NPRG * 0 to 255
* NPRG equals a calculated number based on outside
and in-vehicle conditions. This value is used by the
AZC to position the Mode motor, Air Inlet motor, and
control blower motor speed.
04 Right NPRG 0 to 255
WJ CONTROLS 24 - 21
HVAC SYSTEM POINTER
05 Avg NPRG 0 TO
255
06 Primary control side 0 or 1
0 = left 1
= right
07 EE Check sum (calculated) 0 to 255
08 Target intensity (in % ON time) 0 to 255
09 Not Used 0 to 0
10 Not Used 0 to 0
11 Right NINC * 0 to 255
* NINC equals a calculated number based on the IR
sensor and IR thermistor values used to calculate the
NPRG.
12 Left NINC 0 to 255
13 Right NMIX * 0 to 255
* NMIX equals a calculated number based on outside
and in-vehicle conditions used by the AZC to position
the Temperature motors.
HVAC SYSTEM POINTER
14 Left NMIX 0 to 255
increase; CW = decrease
15 Not Used 0 to 0
16 Not Used 0 to 0
17 Reserved
18 Reserved
19 Reserved
MODE VALUE POINTER
Pointer
Number
DESCRIPTION Value
Displayed
20 mode range in delta counts 0 to
9999
21 Current mode position (in
counts)
0 to
9999
22 mode target position in ratio 0 to 255
23 mode target position in counts 0 to
9999
24 Not Used 0 to 0
25 number of valve moves since
last index
0 to
9999
26 Not Used 0 to 0
27 Not Used 0 to 0
28 Not Used 0 to 0
29 mode motor state 0 to 5
0 = in position, 1 = moving
toward panel, 2 = moving
toward defrost, 3 = searching
range, 4 = stalled moving
toward panel, 5 = stalled
moving toward defrost
24 - 22 CONTROLS WJ
LEFT SIDE TEMPERATURE POINTER
Pointer
Number
DESCRIPTION Value
Displayed
30 Left side temp range in delta
counts
0 to
9999
31 Current left side temp position
(in counts)
0 to
9999
32 Left side temp target position
(in ratio)
0 to 255
33 Left side temp target in counts 0 to
9999
34 Not used 0 to 0
last index
0 to
9999
36 Not used 0 to 0
37 Not used 0 to 0
38 Not used 0 to 0
39 Left side temp motor state 0 to 5
RIGHT SIDE TEMPERATURE POINTER
Pointer
Number
DESCRIPTION Value
Displayed
40 Right side temp range in delta
counts
0 to
9999
41 Current right side temp
position (in counts)
0 to
9999
42 Right side temp target position
(in ratio)
0 to 255
43 Right side temp target in
counts
0 to
9999
44 Not used 0 to 0
RIGHT SIDE TEMPERATURE POINTER
last index
0 to
9999
46 Not used 0 to 0
47 Not used 0 to 0
48 Not used 0 to 0
49 Right side temp motor state 0 to 5
AIR INLET POINTER
Pointer
Number
DESCRIPTION Value
Displayed
50 Air inlet range (in counts) 0 to
9999
51 Current air inlet position (in
counts)
0 to
9999
52 Air inlet target position (in
ratio)
0 to 255
53 Air inlet target in counts 0 to
9999
54 Not used 0 to 0
55 number of motor moves since
last index
0 to
9999
56 Not used 0 to 0
57 Not used 0 to 0
58 Not used 0 to 0
59 Air inlet motor state 0 to 5
60 Reserved
61 Actual Outside Air Temp (in
degrees F)
-40 to
215
62 Not used 0 to 0
WJ CONTROLS 24 - 23
AIR INLET POINTER
63 Engine Intake Air Temperature
(in degrees F)
-40 to
215
64 Vehicle speed in MPH 0 to 255
65 Engine RPM/100 -0 to 82
66 Engine Coolant Temp - 40 (in
degrees F)
-40 to
215
67 Country Code 0 to 255
68 Not used 0 to 0
69 Not used 0 to 0
IR SENSOR POINTER
Pointer
Number
DESCRIPTION Value
Displayed
70 Thermistor temp (in degrees) -40 to
215
71 Left side sensor A/D (filtered) 0 to 255
72 Right side sensor A/D (filtered) 0 to 255
73 Left side temp (in degrees F) -40 to
140
74 Right side temp (in degrees F) -40 to
140
75 Not used 0 to 0
76 Not used 0 to 0
77 Not used 0 to 0
78 Not used 0 to 0
79 Not used 0 to 0
IDENTIFICATION POINTER
Pointer
Number
DESCRIPTION Value
Displayed
80 ROM bit pattern number (digits
1,2,3 & 4)
0 to
9999
81 ROM bit pattern number (digits
5,6,7 & 8)
0 to
9999
82 CAL bit pattern number (digits
1,2,3 & 4)
0 to
9999
83 CAL bit pattern number (digits
5,6,7 & 8)
0 to
9999
84 Not used 0 to 0
85 Not used 0 to 0
86 Not used 0 to 0
87 Not used 0 to 0
88 Not used 0 to 0
89 Not used 0 to 0
OUTPUT CIRCUIT/ACTUATOR TESTS
I n the Output Ci rcui t/Actuator Test mode, the out-
put ci rcui ts can be vi ewed, moni tored, overri dden,
and tested. I f a fai l ure occurs i n an output ci rcui t,
test the ci rcui t by overri di ng the system. Test the
actuator through i ts ful l range of operati on.
(1) To begi n the Output Ci rcui t/Actuator Tests you
must be i n the Sel ect Test mode.
(2) Wi th a 00 val ue di spl ayed i n the Test Sel ector
and no sti ck man, turn the rotary temperature con-
trol knob unti l the test number you are l ooki ng for
appears i n the Test Sel ector di spl ay. See the Ci rcui t
Testi ng charts for a l i sti ng of the test numbers, test
i tems, test types, system tested, and di spl ayed val -
ues.
(3) To see the output val ue, depress the a/c or
reci rc button. The val ues di spl ayed wi l l represent the
output from the AZC control modul e.
(4) To enter the actuator test, depress the a/c or
reci rc button. Then, rotate the ri ght temperature set
knob to the desi red posi ti on.
REMOVAL
INJURY.
cabl e.
(2) Remove the center upper, and center l ower
bezel s from the i nstrument panel . Refer to I nstru-
ment Panel System for the procedures.
(3) Remove the 4 screws that secure the a/c heater
control to the i nstrument panel (Fi g. 13).
(4) Pul l the a/c heater control assembl y away from
the i nstrument panel far enough to access the con-
necti ons on the back of the control .
(5) Unpl ug the wi re and/or vacuum harness con-
nectors from the back of the a/c heater control (Fi g.
14).
(6) Remove the a/c heater control from the i nstru-
ment panel .
24 - 24 CONTROLS WJ
INSTALLATION
(1) Pl ug the wi re harness and/or vacuum harness
connectors i nto the back of the a/c heater control .
(2) Posi ti on the a/c heater control i n the i nstru-
ment panel and secure i t wi th 4 screws. Ti ghten the
(3) Rei nstal l the center upper, and center l ower
bezel s onto the i nstrument panel . Refer to I nstru-
ment Panel System for the procedures.
A/C PRESSURE TRANSDUCER
DESCRIPTION
The A/C pressure transducer i s i nstal l ed on a fi t-
ti ng l ocated on the refri gerant di scharge l i ne near
the condenser. An i nternal l y threaded hex fi tti ng on
the transducer connects i t to the external l y threaded
Schrader-type fi tti ng on the di scharge l i ne. A rubber
O-ri ng seal s the connecti on between the transducer
and the di scharge l i ne fi tti ng. Three termi nal s wi thi n
a mol ded pl asti c connector receptacl e on the top of
the transducer connect i t to the vehi cl e el ectri cal sys-
tem through a take out and connector of the head-
l amp and dash wi re harness.
The A/C pressure transducer cannot be adjusted or
repai red and i f faul ty or damaged, i t must be
repl aced.
OPERATION
The A/C pressure transducer moni tors the pres-
sures i n the hi gh si de of the refri gerant system
through i ts connecti on to a fi tti ng on the di scharge
l i ne. The transducer wi l l change i ts i nternal resi s-
tance i n response to the pressures i t moni tors. The
Powertrai n Control Modul e (PCM) provi des a fi ve
vol t reference si gnal and a sensor ground to the
transducer, then moni tors the output vol tage of the
transducer on a sensor return ci rcui t to determi ne
refri gerant pressure. The PCM i s preporgrammed to
respond to thi s and other sensor i nputs by control l i ng
the operati on of the ai r condi ti oni ng compressor
cl utch and the radi ator cool i ng fan to hel p opti mi ze
ai r condi ti oni ng system performance and to protect
the system components from damage. The A/C pres-
sure transducer i nput to the PCM wi l l al so prevent
the ai r condi ti oni ng compressor cl utch from engagi ng
when the ambi ent temperatures are bel ow about
0.556 C (33 F) due to the pressure/temperature
rel ati onshi p of the refri gerant. The Schrader-type
val ve i n the l i qui d l i ne fi tti ng permi ts the A/C pres-
sure transducer to be removed or i nstal l ed wi thout
di strubi ng the refri gerant i n the system. The A/C
pressure transducer i s di agnosed usi ng the DRBI I I
mati on.
Fig. 13 A/C HEATER CONTROL REMOVE/INSTALL
1 - MOUNTING SCREW TABS
Fig. 14 A/C HEATER CONTROL CONNECTIONS
1 - MODE SWITCH
2 - ELECTRICAL CONNECTIONS
3 - VACUUM HARNESS
WJ CONTROLS 24 - 25
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER
The A/C pressure transducer i s tested usi ng a
ti c i nformati on. Before testi ng the A/C pressure
transducer, be certai n that the transducer wi re har-
ness connecti on i s cl ean of corrosi on and properl y
connected. For the ai r condi ti oni ng system to operate,
an A/C pressure transducer vol tage readi ng between
0.7 and 4.56 vol ts i s requi red. Vol tage outsi de thi s
range i ndi cate a l ow or hi gh refri gerant system pres-
sure condi ti on to the Powertrai n Control Modul e
(PCM). The PCM i s programmed to respond to a l ow
or hi gh refri gerant system pressure by suppressi ng
operati on of the compressor. Refer to the A/C Pres-
sure Transducer Vol tage tabl e for the possi bl e condi -
ti on i ndi cated by the transducer vol tage readi ngs.
A/C PRESSURE TRANSDUCER VOLTAGE
VOLTAGE POSSIBLE INDICATION
0.0 1. NO SENSOR SUPPLY VOLTAGE FROM PCM.
2. SHORTED SENSOR CIRCUIT.
3. FAULTY TRANSDUCER
0.150 TO 0.450 1. AMBIENT TEMPERATURE BELOW 10c (50F).
2. LOW REFRIGERANT SYSTEM PRESSURE.
0.451 TO 4.519 1. NORMAL REFRIGERANT SYSTEM PRESSURE.
4.520 TO 4.850 1. HIGH REFRIGERANT SYSTEM PRESSURE.
5.0 1. OPEN SENSOR CIRCUIT.
2. FAULTY TRANSDUCER.
REMOVAL
WARNING: Transducer can be removed without
recoverying the system, but some loss of refriger-
ant can be expected(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNING) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION).
cabl e.
(2) Di sconnect the headl amp and dash wi re har-
ness connector for the A/C pressure transducer from
the transducer connector receptacl e.
(3) Usi ng an open end wrench, unscrew the A/C
pressure transducer from the fi tti ng on the di scharge
l i ne.
(4) Remove the seal from the A/C pressure trans-
ducer fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the A/C pressure trans-
ducer fi tti ng.
(2) Usi ng an open end wrench, i nstal l and ti ghten
the A/C pressure transducer onto the fi tti ng on the
di scharge l i ne.
(3) Reconnect the headl amp and dash wi re harness
connector for the A/C pressure transducer to the
transducer connector receptacl e.
BLOWER MOTOR
CONTROLLER
DESCRIPTION
Model s equi pped wi th the opti onal Automati c Zone
Control (AZC) system have a bl ower motor control l er.
The control l er al l ows the sel ecti on of al most i nfi -
ni tel y vari abl e bl ower motor speeds. The control l er i s
mounted to the HVAC housi ng, under the i nstrument
panel and just i nboard of the bl ower motor, i n the
same l ocati on used for the bl ower motor resi stor on
manual temperature control systems. I t can be
accessed wi thout removi ng any other components.
OPERATION
The bl ower motor control l er output to the bl ower
motor can be adjusted by the bl ower motor speed
swi tch knob on the AZC A/C Heater control panel , or
i t can be adjusted automati cal l y by the l ogi c ci rcui try
and programmi ng of the AZC control modul e. I n
ei ther case, the AZC control modul e sends the correct
pul se wi dth modul ated si gnal to the bl ower motor
control l er to obtai n the sel ected or programmed
bl ower motor speed.
The bl ower motor control l er cannot be repai red
24 - 26 CONTROLS WJ
A/C PRESSURE TRANSDUCER (Continued)
REMOVAL
cabl e.
(2) Depress l ocki ng tab and unpl ug the wi re har-
ness connector from the bl ower motor control l er.
(3) Depress l ocki ng tab and unpl ug the control l er
connector from the bl ower motor.
(4) Remove the 2 screws that secure the bl ower
motor control l er to the HVAC housi ng.
(5) Remove the bl ower motor control l er from the
HVAC housi ng (Fi g. 15).
INSTALLATION
(1) I nstal l the bl ower motor control l er i n the
HVAC housi ng. The housi ng i s i ndexed to al l ow con-
trol l er mounti ng i n onl y one posi ti on. Ti ghten the
mounti ng screws to 2.2 Nm (20 i n. l bs.).
(2) Pl ug i n the wi re harness connector to the
bl ower motor control l er.
(3) Pl ug i n the connector from the bl ower motor
control l er to the bl ower motor.
BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
Model s wi th the standard manual temperature
control system have a bl ower motor resi stor. The
bl ower motor resi stor i s mounted to the bottom of the
HVAC housi ng, under the i nstrument panel and just
i nboard of the bl ower motor. I t can be accessed for
servi ce wi thout removi ng any other components.
OPERATION
The resi stor has mul ti pl e resi stor wi res, each of
whi ch wi l l reduce the current fl ow to the bl ower
motor to change the bl ower motor speed by changi ng
the resi stance i n the bl ower motor ground path. The
bl ower motor swi tch di rects the ground path through
the correct resi stor wi re to obtai n the sel ected speed.
Wi th the bl ower motor swi tch i n the l owest speed
posi ti on, the ground path for the motor i s appl i ed
through al l of the resi stor wi res. Each hi gher speed
sel ected wi th the bl ower motor swi tch appl i es the
bl ower motor ground path through fewer of the resi s-
tor wi res, i ncreasi ng the bl ower motor speed. When
the bl ower motor swi tch i s i n the hi ghest speed posi -
ti on, the bl ower motor resi stor i s bypassed and the
bl ower motor recei ves a di rect path to ground.
The bl ower motor resi stor cannot be repai red and,
DIAGNOSIS AND TESTING - BLOWER MOTOR
RESISTOR BLOCK
INJURY.
cabl e.
(2) Unpl ug the wi re harness connector from the
bl ower motor resi stor.
Fig. 15 BLOWER MOTOR CONTROLLER REMOVE/
INSTALL
1 - BLOWER MOTOR CONTROLLER
2 - BLOWER MOTOR
3 - GROUND STRAP
5 - HEATER CORE TUBES
WJ CONTROLS 24 - 27
BLOWER MOTOR CONTROLLER (Continued)
(3) Check for conti nui ty between each of the
bl ower motor swi tch i nput termi nal s of the resi stor
and the resi stor output termi nal . I n each case there
shoul d be conti nui ty. I f OK, repai r the wi re harness
ci rcui ts between the bl ower motor swi tch and the
bl ower motor resi stor or bl ower motor as requi red. I f
not OK, repl ace the faul ty bl ower motor resi stor.
REMOVAL
cabl e.
(2) Depress l ocki ng tab and unpl ug the wi re har-
ness connector from the bl ower motor resi stor.
(3) Depress l ocki ng tab and unpl ug the resi stor
connector from the bl ower motor.
(4) Remove the 2 screws that secure the bl ower
motor resi stor to the HVAC housi ng.
(5) Remove the bl ower motor resi stor from the
INSTALLATION
(1) I nstal l the bl ower motor resi stor i n the HVAC
housi ng. The housi ng i s i ndexed to al l ow mounti ng i n
onl y one posi ti on. Ti ghten the mounti ng screws to 2.2
Nm (20 i n. l bs.).
(2) Pl ug i n the wi re harness connector to the
bl ower motor resi stor.
(3) Pl ug i n the connector from the bl ower motor
resi stor to the bl ower motor.
BLOWER MOTOR SWITCH
DESCRIPTION
The A/C Heater bl ower motor i s control l ed by a
rotary-type bl ower motor swi tch, mounted i n the A/C
Heater control panel . On vehi cl es wi th manual tem-
perature control systems, the swi tch al l ows the sel ec-
ti on of four bl ower motor speeds, but wi l l onl y
operate wi th the i gni ti on swi tch i n the On posi ti on
and the A/C Heater mode control swi tch i n any posi -
ti on, except Off. On vehi cl es wi th the Automati c Zone
Control (AZC) systems, the swi tch al l ows the sel ec-
ti on of Lo Auto, Hi Auto, and ten speed setti ngs
between Lo and Hi .
OPERATION
On manual temperature control systems, the
bl ower motor swi tch i s connected i n seri es wi th the
bl ower motor ground path through the a/c heater
mode control swi tch. The bl ower motor swi tch di rects
thi s ground path to the bl ower motor through the
bl ower motor resi stor wi res, or di rectl y to the bl ower
motor, as requi red to achi eve the sel ected bl ower
motor speed.
On AZC systems, the bl ower motor swi tch i s just
one of many i nputs to the AZC control modul e. I n the
manual bl ower modes, the AZC control modul e
adjusts the bl ower motor speed through the bl ower
motor control l er as requi red to achi eve the sel ected
bl ower swi tch posi ti on. I n the auto bl ower modes, the
AZC control assembl y i s programmed to sel ect and
adjust the bl ower motor speed through the bl ower
motor control l er as requi red to achi eve and mai ntai n
the sel ected comfort l evel .
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, i t must be repl aced. The swi tch i s
servi ced onl y as a part of the a/c heater control
assembl y.
SWITCH-MANUAL TEMPERATURE CONTROL
SYSTEM
Fig. 16 BLOWER MOTOR RESISTOR REMOVE/
INSTALL
1 - BLOWER MOTOR RESISTOR
2 - BLOWER MOTOR
3 - GROUND STRAP
24 - 28 CONTROLS WJ
BLOWER MOTOR RESISTOR BLOCK (Continued)
INJURY.
(1) Check for battery vol tage at the fuse i n the
Power Di stri buti on Center (PDC). I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
Remove the a/c heater control from the i nstrument
panel . (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/CONTROLS/A/C HEATER CONTROL -
REMOVAL) Check for conti nui ty between the ground
ci rcui t cavi ty of the a/c heater control wi re harness
connector and a good ground. There shoul d be conti -
(3) Wi th the a/c heater control wi re harness con-
nector unpl ugged, pl ace the a/c heater mode control
swi tch knob i n any posi ti on except the Off posi ti on.
Check for conti nui ty between the ground ci rcui t ter-
mi nal and each of the bl ower motor dri ver ci rcui t ter-
mi nal s of the a/c heater control as you move the
bl ower motor swi tch knob to each of the four speed
posi ti ons. There shoul d be conti nui ty at each dri ver
ci rcui t termi nal i n onl y one bl ower motor swi tch
speed posi ti on. I f OK, test and repai r the bl ower
dri ver ci rcui ts between the a/c heater control connec-
tor and the bl ower motor resi stor as requi red. I f not
OK, repl ace the faul ty a/c heater control uni t.
REMOVAL
INJURY.
The bl ower motor swi tch cannot be adjusted or
repai red, and i f faul ty or damaged, the a/c heater
control must be repl aced. (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/CONTROLS/A/C HEATER
CONTROL - REMOVAL)
IN-CAR TEMPERATURE
SENSOR
DESCRIPTION
Model s equi pped wi th the opti onal Automati c Zone
Control (AZC) system use automati c dual zone tem-
perature control wi th i nfrared sensi ng technol ogy.
The temperature sensor i s l ocated i n the center
i nstrument panel , between the dual temperature
knobs of the AZC.
OPERATION
The Automati c Zone Control uses i nfrared sensi ng
technol ogy to control occupant comfort l evel s, not the
actual passenger compartment ai r temperature. Dual
i nfrared sensors mounted i n the face of the control
uni t i ndependentl y measure the surface temperature
to mai ntai n customer-percei ved comfort temperature
under changi ng condi ti ons. Dual Zone temperature
control provi des wi de si de-to-si de vari ati on i n comfort
temperature to exceed the needs of ei ther front seat
occupant. Thi s sensi ng system repl aces i nteri or ai r
temperature and sol ar sensors used to approxi mate
di rect sensi ng control through compl ex control pro-
grams.
The i nfrared temperature sensor cannot be
AZC head must be repl aced.
NOTE: The infrared sensor window may be perma-
nently damaged if any type of cosmetic vinyl dress-
ings are allowed to contact the lens. Avoid spraying
or wiping this area with any cleaner or conditioner.
This may result in impaired temperature sensing
and control.
REMOVAL
The i nfrared temperature sensor cannot be
AZC head must be repl aced. (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/CONTROLS/A/C HEATER
CONTROL - REMOVAL)
WJ CONTROLS 24 - 29
BLOWER MOTOR SWITCH (Continued)
BLEND DOOR ACTUATOR
DESCRIPTION
The bl end door for al l model s i s actuated by an
el ectri c actuator, whi l e the AZC system uses 2 sepa-
rate actuators to al l ow the dri ver and passenger to
sel ect i ndi vi dual comfort l evel s. I n the fol l owi ng pro-
cedures, servi ce for both types of actuators i s cov-
ered.
REMOVAL
INJURY.
The bl end door actuator i s used on al l model s,
whether equi pped wi th manual or Automati c Zone
Control (AZC). Thi s actuator i s l ocated on the front of
the HVAC housi ng to the ri ght of the fl oor panel
transmi ssi on tunnel , and can be removed from the
passenger compartment wi thout i nstrument panel or
HVAC housi ng removal .
cabl e.
(2) Remove the gl ove box door. Refer to I nstrument
(3) Remove the l ower I /P gl ove box door surround
panel . Refer to I nstrument Panel System for the pro-
cedures.
bl end door actuator (Fi g. 17).
(5) Remove the 2 screws that secure the bl end
door actuator to the HVAC housi ng.
(6) Remove the bl end door actuator from the
HVAC housi ng.
INSTALLATION
(1) I nstal l the bl end door actuator on the HVAC
housi ng and ti ghten the two mounti ng screws to 2.2
Nm (20 i n. l bs.).
(2) Pl ug i n the wi re harness connector to the bl end
door actuator.
(3) I nstal l the gl ove box door. Refer to I nstrument
(4) I nstal l the l ower I /P gl ove box door surround
panel . Refer to I nstrument Panel System for the pro-
cedures.
(5) Connect and the battery negati ve cabl e.
MODE DOOR ACTUATOR
DESCRIPTION
The mode door actuators for vehi cl es equi pped wi th
the standard equi pment manual temperature control
system are vacuum control l ed. The opti onal Auto-
mati c Zone Control (AZC) system uses el ectri c motors
to actuate al l mode doors. The servi ce procedures for
both types of actuators are covered by the fol l owi ng
procedures.
Fig. 17 BLEND DOOR ACTUATOR
1 - BLEND DOOR ACTUATOR
24 - 30 CONTROLS WJ
REMOVAL
REMOVAL - HEAT/DEFROST - PANEL/DEFROST
DOOR ELECTRIC ACTUATOR
INJURY.
These actuators are used onl y on model s equi pped
wi th the opti onal Automati c Zone Control (AZC) sys-
tem.
cabl e.
(2) Remove the two bol ts that secure the center
i nstrument panel support bracket to the l eft si de of
(3) Remove the two bol ts that secure the center
i nstrument panel support bracket to the i nstrument
panel .
(4) Remove the center i nstrument panel support
bracket from the vehi cl e.
heat/defrost - panel /defrost door actuator (Fi g. 18).
(6) Remove the three screws that secure the heat/
defrost-panel /defrost door motor to the HVAC hous-
i ng.
(7) Remove the heat/defrost-panel /defrost door
motor from the HVAC housi ng.
REMOVAL - HEAT/DEFROST DOOR VACUUM
ACTUATOR
SYSTEM. FAILURE TO TAKE THE PROPER PRECAU-
TIONS COULD RESULT IN AN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Thi s actuator i s used onl y on model s equi pped wi th
the standard manual temperature control system.
(1) Remove the HVAC housi ng from the vehi cl e.
DI STRI BUTI ON/HVAC HOUSI NG - REMOVAL)
(2) Unpl ug the vacuum harness connector from the
heat/defrost door vacuum actuator (Fi g. 19).
(3) Di sengage the heat/defrost door pi vot connec-
ti on from the heat/defrost door pi vot pi n.
(4) Remove the screws that secure the heat/defrost
door vacuum actuator to the HVAC housi ng.
(5) Remove the heat/defrost door vacuum actuator
from the HVAC housi ng.
Fig. 18 HEAT/DEFROST - PANEL/DEFROST DOOR
ACTUATOR
1 - LEVER ASSEMBLY
2 - LINKAGE
3 - ELECTRIC ACTUATOR
WJ CONTROLS 24 - 31
MODE DOOR ACTUATOR (Continued)
REMOVAL - PANEL/DEFROST DOOR VACUUM
ACTUATOR
INJURY.
heat/defrost door vacuum actuator (Fi g. 20).
(3) Di sengage the panel /defrost door pi vot connec-
ti on from the panel /defrost door pi vot pi n.
(4) Remove the screws that secure the panel /de-
frost door vacuum actuator to the HVAC housi ng.
(5) Remove the panel /defrost door vacuum actuator
INSTALLATION
INSTALLATION - HEAT/DEFROST - PANEL/
DEFROST DOOR ELECTRIC ACTUATOR
(1) I nstal l the heat/defrost-panel /defrost door
actuator on the HVAC housi ng, and ti ghten the three
(2) Pl ug i n the wi re harness connector to the heat/
defrost - panel /defrost door actuator.
(3) I nstal l the center i nstrument panel support
bracket on the vehi cl e.
(4) I nstal l the two bol ts that secure the center
i nstrument panel support bracket to the i nstrument
panel .
(5) I nstal l the two bol ts that secure the center
i nstrument panel support bracket to the l eft si de of
Fig. 19 MODE DOOR ACTUATORS-MANUAL
SYSTEM
1 - VACUUM LINES
2 - ACTUATING LEVERS
3 - LINKAGE
4 - VACUUM ACTUATORS
5 - ACTUATING LEVER
Fig. 20 PANEL/DEFROST DOOR ACTUATOR
1 - VACUUM LINE
2 - PANEL/DEFROST DOOR ACTUATOR
3 - SHAFT RETAINER
24 - 32 CONTROLS WJ
VACUUM ACTUATOR
(1) I nstal l the heat/defrost door vacuum actuator
on the HVAC housi ng and ti ghten the mounti ng
(2) Engage the heat/defrost door pi vot connecti on
wi th the heat/defrost door pi vot pi n.
(3) Pl ug i n the vacuum harness connector to the
heat/defrost door vacuum actuator.
(4) I nstal l the HVAC housi ng i n the vehi cl e. (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/DI STRI -
BUTI ON/HVAC HOUSI NG - I NSTALLATI ON)
VACUUM ACTUATOR
(1) I nstal l the panel /defrost door vacuum actuator
(2) Engage the panel /defrost door pi vot connecti on
wi th the panel /defrost door pi vot pi n.
heat/defrost door vacuum actuator.
RECIRCULATION DOOR
ACTUATOR
DESCRIPTION
The reci rcul ati on door actuator for vehi cl es
equi pped wi th the standard equi pment manual tem-
perature control system i s vacuum control l ed. The
opti onal Automati c Zone Control (AZC) system uses
an el ectri c reci rcul ati on door actuator. I n the fol l ow-
i ng procedures, servi ce for both types of actuators i s
covered.
REMOVAL
REMOVAL - RECIRCULATION DOOR VACUUM
ACTUATOR
INJURY.
Refer to I nstrument Panel System for the procedures.
reci rcul ati on door vacuum actuator.
(3) Di sengage the reci rcul ati on door pi vot connec-
ti on from the door pi vot pi n.
(4) Di sengage the reci rcul ati on door actuati ng rod
from the reci rcul ati on door l ever.
(5) Remove the screws that secure the reci rcul a-
ti on door vacuum actuator to the HVAC housi ng.
(6) Remove the reci rcul ati on door vacuum actuator
REMOVAL - RECIRCULATION DOOR ELECTRIC
ACTUATOR
INJURY.
the opti onal Automati c Zone Control (AZC) system.
reci rcul ati on door actuator.
(3) Remove the 2 screws securi ng the reci rcul ati on
door housi ng to the HVAC uni t (Fi g. 21). Ti l t the
front of the housi ng up whi l e reachi ng around the
back rel easi ng 2 tangs hol di ng the rear of the hous-
i ng down.
(4) Remove the reci rcul ati on door housi ng from the
HVAC uni t.
(5) Remove the screws that secure the reci rcul a-
ti on door actuator to the HVAC housi ng.
(6) Remove the reci rcul ati on door actuator from
the HVAC housi ng.
WJ CONTROLS 24 - 33
INSTALLATION
VACUUM ACTUATOR
(1) I nstal l the reci rcul ati on door vacuum actuator
(2) Engage the reci rcul ati on door actuati ng rod
wi th the reci rcul ati on door l ever.
(3) Engage the reci rcul ati on door pi vot connecti on
wi th the door pi vot pi n.
reci rcul ati on door vacuum actuator.
(5) I nstal l the i nstrument panel i n the vehi cl e.
ELECTRIC ACTUATOR
(1) I nstal l the reci rcul ati on door actuator on the
reci rcul ati on door housi ng and ti ghten the mounti ng
(2) I nstal l the reci rcul ati on door housi ng on the
HVAC uni t and ti ghten the mounti ng screws to 2.2
Nm (20 i n. l bs.).
(3) Pl ug i n the wi re harness connector to the reci r-
cul ati on door actuator.
(4) I nstal l the i nstrument panel i n the vehi cl e.
VACUUM CHECK VALVE
DESCRIPTION
Two vacuum check val ves (non AZC onl y) are
i nstal l ed on the vacuum suppl y system. One i s on the
accessory vacuum suppl y l i ne i n the engi ne compart-
ment, near the vacuum tap on the engi ne i ntake
mani fol d. A second vacuum check val ve i s l ocated on
the bottom of the HVAC uni t behi nd the passenger
front fl oor duct on the bl ack vacuum l i ne. The vac-
uum check val ves are desi gned to al l ow vacuum to
fl ow i n onl y one di recti on through the accessory vac-
uum suppl y ci rcui ts.
OPERATION
The use of a vacuum check val ve hel ps to mai ntai n
the system vacuum needed to retai n the sel ected A/C
Heater mode setti ngs. The check val ve wi l l prevent
the engi ne from bl eedi ng down system vacuum
through the i ntake mani fol d duri ng extended heavy
engi ne l oad (l ow engi ne vacuum) operati on.
The vacuum check val ve cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
REMOVAL
(1) Unpl ug the HVAC vacuum suppl y l i ne connec-
tor at the vacuum check val ve near the engi ne i ntake
mani fol d vacuum adapter fi tti ng.
(2) Note the ori entati on of the check val ve i n the
vacuum suppl y l i ne for correct i nstal l ati on.
(3) Unpl ug the vacuum check val ve from the vac-
uum suppl y l i ne fi tti ngs.
INSTALLATION
(1) Pl ug i n the vacuum check val ve at the vacuum
suppl y l i ne fi tti ngs, noti ng the ori entati on of the
check val ve i n the vacuum suppl y l i ne for correct
i nstal l ati on.
(2) Pl ug i n the HVAC vacuum suppl y l i ne connec-
tor at the vacuum check val ve near the engi ne i ntake
mani fol d vacuum adapter fi tti ng.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s mounted i n the ri ght front
of the vehi cl e behi nd the headl amp mounti ng modul e
(Fi g. 22). The headl amp mounti ng modul e and head-
l amp assembl y must be removed from the vehi cl e to
access the vacuum reservoi r for servi ce. Refer to
Lamps/Li ghti ng for the procedures.
OPERATION
Engi ne vacuum i s stored i n the vacuum reservoi r.
The stored vacuum i s used to operate the vacuum-
Fig. 21 RECIRCULATION DOOR HOUSING
1 - RECIRCULATION DOOR HOUSING
2 - ATTACHING SCREWS
24 - 34 CONTROLS WJ
RECIRCULATION DOOR ACTUATOR (Continued)
control l ed vehi cl e accessori es duri ng peri ods of l ow
engi ne vacuum such as when the vehi cl e i s cl i mbi ng
a steep grade, or under other hi gh engi ne l oad oper-
The vacuum reservoi r cannot be repai red and, i f
REMOVAL
(1) Remove the ri ght si de headl amp mounti ng
modul e and headl amp assembl y. Refer to Lamps/
Li ghti ng for the procedures.
(2) Remove the two screws that secure the vacuum
reservoi r to the base of the radi ator cl osure panel .
(3) Remove the vacuum reservoi r.
INSTALLATION
(1) I nstal l the vacuum reservoi r i n the vehi cl e and
ti ghten the two screws to 3.4 Nm (30 i n. l bs.).
(2) I nstal l the ri ght si de headl amp mounti ng mod-
ul e and headl amp assembl y. Refer to Lamps/Li ghti ng
for the procedures.
EVAPORATOR TEMPERATURE
SENSOR
DESCRIPTION
The evaporator probe i s a 2 wi re temperature sens-
i ng el ement l ocated at the col dest poi nt on the face of
the evaporator. The swi tch i s attached to the evapo-
rator coi l fi ns. The evaporator temperature probe
prevents condensate water on the evaporator coi l
from freezi ng and obstructi ng A/C system ai r fl ow.
OPERATION
The probe i s used to swi tch the cl utch OFF before
evaporator freeze-up occurs. Output from the probe i s
sampl ed by the Body Control Modul e (BCM). The
cl utch i s swi tched OFF when the probe temperature
reaches 1.1 C (34 F). I t i s al l owed to swi tch ON
when the probe temperature reaches 2.2 C (36 F).
REMOVAL
cabl e.
(2) Remove the HVAC housi ng from the vehi -
cl e(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
DI STRI BUTI ON/HVAC HOUSI NG - REMOVAL).
(3) Di sassembl e the HVAC housi ng(Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - DI SASSEMBLY).
(4) Careful l y pul l the probe out of the evaporator
core.
INSTALLATION
(1) I nstal l the new probe i nto the evaporator.
NOTE: The new probe must not go into the same
hole (in the evaporator core) that the old probe was
removed from.
(2) Reassembl e the HVAC housi ng(Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - ASSEMBLY).
(3) Rei nstal l the HVAC assembl y i n the vehi cl e(Re-
fer to 24 - HEATI NG & AI R CONDI TI ONI NG/DI S-
TRI BUTI ON/HVAC HOUSI NG - I NSTALLATI ON).
Fig. 22 VACUUM RESERVOIR
1 - FAN RELAY
2 - SPEED CONTROL SERVO
WJ CONTROLS 24 - 35
VACUUM RESERVOIR (Continued)
DISTRIBUTION
TABLE OF CONTENTS
page page
AIR OUTLETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
BLOWER MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
DEFROSTER DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
FLOOR DISTRIBUTION DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTRUMENT PANEL DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
REAR FLOOR HEAT DUCT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
HVAC HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 42
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
BLEND DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
MODE DOOR
REMOVAL
REMOVAL - PANEL OUTLET DOOR . . . . . . . 46
REMOVAL - HEAT/DEFROST DOOR . . . . . . . 47
REMOVAL - PANEL/DEFROST DOOR . . . . . . 48
INSTALLATION
INSTALLATION - PANEL OUTLET DOOR . . . . 49
INSTALLATION - HEAT/DEFROST DOOR . . . 49
INSTALLATION - PANEL/DEFROST DOOR . . 49
RECIRCULATION DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
AIR OUTLETS
REMOVAL
The dri ver si de, and passenger si de panel outl ets
are avai l abl e for servi ce. The center outl ets are onl y
servi ced as part of the i nstrument cl uster center
bezel uni t.
(1) Remove the i nstrument panel top pad from the
i nstrument panel . Refer to I nstrument Panel System
for the procedures.
(2) Remove the two screws that secure each outl et
to the backsi de of the i nstrument panel top pad (Fi g.
1).
(3) Remove the outl et from the top pad.
INSTALLATION
(1) Fasten the outl et to the top pad. Ti ghten the
(2) I nstal l the i nstrument panel top pad on the
i nstrument panel . Refer to I nstrument Panel System
for the procedures.
Fig. 1 PANEL OUTLETS (PASSENGER SIDE)
1 - MOUNTING SCREWS
2 - MOUNTING SCREWS
3 - PANEL OUTLETS
24 - 36 DISTRIBUTION WJ
BLOWER MOTOR
DESCRIPTION
The bl ower motor and bl ower wheel are l ocated i n
the passenger si de end of the HVAC housi ng, bel ow
the gl ove box modul e. The bl ower motor control s the
vel oci ty of the ai r fl owi ng through the HVAC housi ng
by spi nni ng a squi rrel cage-type bl ower wheel wi thi n
the housi ng at the sel ected speed. The bl ower motor
and bl ower wheel can be servi ced from the passenger
compartment si de of the housi ng.
OPERATION
The bl ower motor wi l l onl y operate when the i gni -
ti on swi tch i s i n the On posi ti on, and the a/c heater
mode control swi tch i s i n any posi ti on, except off. The
bl ower motor ci rcui t i s protected by a fuse i n the
juncti on bl ock. On model s wi th the standard manual
temperature control system, the bl ower motor speed
i s control l ed by regul ati ng the battery feed through
the bl ower motor swi tch and the bl ower motor resi s-
tor. On model s wi th the opti onal Automati c Zone
Control (AZC) system, the bl ower motor speed i s con-
trol l ed by usi ng Pul se Wi dth Modul ati on (PWM). The
bl ower motor control l er adjusts the battery feed vol t-
age to the bl ower motor, based upon an i nput from
the bl ower motor swi tch, through the AZC control
modul e. Pul se wi dth modul ati on of bl ower power
al l ows the bl ower to operate at any speed from sta-
ti onary, to ful l speed.
The bl ower motor and bl ower motor wheel cannot
be repai red, and i f faul ty or damaged, they must be
repl aced. The bl ower motor and bl ower wheel are
each servi ced separatel y.
INJURY.
appropri ate wi ri ng i nformati on. Possi bl e causes of an
i noperati ve bl ower motor i ncl ude:
Faul ty fuse
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connecti ons
Faul ty bl ower motor resi stor (i f the vehi cl e i s so
equi pped)
Faul ty bl ower motor control l er (i f the vehi cl e i s
so equi pped)
Faul ty bl ower motor swi tch
Faul ty a/c heater mode control swi tch
Faul ty bl ower motor.
Possi bl e causes of the bl ower motor not operati ng
i n al l speeds i ncl ude:
Faul ty fuse
Faul ty bl ower motor swi tch
Faul ty bl ower motor resi stor (i f the vehi cl e i s so
equi pped)
Faul ty bl ower motor control l er (i f the vehi cl e i s
so equi pped)
Faul ty AZC modul e (i f the vehi cl e i s so
equi pped)
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connecti ons.
VIBRATION
Possi bl e causes of bl ower motor vi brati on i ncl ude:
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower wheel out of bal ance or bent
Bl ower motor faul ty.
NOISE
To veri fy that the bl ower i s the source of the noi se,
unpl ug the bl ower motor wi re harness connector and
operate the HVAC system. I f the noi se goes away,
possi bl e causes i ncl ude:
Forei gn materi al i n the HVAC housi ng
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower motor faul ty.
REMOVAL
INJURY.
WJ DISTRIBUTION 24 - 37
cabl e.
(2) Pi nch the connector retai ner and unpl ug the
bl ower motor wi re harness from the bl ower motor
(Fi g. 2).
bl ower motor and bl ower wheel assembl y to the
HVAC housi ng, usi ng ei ther a T-25 Torx head or
fl at-bl aded screwdri ver.
(4) Lower the bl ower motor and wheel from the
HVAC housi ng.
(5) Remove the bl ower wheel retai ner cl i p (Fi g. 3).
(6) Remove the wheel from the bl ower motor shaft.
INSTALLATION
(1) Press the bl ower wheel hub onto the bl ower
motor shaft. Be sure the fl at on the bl ower motor
shaft i s i ndexed to the fl at on the i nsi de of the bl ower
wheel hub.
(2) I nstal l the retai ner cl i p over the bl ower wheel
hub.
(3) I nstal l the bl ower motor i n the HVAC housi ng
wi th three mounti ng screws. Ti ghten the mounti ng
(4) Pl ug the bl ower motor wi re harness connector
i nto the bl ower motor socket.
DEFROSTER DUCTS
REMOVAL
(1) Remove the i nstrument panel assembl y from
the vehi cl e(Refer to 23 - BODY/I NSTRUMENT
PANEL - REMOVAL).
defroster duct to the HVAC uni t housi ng (Fi g. 4).
(3) Remove the defroster duct from the HVAC uni t
housi ng.
Fig. 2 BLOWER MOTOR (HOUSING REMOVED
FROM VEHICLE)
2 - BLOWER MOTOR
3 - GROUND STRAP
Fig. 3 BLOWER MOTOR WHEEL REMOVE/INSTALL
1 - BLOWER MOTOR WHEEL
2 - RETAINER CLIP
Fig. 4 HVAC DEFROSTER DUCT
1 - HVAC UNIT HOUSING
3 - SCREWS
4 - DEFROSTER DUCT
BLOWER MOTOR (Continued)
INSTALLATION
(1) I nstal l the defroster duct on the HVAC uni t
housi ng.
(2) I nstal l the three screws that secure the
defroster duct to the HVAC uni t housi ng. Ti ghten the
(3) I nstal l the i nstrument panel assembl y i n the
vehi cl e(Refer to 23 - BODY/I NSTRUMENT PANEL -
I NSTALLATI ON).
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) To remove the dri ver si de fl oor duct from the
vehi cl e, remove the knee bl ocker panel for access to
attachi ng screw. See I nstrument Panel System for
the procedures.
(2) The passenger si de fl oor duct fastener can be
accessed under the ri ght-center i nstrument panel .
(3) Remove the screw that secures the fl oor duct(s)
to the HVAC housi ng (Fi g. 5).
INSTALLATION
(1) Attach the fl oor duct(s) to the HVAC housi ng.
(2) I nstal l the screw that secures the fl oor duct(s)
to the HVAC housi ng. Ti ghten the mounti ng screws
to 2.2 Nm (20 i n. l bs.).
(3) I nstal l the knee bl ocker panel . See I nstrument
INSTRUMENT PANEL DUCTS
REMOVAL
(1) Remove the i nstrument panel top pad from the
vehi cl e(Refer to 23 - BODY/I NSTRUMENT PANEL/
(2) Unsnap the duct extensi on(s) from the i nstru-
ment panel structural duct assembl y (Fi g. 6).
(3) Remove the duct extensi on(s) from the i nstru-
ment panel (Fi g. 7).
INSTALLATION
(1) Connect the duct extensi on(s) to the i nstru-
ment panel .
(2) Snap the duct extensi on(s) to the i nstrument
panel structural duct assembl y.
(3) I nstal l the i nstrument panel top pad i n the
vehi cl e(Refer to 23 - BODY/I NSTRUMENT PANEL/
TI ON).
REAR FLOOR HEAT DUCT
REMOVAL
(1) To remove the rear fl oor ducts from the vehi cl e,
remove the knee bl ocker panel s for access, and pul l
carpeti ng back.
(2) Pul l the fl oor ducts from the HVAC housi ng
(Fi g. 8).
NOTE: The ductwork running from the HVAC hous-
ing rearward through the passenger compartment is
molded into the carpeting, and must be replaced as
a unit if damaged.
INSTALLATION
(1) Attach the fl oor ducts to the HVAC housi ng.
(2) I nstal l the knee bl ocker panel s.
(3) I nstal l the carpeti ng back i n i ts ori gi nal posi -
ti on.
Fig. 5 FLOOR DUCTS (HOUSING REMOVED)
1 - FLOOR DUCT ADAPTER
2 - HEAT/DEFROST DOOR SUB-ASSEMBLY
3 - DOOR LEVERS
4 - LOWER HOUSING
5 - FLOOR DUCTS
6 - LINKAGE
7 - RETAINING TABS
DEFROSTER DUCTS (Continued)
Fig. 6 INSTRUMENT PANEL STRUCTURAL DUCT ASSEMBLY
1 - CENTER DUCT 2 - INSTRUMENT PANEL STRUCTURAL DUCT ASSEMBLY
3 - PANEL DUCT EXTENSIONS
Fig. 7 INSTRUMENT PANEL DUCT EXTENSION
1 - INSTRUMENT PANEL STRUCTURAL DUCT ASSEMBLY
2 - PANEL DUCT EXTENSION
Fig. 8 REAR FLOOR DUCTS
1 - LEFT REAR PASSENGER FLOOR AIR DUCT
2 - RIGHT REAR PASSENGER FLOOR AIR DUCT
3 - TO CARPET DUCT
4 - TO CARPET DUCT
REAR FLOOR HEAT DUCT (Continued)
HVAC HOUSING
REMOVAL
The HVAC housi ng assembl y must be removed
from the vehi cl e and the two hal ves of the housi ng
separated for servi ce access of the heater core, evap-
orator coi l , bl end door(s), and each of the vari ous
mode doors.
INJURY.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN PLUMBING BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) (Refer
CAUTION)
cabl e.
(2) Remove the i nstrument panel from the vehi -
cl e(Refer to 23 - BODY/I NSTRUMENT PANEL -
REMOVAL).
(3) Recover the refri gerant from the refri gerant
system. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG - STANDARD PROCEDURE -
REFRI GERANT RECOVERY)
(4) Di sconnect the l i qui d l i ne refri gerant l i ne from
the evaporator i nl et tube(Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG/LI QUI D LI NE -
REMOVAL) or (Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/PLUMBI NG/LI QUI D LI NE - REMOV-
AL). I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(5) Di sconnect the sucti on l i ne refri gerant l i ne
from the evaporator outl et tube(Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/SUCTI ON
LI NE - REMOVAL), (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG/SUCTI ON LI NE -
REMOVAL) or (Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/PLUMBI NG/SUCTI ON LI NE - REMOV-
AL). I nstal l pl ugs i n, or tape over al l of the opened
(6) Di sconnect the heater hoses from the heater
core tubes. Cl amp off the heater hoses to prevent l oss
of cool ant. Refer to Cool i ng for the procedures. I nstal l
pl ugs i n, or tape over the opened heater core tubes.
(7) I f the vehi cl e i s equi pped wi th the manual tem-
perature control system, unpl ug the HVAC system
vacuum suppl y l i ne connector from the tee fi tti ng
near the heater core tubes.
(8) Remove the cool ant reserve/overfl ow bottl e
from the passenger si de i nner fender shi el d. Refer to
(9) Remove the Powertrai n Control Modul e (PCM)
from the passenger si de dash panel i n the engi ne
compartment and set i t asi de. Do not unpl ug the
PCM wi re harness connectors. Refer to El ectroni c
Control Modul es for the procedures.
(10) Remove the nuts from the HVAC housi ng
mounti ng studs on the engi ne compartment si de of
the dash panel (Fi g. 9).
(11) Remove the rear fl oor heat ducts from the
fl oor heat duct outl ets (Fi g. 10).
(12) Unpl ug the HVAC housi ng wi re harness con-
nectors.
(13) Remove the HVAC housi ng mounti ng nuts
from the studs on the passenger compartment si de of
the dash panel (Fi g. 11).
Fig. 9 HVAC Housing - (rear view)
1 - Instrument Panel
2 - Air Intake
3 - Expansion Valve
4 - HVAC Housing
5 - Heater Core Input/Output Ports
6 - Instrument Panel Wiring Harness
7 - Blower Motor
(14) Remove the HVAC housi ng from the vehi cl e,
ensuri ng that the i nteri or i s covered i n case of l oss of
fl ui ds.
DISASSEMBLY
(2) Pl ace the HVAC housi ng wi th the tubi ng si de
down on a work bench, maki ng al l owance for l eakage
of fl ui ds.
(3) Usi ng a sharp kni fe, spl i t the foam seal sur-
roundi ng the panel outl et openi ng, at the di vi di ng
l i ne of the upper and l ower cases (Fi g. 12).
(4) Pl ace the HVAC housi ng i n the upri ght posi ti on
on the work bench.
(5) Remove the mode door actuator on the l eft si de
of the housi ng, whi ch control s the mode door i n the
top of the case (Fi g. 13) (Fi g. 14).
(6) Remove the screw wi th pl asti c washer hol di ng
the l ever assembl y to the upper case secti on, and
move asi de (Fi g. 15).
(7) Remove the 5 cl i ps that secure the two housi ng
hal ves to each other. There are 2 on ei ther si de at
the center, and 1 l ocated at the forward end of the
mode door si de of the case (Fi g. 16).
Fig. 10 REAR FLOOR DUCTS
1 - LEFT REAR PASSENGER FLOOR AIR DUCT
2 - RIGHT REAR PASSENGER FLOOR AIR DUCT
3 - TO CARPET DUCT
4 - TO CARPET DUCT
Fig. 11 Passenger Side Instrument Panel to
Heater-A/C Housing Mounting
3 - SCREW (2)
Fig. 12 SPLIT FOAM SEAL AT PANEL OUTLET
1 - ONE PIECE FOAM SEAL
2 - FLOOR DUCT
3 - TO REAR PASSENGER FLOOR AIR DUCT
HVAC HOUSING (Continued)
(8) Rel ease the wi re harness el ectri cal connector(s)
from the mounts on the l ower case at the bl ower
motor end of the uni t (Fi g. 17).
Fig. 13 MODE DOOR ACTUATORS - MANUAL
SYSTEM
1 - VACUUM LINES
2 - ACTUATING LEVERS
3 - LINKAGE
5 - ACTUATING LEVER
Fig. 14 MODE DOOR ACTUATOR - AZC SYSTEM
1 - LEVER ASSEMBLY
2 - LINKAGE
Fig. 15 REMOVE SCREW WITH PLASTIC WASHER
1 - SCREW WITH PLASTIC WASHER
Fig. 16 HVAC HOUSING CLIPS
1 - ACTUATING LEVERS AND LINKAGE
2 - HOUSING CLIP
(9) Remove the 10 screws that secure the two
housi ng hal ves to each other.
(10) Separate the top hal f of the HVAC housi ng
from the bottom hal f (Fi g. 18).
Fig. 17 WIRE HARNESS ELECTRICAL
CONNECTOR(S)
2 - BLOWER MOTOR
3 - GROUND STRAP
Fig. 18 HVAC HOUSING- CASE SEPARATED
1 - ELECTRICIAL CONNECTORS
2 - VACUUM ACTUATOR
3 - RECIRCULATION DOOR
4 - THERMAL EXPANSION VALVE
5 - BLOWER MOTOR RESISTOR/CONTROLLER
6 - BLOWER WHEEL
7 - EVAPORATOR AND TUBES
8 - FIN SENSOR PROBE
9 - BLEND DOOR
10 - PIVOT SHAFT (MOTOR REMOVED)
11 - PANEL/OUTLET DOOR
12 - LOWER HOUSING
14 - UPPER HOUSING
15 - VACUUM HARNESS
NOTE: The blend door sub-assembly is attached to
the housing with 2 screws, and may be removed for
service (Fig. 19).
ASSEMBLY
(1) Pl ace the top hal f of the HVAC housi ng on the
bottom hal f. Be certai n that each of the door pi vot
pi ns al i gn wi th the pi vot hol es i n the HVAC housi ng.
(2) I nstal l the 10 screws that secure the two hous-
i ng hal ves to each other. Ti ghten the HVAC housi ng
(3) Attach the wi re harness el ectri cal connector(s)
to the mounts on the l ower case at the bl ower motor
end of the uni t.
(4) I nstal l the 5 cl i ps that secure the two housi ng
hal ves to each other. Check doors for bi ndi ng after
repl acement, and after assembl y of housi ng.
(5) I nstal l the screw wi th pl asti c washer hol di ng
the l ever assembl y to the upper case secti on.
(6) I nstal l the mode door actuator on the l eft si de
of the housi ng.
INSTALLATION
TIONS IN PLUMBING BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) (Refer
CAUTION)
Any ki nks or sharp bends i n the refri gerant pl umb-
i ng wi l l reduce the capaci ty of the enti re ai r condi -
ti oni ng system. Ki nks and sharp bends reduce the
fl ow of refri gerant i n the system. A good rul e for the
fl exi bl e hose refri gerant l i nes i s to keep the radi us of
al l bends at l east ten ti mes the di ameter of the hose.
I n addi ti on, the fl exi bl e hose refri gerant l i nes shoul d
be routed so they are at l east 80 mi l l i meters (3
i nches) from the exhaust mani fol d.
Hi gh pressures are produced i n the refri gerant sys-
tem when the ai r condi ti oni ng compressor i s operat-
i ng. Extreme care must be exerci sed to make sure
that each of the refri gerant system connecti ons i s
pressure-ti ght and l eak free. I t i s a good practi ce to
i nspect al l fl exi bl e hose refri gerant l i nes at l east once
a year to make sure they are i n good condi ti on and
properl y routed.
(1) Posi ti on the HVAC housi ng to the dash panel .
Be certai n that the evaporator condensate drai n tube
and the housi ng mounti ng studs are i nserted i nto
thei r correct mounti ng hol es.
(2) I nstal l the HVAC housi ng mounti ng nuts to the
studs on the passenger compartment si de of the dash
panel . Ti ghten the nuts to 4.5 Nm (40 i n. l bs.).
(3) Connect the HVAC housi ng wi re harness con-
nectors.
(4) Rei nstal l the rear fl oor heat ducts to the center
fl oor heat duct outl ets.
(5) I nstal l and ti ghten the nuts onto the HVAC
housi ng mounti ng studs on the engi ne compartment
si de of the dash panel . Ti ghten the nuts to 7 Nm (60
i n. l bs.).
(6) Rei nstal l the PCM to the passenger si de dash
panel i n the engi ne compartment. Refer to El ectroni c
Control Modul es for the procedures.
(7) Rei nstal l the cool ant reserve/overfl ow bottl e to
the passenger si de i nner fender shi el d. Refer to Cool -
i ng for the procedures.
(8) I f the vehi cl e i s equi pped wi th the manual tem-
perature control system, connect the HVAC system
vacuum suppl y l i ne connector to the tee fi tti ng near
the heater core tubes.
(9) Uncl amp/unpl ug the heater core hoses and
tubes. Connect the heater hoses to the heater core
tubes and fi l l the engi ne cool i ng system. Refer to
(10) Unpl ug or remove the tape from the sucti on
l i ne and the evaporator outl et tube fi tti ngs. Connect
the sucti on l i ne to the evaporator outl et tube.
Ti ghten retai ni ng nut to 28 Nm (250 i n. l bs.).
(11) Unpl ug or remove the tape from the l i qui d
l i ne and the evaporator i nl et tube fi tti ngs. Connect
the l i qui d l i ne to the evaporator i nl et tube. Ti ghten
retai ni ng nut to 28 Nm (250 i n. l bs.).
(12) Evacuate the refri gerant system. (Refer to 24
Fig. 19 BLEND DOOR SUB-ASSEMBLY (AZC)
1 - PASSENGER SIDE BLEND DOOR
2 - BLEND DOOR SUB-ASSEMBLY
3 - DOOR PIVOT SHAFT BUSHING
4 - DOOR SHAFT LEVER
5 - DRIVER SIDE BLEND DOOR
STANDARD PROCEDURE - REFRI GERANT SYS-
TEM EVACUATE)
(13) Charge the refri gerant system. (Refer to 24 -
TEM CHARGE)
(14) I nstal l the i nstrument panel i n the vehi cl e(Re-
fer to 23 - BODY/I NSTRUMENT PANEL - I NSTAL-
LATI ON).
(16) Start the engi ne and check for proper opera-
ti on of the heati ng and ai r condi ti oni ng systems.
BLEND DOOR
REMOVAL
INJURY.
(1) Remove and di sassembl e the HVAC housi ng.
DI STRI BUTI ON/HVAC HOUSI NG - DI SASSEMBLY)
(2) Remove evaporator from l ower case to ease
access to pl asti c door shaft bushi ng.
(3) Pi nch the retenti on tabs hol di ng the bl end door
pi vot shaft to the case. The 3 pl asti c tabs, l ocated on
the i nsi de of the case, are part of the shaft retai ner.
(4) Remove door(s).
INSTALLATION
(1) I nstal l the bl end door(s) by snappi ng the pi vot
shaft i nto the HVAC case.
(2) I nstal l the evaporator i n the l ower case.
(3) Reassembl e the HVAC housi ng and i nstal l i n
the vehi cl e. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/DI STRI BUTI ON/HVAC HOUSI NG -
ASSEMBLY) (Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/DI STRI BUTI ON/HVAC HOUSI NG -
I NSTALLATI ON)
NOTE: The blend door sub-assembly is attached to
the housing with 2 screws, and may be removed for
service (Fig. 20).
MODE DOOR
REMOVAL
REMOVAL - PANEL OUTLET DOOR
INJURY.
Fig. 20 BLEND DOOR SUB-ASSEMBLY
1 - PASSENGER SIDE BLEND DOOR
2 - BLEND DOOR SUB-ASSEMBLY
3 - DOOR PIVOT SHAFT BUSHING
4 - DOOR SHAFT LEVER
5 - DRIVER SIDE BLEND DOOR
(2) Pi nch the retenti on tabs hol di ng the panel out-
l et door pi vot shaft to the case. The 3 pl asti c tabs,
l ocated on the i nsi de of the case, are part of the shaft
fl at-bl aded tool , gentl y pry the panel outl et door pi vot
shaft retai ner from the pi vot shaft.
(4) Remove the panel outl et door from the HVAC
housi ng.
REMOVAL - HEAT/DEFROST DOOR
INJURY.
(2) Remove the evaporator, and styrofoam tray
from the l ower case.
(3) Pl ace the HVAC housi ng upsi de down on a
work bench.
(4) Unscrew and remove the 2 fl oor heat ducts.
(5) Unsnap and remove the duct adapter from the
bottom of the heat/defrost door sub-assembl y (Fi g.
22).
(6) Gentl y pry the metal l i nkage from the heat/de-
frost door l ever.
(7) Remove the heat/defrost door sub-assembl y,
whi ch i s attached to the housi ng wi th 4 screws (Fi g.
23).
(8) Pi nch the retenti on tabs hol di ng the heat/de-
frost door pi vot shaft l ever to the case. The 3 pl asti c
tabs, l ocated on the i nsi de of the case, are part of the
shaft retai ner.
(9) Remove the heat/defrost door (Fi g. 24).
Fig. 21 PANEL OUTLET DOOR
2 - DOOR SHAFT
3 - FOAM SEAL
(SPLIT)
4 - LOWER HOUSING
5 - PANEL OUTLET DOOR LEVER
6 - LEVER
Fig. 22 HEAT/DEFROST DOOR DUCTS, AND
ADAPTER
1 - FLOOR DUCT ADAPTER
3 - DOOR LEVERS
4 - LOWER HOUSING
5 - FLOOR DUCTS
6 - LINKAGE
7 - RETAINING TABS
MODE DOOR (Continued)
REMOVAL - PANEL/DEFROST DOOR
INJURY.
See HVAC Housi ng i n thi s group for the procedures.
(2) Pi nch the retenti on tabs hol di ng the panel /de-
frost door pi vot shaft to the case. The 3 pl asti c tabs,
fl at-bl aded tool , gentl y pry the panel /defrost door
pi vot shaft retai ner from the pi vot shaft.
(4) Remove the panel /defrost door from the HVAC
housi ng.
Fig. 23 HEAT/DEFROST DOOR SUB-ASSEMBLY
REMOVAL
2 - LEVERS
3 - LOWER HOUSING
4 - SCREWS
5 - LINKAGE
Fig. 24 HEAT/DEFROST DOOR REMOVAL
1 - HEAT/DEFROST DOOR
2 - LOWER HOUSING
4 - FLOOR DUCTS
5 - DOOR LEVER
Fig. 25 PANEL/DEFROST DOOR
1 - UPPER HOUSING
2 - LEVER
3 - PANEL/DEFROST MODE DOOR
INSTALLATION
INSTALLATION - PANEL OUTLET DOOR
(1) Snap the panel outl et door pi vot shaft retai ner
on the pi vot shaft.
(2) Attach the panel outl et door pi vot shaft to the
HVAC case.
I NSTALLATI ON)
(1) I nstal l the heat/defrost door by snappi ng the
heat/defrost door pi vot shaft i nto the HVAC case.
(2) I nstal l the heat/defrost door sub-assembl y and
ti ghten the mounti ng screws to 2.2 Nm (20 i n. l bs.).
(3) Attach the metal l i nkage to the heat/defrost
door l ever.
(4) Snap the duct adapter to the bottom of the
heat/defrost door sub-assembl y.
(5) I nstal l the 2 fl oor heat ducts and ti ghten the
mounti ng screws to 2.2 Nm (20 i n. l bs.)..
(6) I nstal l the evaporator, and styrofoam tray i n
the l ower case.
I NSTALLATI ON)
(1) Snap the panel /defrost door pi vot shaft retai ner
on the pi vot shaft.
(2) Attach the panel /defrost door pi vot shaft to the
HVAC case.
I NSTALLATI ON)
RECIRCULATION DOOR
REMOVAL
INJURY.
(2) Pl ace the HVAC housi ng ri ght si de up on the
work bench.
(3) Unpl ug the wi re/vacuum connector from the
reci rcul ati on door actuator.
(4) Remove the 2 screws fasteni ng the reci rcul a-
ti on door sub-assembl y to the mai n housi ng (Fi g. 26).
Fig. 26 RECIRCULATION DOOR HOUSING
1 - RECIRCULATION DOOR HOUSING
2 - ATTACHING SCREWS
(5) Rai se the front of the door sub-assembl y whi l e
rel easi ng the 2 tabs hol di ng the rear to the mai n
housi ng, and remove the reci rcul ati on door housi ng.
(6) Remove the el ectri c/vacuum actuator from the
reci rcul ati on door sub-assembl y and set asi de.
(7) Pi nch the retenti on tabs hol di ng the reci rcul a-
ti on door pi vot shaft to the case. The 3 pl asti c tabs,
retai ner.
(8) Remove the reci rcul ati on door from the reci rcu-
l ati on ai r door housi ng.
INSTALLATION
(1) I nstal l the reci rcul ati on door i n the reci rcul a-
ti on ai r door housi ng by snappi ng the pi vot shaft
retenti on tabs i nto the case.
(2) I nstal l the el ectri c/vacuum actuator on the
reci rcul ati on door sub-assembl y. Check door for bi nd-
i ng after repl acement.
(3) I nstal l the reci rcul ati on door housi ng on the
HVAC case and ti ghten the 2 screws to 2.2 Nm (20
i n. l bs.).
(4) Pl ug i n the wi re/vacuum connector to the reci r-
cul ati on door actuator.
RECIRCULATION DOOR (Continued)
PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION - REFRIGERANT LINE . . . . . . . 52
OPERATION - REFRIGERANT LINE . . . . . . . . . 52
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CAUTION
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . 53
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS . . . . . . . . . . . . . . . . . . . . . . 54
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT . . . . . . . . . . 54
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . . 55
SYSTEM CHARGE. . . . . . . . . . . . . . . . . . . . . 56
SPECIFICATIONS
CHARGE CAPACITY . . . . . . . . . . . . . . . . . . . 57
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION - A/C COMPRESSOR . . . . . . . 57
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
OPERATION
OPERATION - A/C COMPRESSOR . . . . . . . . 57
OPERATION - HIGH PRESSURE RELIEF
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL - 2.7L TURBO DIESEL . . . . . . . . . 60
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION - 2.7L TURBO DIESEL . . . . . . 61
A/C CONDENSER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 62
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
A/C DISCHARGE LINE
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 65
A/C EXPANSION VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DIAGNOSIS AND TESTING - A/C EXPANSION
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
LIQUID LINE
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 66
SUCTION LINE
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 68
A/C EVAPORATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 69
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
HEATER CORE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
RECEIVER / DRIER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 72
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
REFRIGERANT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 75
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
REFRIGERANT OIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 75
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
WJ PLUMBING 24 - 51
VISCOUS HEATER
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 76
DESCRIPTION - VISCOUS HEATER
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
OPERATION
OPERATION - VISCOUS HEATER . . . . . . . . . 76
OPERATION - VISCOUS HEATER CLUTCH . . 76
REMOVAL
REMOVAL - VISCOUS HEATER . . . . . . . . . . . 76
REMOVAL - VISCOUS HEATER CLUTCH . . . 76
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION - VISCOUS HEATER
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
PLUMBING
DESCRIPTION - REFRIGERANT LINE
The refri gerant l i nes and hoses are used to carry
the refri gerant between the vari ous ai r condi ti oni ng
system components. A barri er hose desi gn wi th a
nyl on tube, whi ch i s sandwi ched between rubber l ay-
ers, i s used for the R-134a ai r condi ti oni ng system on
thi s vehi cl e. Thi s nyl on tube hel ps to further contai n
the R-134a refri gerant, whi ch has a smal l er mol ecu-
l ar structure than R-12 refri gerant. The ends of the
refri gerant hoses are made from l i ghtwei ght al umi -
num or steel , and commonl y use braze-l ess fi tti ngs.
OPERATION - REFRIGERANT LINE
properl y routed.
The refri gerant l i nes and hoses cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
WARNING
WARNING: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC LEAK
DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE THE WORK AREA BEFORE RESUMING
SERVICE. LARGE AMOUNTS OF REFRIGERANT
RELEASED IN A CLOSED WORK AREA WILL DIS-
PLACE THE OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGER-
ANT AT AVERAGE TEMPERATURE AND ALTITUDE
IS EXTREMELY HIGH. AS A RESULT, ANYTHING
THAT COMES IN CONTACT WITH THE REFRIGER-
ANT WILL FREEZE. ALWAYS PROTECT THE SKIN
OR DELICATE OBJECTS FROM DIRECT CONTACT
WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHI-
CLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
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 PROP-
ERTY DAMAGE.
24 - 52 PLUMBING WJ
CAUTION
CAUTION
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a
system. Damage to the system will result.
Do not overcharge the refrigerant system. This will
cause excessive compressor head pressure and
can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
The refrigerant system must always be evacuated
before charging.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system.
Before disconnecting a component, clean the out-
side of the fittings thoroughly to prevent contami-
nation from entering the refrigerant system.
Immediately after disconnecting a component from
the refrigerant system, seal the open fittings with a
cap or plug.
Before connecting an open refrigerant fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connect-
ing.
Do not remove the sealing caps from a replacement
component until it is to be installed.
When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system compo-
nents or any sharp edges, which may damage the
line.
Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refriger-
ant system will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will pre-
vent twisting of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of the refrigerant system through care-
less work habits must be avoided.
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS
Ki nks or sharp bends i n the refri gerant pl umbi ng
wi l l reduce the capaci ty of the enti re system. Hi gh
pressures are produced i n the system when i t i s oper-
ati ng. Extreme care must be exerci sed to make sure
that al l refri gerant system connecti ons are pressure
ti ght.
A good rul e for the fl exi bl e hose refri gerant l i nes i s
to keep the radi us of al l bends at l east ten ti mes the
di ameter of the hose. Sharp bends wi l l reduce the
fl ow of refri gerant. The fl exi bl e hose l i nes shoul d be
routed so they are at l east 80 mi l l i meters (3 i nches)
from the exhaust mani fol d. I t i s a good practi ce to
i nspect al l fl exi bl e refri gerant system hose l i nes at
l east once a year to make sure they are i n good con-
di ti on and properl y routed.
There are two types of refri gerant fi tti ngs:
Al l fi tti ngs wi th O-ri ngs need to be coated wi th
refri gerant oi l before i nstal l ati on. Use onl y O-ri ngs
that are the correct si ze and approved for use wi th
R-134a refri gerant. Fai l ure to do so may resul t i n a
l eak.
Uni fi ed pl umbi ng connecti ons wi th gaskets can-
not be servi ced wi th O-ri ngs. The gaskets are not
reusabl e and new gaskets do not requi re l ubri cati on
before i nstal l i ng.
Usi ng the proper tool s when maki ng a refri gerant
pl umbi ng connecti on i s very i mportant. I mproper
tool s or i mproper use of the tool s can damage the
refri gerant fi tti ngs. Al ways use two wrenches when
l ooseni ng or ti ghteni ng tube fi tti ngs. Use one wrench
to hol d one si de of the connecti on stati onary, whi l e
l ooseni ng or ti ghteni ng the other si de of the connec-
ti on wi th a second wrench.
The refri gerant must be recovered compl etel y from
the system before openi ng any fi tti ng or connecti on.
Open the fi tti ngs wi th cauti on, even after the refri g-
erant has been recovered. I f any pressure i s noti ced
as a fi tti ng i s l oosened, ti ghten the fi tti ng and
recover the refri gerant from the system agai n.
Do not di scharge refri gerant i nto the atmosphere.
Use an R-134a refri gerant recovery/recycl i ng devi ce
that meets SAE Standard J2210.
The refri gerant system wi l l remai n chemi cal l y sta-
bl e as l ong as pure, moi sture-free R-134a refri gerant
and refri gerant oi l i s used. Di rt, moi sture, or ai r can
upset thi s chemi cal stabi l i ty. Operati onal troubl es or
seri ous damage can occur i f forei gn materi al i s
present i n the refri gerant system.
When i t i s necessary to open the refri gerant sys-
tem, have everythi ng needed to servi ce the system
WJ PLUMBING 24 - 53
PLUMBING (Continued)
ready. The refri gerant system shoul d not be l eft open
to the atmosphere any l onger than necessary. Cap or
pl ug al l l i nes and fi tti ngs as soon as they are opened
to prevent the entrance of di rt and moi sture. Al l l i nes
and components i n parts stock shoul d be capped or
seal ed unti l they are to be i nstal l ed.
Al l tool s, i ncl udi ng the refri gerant recycl i ng equi p-
ment, the mani fol d gauge set, and test hoses shoul d
be kept cl ean and dry. Al l tool s and equi pment must
be desi gned for R-134a refri gerant.
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
I f the ai r condi ti oni ng system i s not cool i ng prop-
erl y, determi ne i f the refri gerant system i s ful l y-
charged. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG - DI AGNOSI S AND TESTI NG -
A/C PERFORMANCE)
An el ectroni c l eak detector desi gned for R-134a
refri gerant i s recommended for l ocati ng and confi rm-
i ng refri gerant system l eaks. Refer to the operati ng
i nstructi ons suppl i ed by the equi pment manufacturer
for proper care and use of thi s equi pment.
An oi l y resi due on or near refri gerant system l i nes,
connector fi tti ngs, components, or component seal s
can i ndi cate the general l ocati on of a possi bl e refri g-
erant l eak. However, the exact l eak l ocati on shoul d
be confi rmed wi th an el ectroni c l eak detector pri or to
component repai r or repl acement.
To detect a l eak i n the refri gerant system, perform
one of the fol l owi ng procedures:
SYSTEM EMPTY
(1) Evacuate the refri gerant system. (Refer to 24 -
TEM EVACUATE)
(2) Connect and di spense 0.283 ki l ograms (0.625
pounds or 10 ounces) of R-134a refri gerant i nto the
evacuated refri gerant system. (Refer to 24 - HEAT-
DARD PROCEDURE - REFRI GERANT SYSTEM
CHARGE)
(3) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(4) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Because
R-134a refri gerant i s heavi er than ai r, the l eak detec-
tor probe shoul d be moved sl owl y al ong the bottom
si de of al l refri gerant l i nes, connector fi tti ngs and
components.
(5) To i nspect the evaporator coi l for l eaks, i nsert
the el ectroni c l eak detector probe i nto the center
i nstrument panel outl et. Set the bl ower motor swi tch
to the l owest speed posi ti on, the A/C button i n the
On posi ti on, and sel ect the Reci rcul ati on Mode.
SYSTEM LOW
(1) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(2) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run wi th the ai r condi ti oni ng system
turned on for fi ve mi nutes.
(3) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Because
R-134a refri gerant i s heavi er than ai r, the l eak detec-
tor probe shoul d be moved sl owl y al ong the bottom
si de of al l refri gerant l i nes, connector fi tti ngs and
components.
(4) To i nspect the evaporator coi l for l eaks, i nsert
the el ectroni c l eak detector probe i nto the center
i nstrument panel outl et. Set the bl ower motor swi tch
to the l owest speed posi ti on, the A/C button i n the
On posi ti on, and sel ect the Reci rcul ati on Mode.
STANDARD PROCEDURE
SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED,
BEFORE CONNECTING TO OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
When servi ci ng the ai r condi ti oni ng system, a
R-134a refri gerant recovery/recycl i ng/chargi ng sta-
ti on that meets SAE Standard J2210 must be used.
Contact an automoti ve servi ce equi pment suppl i er for
refri gerant recovery/recycl i ng/chargi ng equi pment.
Refer to the operati ng i nstructi ons suppl i ed by the
24 - 54 PLUMBING WJ
equi pment manufacturer for proper care and use of
thi s equi pment.
A mani fol d gauge set may be needed wi th some
recovery/recycl i ng/chargi ng equi pment (Fi g. 1). The
servi ce hoses on the gauge set bei ng used shoul d
have manual (turn wheel ), or automati c back-fl ow
val ves at the servi ce port connector ends. Thi s wi l l
prevent refri gerant from bei ng rel eased i nto the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE The l ow pressure
hose (Bl ue wi th Bl ack stri pe) attaches to the sucti on
servi ce port. Thi s port i s l ocated on the sucti on l i ne
near the dash panel .
HI GH PRESSURE GAUGE HOSE The hi gh pres-
sure hose (Red wi th Bl ack stri pe) attaches to the di s-
charge servi ce port. Thi s port i s l ocated on the
di scharge l i ne between the compressor and the con-
denser i nl et.
RECOVERY/RECYCLI NG/EVACUATI ON/CHARG-
I NG HOSE The center mani fol d hose (Yel l ow, or
Whi te, wi th Bl ack stri pe) i s used to recover, evacu-
ate, and charge the refri gerant system. When the l ow
or hi gh pressure val ves on the mani fol d gauge set
are opened, the refri gerant i n the system wi l l escape
through thi s hose.
RECOVERY
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
used to recover the refri gerant from an R-134a refri g-
erant system. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for the proper
care and use of thi s equi pment.
SYSTEM EVACUATE
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be charged. I f moi sture and ai r enters the system
and becomes mi xed wi th the refri gerant, the com-
pressor head pressure wi l l ri se above acceptabl e
operati ng l evel s. Thi s wi l l reduce the performance of
the ai r condi ti oner and damage the compressor.
Evacuati ng the refri gerant system wi l l remove the
ai r and boi l the moi sture out of the system at near
room temperature. To evacuate the refri gerant sys-
tem, use the fol l owi ng procedure:
(1) Connect a R-134a refri gerant recovery/recy-
cl i ng/chargi ng stati on that meets SAE Standard
J2210 and a mani fol d gauge set to the refri gerant
system of the vehi cl e.
(2) Open the l ow and hi gh si de val ves and start
the chargi ng stati on vacuum pump. When the suc-
ti on gauge reads 88 kPa (26 i n. Hg.) vacuum or
greater, cl ose al l of the val ves and turn off the vac-
uum pump.
Fig. 1 MANIFOLD GAUGE SET - TYPICAL
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK
STRIPE)
4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
WJ PLUMBING 24 - 55
(a) I f the refri gerant system fai l s to reach the
speci fi ed vacuum, the system has a l eak that must
be corrected. (Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/PLUMBI NG - DI AGNOSI S AND
TESTI NG - REFRI GERANT SYSTEM LEAKS)
(b) I f the refri gerant system mai ntai ns the spec-
i fi ed vacuum for fi ve mi nutes, restart the vacuum
pump, open the sucti on and di scharge val ves and
evacuate the system for an addi ti onal ten mi nutes.
(3) Cl ose al l of the val ves, and turn off the charg-
i ng stati on vacuum pump.
(4) The refri gerant system i s now ready to be
charged wi th R-134a refri gerant. (Refer to 24 -
TEM CHARGE)
SYSTEM CHARGE
After the refri gerant system has been tested for
l eaks and evacuated, a refri gerant charge can be
i njected i nto the system. (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - SPECI FI CA-
TI ONS - CHARGE CAPACI TY)
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
used to charge the refri gerant system wi th R-134a
refri gerant. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for proper care
and use of thi s equi pment.
PARTIAL CHARGE METHOD
The parti al charge method i s used to add a parti al
charge to a refri gerant system that i s l ow on refri g-
erant. To perform thi s procedure the evaporator i nl et
and outl et tube temperatures are measured. The
temperature di fference i s measured wi th a tempera-
ture meter wi th one or two cl amp-on thermocoupl e
probes. The di fference between the evaporator i nl et
and outl et tube temperatures wi l l determi ne the
amount of refri gerant needed.
Before addi ng a parti al refri gerant charge, check
for refri gerant system l eaks. (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG - DI AGNOSI S
AND TESTI NG - REFRI GERANT SYSTEM LEAKS)
I f a l eak i s found, make the necessary repai rs before
attempti ng a ful l or parti al refri gerant charge.
(1) Attach a mani fol d gauge set to the refri gerant
system servi ce ports.
(2) Attach the two cl amp-on thermocoupl e probes
to the i nl et and outl et tubes of the evaporator coi l .
I f a si ngl e thermocoupl e probe i s used, attach
the probe to the evaporator i nl et tube just before the
col l ar of the refri gerant l i ne connector fi tti ng. The
probe must make contact wi th the bottom surface of
the evaporator i nl et tube.
I f dual thermocoupl e probes are used, attach
probe 1 to the evaporator i nl et tube, and probe 2 to
the evaporator outl et tube. Attach both probes to the
evaporator tubes just before the col l ar of the refri g-
erant l i ne connector fi tti ngs. The probes must make
contact wi th the bottom surfaces of the evaporator
i nl et and outl et tubes.
(3) Open al l of the wi ndows or doors of the passen-
ger compartment.
(4) Set the A/C button on the A/C Heater control s
to the on posi ti on, the temperature control knob i n
the ful l cool posi ti on, sel ect Reci rcul ati on Mode, and
pl ace the bl ower motor swi tch i n the hi ghest speed
posi ti on.
(5) Start the engi ne and hol d the engi ne i dl e speed
at 1,000 rpm. Al l ow the engi ne to warm up to normal
operati ng temperature.
(6) The compressor cl utch may cycl e, dependi ng
upon ambi ent temperature, humi di ty, and the refri g-
erant system charge l evel .
(7) Hol d the engi ne i dl e speed at 1,000 rpm.
(8) Al l ow three to fi ve mi nutes for the refri gerant
system to stabi l i ze, then record the temperatures of
the evaporator i nl et and outl et tubes.
I f a si ngl e probe i s used, record the temperature
of the evaporator i nl et tube. Then remove the probe
from the i nl et tube and attach i t to the evaporator
outl et tube just before the col l ar of the refri gerant
l i ne connector fi tti ng. The probe must make contact
wi th the bottom surface of the evaporator outl et tube.
Al l ow the thermocoupl e and meter ti me to stabi l i ze,
then record the temperature of the evaporator outl et
tube. Subtract the i nl et tube temperature readi ng
from the outl et tube temperature readi ng.
I f dual probes are used, record the temperatures
of both the evaporator i nl et and outl et tubes. Then
subtract the i nl et tube temperature readi ng from the
outl et tube temperature readi ng.
(9) I f the measured temperature di fferenti al i s
hi gher than 22 C to 26 C (40 F to 47 F), add 0.4
ki l ograms (14 ounces) of refri gerant.
24 - 56 PLUMBING WJ
(10) Al l ow three to fi ve mi nutes for the refri gerant
system to stabi l i ze, then take a second set of thermo-
coupl e measurements. Record the temperature di ffer-
ence to determi ne i f an addi ti onal charge i s requi red.
(11) Record the compressor di scharge pressure. I f
the readi ng i s hi gher than the pressure shown i n the
Compressor Di scharge Pressure Chart, the system
coul d be overcharged. I f the readi ng i s equal to, or
l ower, than the pressure shown i n the chart, conti nue
wi th thi s procedure.
Compressor Discharge Pressure Chart
Ambient
Temperature
16C
(60F)
21C
(70F)
27C
(80F)
32C
(90F)
38C
(100F)
43C
(110F)
Compressor
Discharge
Pressure
1378 kPa
(200 psi)
1516 kPa
(220 psi)
1723 kPa
(250psi)
1930 kPa
(280 psi)
2206 kPa
(320 psi)
2413 kPa
(350 psi)
(12) EXAMPLE: The ambi ent temperature i s 21
C (70 F). The evaporator i nl et tube temperature i s
12 C (54 F) and the evaporator outl et tube temper-
ature i s 10 C (50 F). Subtract the i nl et tube tem-
perature from the outl et tube temperature. The
di fference i s -2 C (-4 F). Wi th a -2 C (-4 F) tem-
perature di fferenti al at 21 C (70 F) ambi ent tem-
perature, the system i s ful l y charged.
(13) Add enough refri gerant to bri ng the refri ger-
ant system up to a ful l charge.
(14) Remove the jumper wi re from the l ow pres-
sure cycl i ng cl utch swi tch wi re harness connector
and pl ug the connector back i nto the swi tch.
SPECIFICATIONS
CHARGE CAPACITY
The R-134a refri gerant system charge capaci ty for
thi s vehi cl e i s 0.765 ki l ograms (1.687 pounds/27
ounces).
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION - A/C COMPRESSOR
The ai r condi ti oni ng system uses a Ni ppondenso
10PA17 ten cyl i nder, doubl e-acti ng swash pl ate-type
compressor on al l model s. Thi s compressor has a
fi xed di spl acement of 170 cubi c centi meters (10.374
cubi c i nches), and has both the sucti on and di scharge
ports l ocated on the cyl i nder head. A l abel i denti fyi ng
the use of R-134a refri gerant i s l ocated on the com-
pressor.
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE
A hi gh pressure rel i ef val ve i s l ocated on the com-
pressor mani fol d, whi ch i s on the si de of the com-
pressor. Thi s mechani cal val ve i s desi gned to vent
refri gerant from the system to protect agai nst dam-
age to the compressor and other system components,
caused by condenser ai r fl ow restri cti on or an over-
charge of refri gerant.
OPERATION
OPERATION - A/C COMPRESSOR
The compressor i s dri ven by the engi ne through an
el ectri c cl utch, dri ve pul l ey and bel t arrangement.
The compressor i s l ubri cated by refri gerant oi l that i s
ci rcul ated throughout the refri gerant system wi th the
refri gerant.
The compressor draws i n l ow-pressure refri gerant
vapor from the evaporator through i ts sucti on port. I t
then compresses the refri gerant i nto a hi gh-pressure,
hi gh-temperature refri gerant vapor, whi ch i s then
pumped to the condenser through the compressor di s-
charge port.
The compressor cannot be repai red. I f faul ty or
damaged, the enti re compressor assembl y must be
repl aced. The compressor cl utch, pul l ey, and coi l , are
avai l abl e for servi ce.
OPERATION - HIGH PRESSURE RELIEF VALVE
The hi gh pressure rel i ef val ve vents the system
when a di scharge pressure of 3445 to 4135 kPa (500
to 600 psi ) or above i s reached. The val ve cl oses
when a mi ni mum di scharge pressure of 2756 kPa
(400 psi ) i s reached.
WJ PLUMBING 24 - 57
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce the system pressure, and then
re-seats i tsel f. The majori ty of the refri gerant i s con-
served i n the system. I f the val ve vents refri gerant, i t
does not mean that the val ve i s faul ty.
The hi gh pressure rel i ef val ve i s a factory-cal i -
brated uni t. The val ve cannot be adjusted or
repai red, and must not be removed or otherwi se di s-
turbed. The val ve i s onl y servi ced as a part of the
compressor assembl y.
NOISE
When i nvesti gati ng an ai r condi ti oni ng rel ated
noi se, you must fi rst know the condi ti ons under
whi ch the noi se occurs. These condi ti ons i ncl ude:
weather, vehi cl e speed, transmi ssi on i n gear or neu-
tral , engi ne speed, engi ne temperature, and any
other speci al condi ti ons. Noi ses that devel op duri ng
ai r condi ti oni ng operati on can often be mi sl eadi ng.
For exampl e: What sounds l i ke a fai l ed front beari ng
or connecti ng rod, may be caused by l oose bol ts, nuts,
mounti ng brackets, or a l oose compressor cl utch
assembl y.
Dri ve bel ts are speed sensi ti ve. At di fferent engi ne
speeds and dependi ng upon bel t tensi on, bel ts can
devel op noi ses that are mi staken for a compressor
noi se. I mproper bel t tensi on can cause a mi sl eadi ng
noi se when the compressor cl utch i s engaged, whi ch
may not occur when the compressor cl utch i s di sen-
gaged. Check the serpenti ne dri ve bel t condi ti on and
tensi on as descri bed i n Cool i ng before begi nni ng thi s
procedure.
(1) Sel ect a qui et area for testi ng. Dupl i cate the
compl ai nt condi ti ons as much as possi bl e. Swi tch the
compressor on and off several ti mes to cl earl y i den-
ti fy the compressor noi se. Li sten to the compressor
whi l e the cl utch i s engaged and di sengaged. Probe
the compressor wi th an engi ne stethoscope or a l ong
screwdri ver wi th the handl e hel d to your ear to bet-
ter l ocal i ze the source of the noi se.
(2) Loosen al l of the compressor mounti ng hard-
ware and reti ghten. Ti ghten the compressor cl utch
mounti ng nut. Be certai n that the cl utch coi l i s
mounted securel y to the compressor, and that the
cl utch pl ate and pul l ey are properl y al i gned and have
the correct ai r gap. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/CONTROLS/A/C COMPRESSOR
CLUTCH - I NSTALLATI ON)
(3) To dupl i cate a hi gh-ambi ent temperature condi -
ti on (hi gh head pressure), restri ct the ai r fl ow
through the condenser. I nstal l a mani fol d gauge set
to be certai n that the di scharge pressure does not
exceed 2760 kPa (400 psi ).
(4) Check the refri gerant system pl umbi ng for
i ncorrect routi ng, rubbi ng or i nterference, whi ch can
cause unusual noi ses. Al so check the refri gerant l i nes
for ki nks or sharp bends that wi l l restri ct refri gerant
fl ow, whi ch can cause noi ses. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - CAU-
TI ON - REFRI GERANT HOSES/LI NES/TUBES
PRECAUTI ONS)
(5) I f the noi se i s from openi ng and cl osi ng of the
hi gh pressure rel i ef val ve, recl ai m, evacuate, and
recharge the refri gerant system. (Refer to 24 - HEAT-
DARD PROCEDURE - REFRI GERANT RECOVERY)
PLUMBI NG - STANDARD PROCEDURE - REFRI G-
ERANT SYSTEM EVACUATE) (Refer to 24 -
TEM CHARGE)I f the hi gh pressure rel i ef val ve sti l l
does not seat properl y, repl ace the a/c compressor.
PLUMBI NG/A/C COMPRESSOR - REMOVAL)
(6) I f the noi se i s from l i qui d sl uggi ng on the suc-
ti on l i ne, check the refri gerant oi l l evel and the
refri gerant system charge. (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG/REFRI GER-
ANT OI L - STANDARD PROCEDURE) (Refer to 24 -
SPECI FI CATI ONS - CHARGE CAPACI TY).
(7) I f the noi se conti nues, repl ace the compressor
and repeat Step 1.
REMOVAL
REMOVAL
The compressor may be removed and reposi ti oned
wi thout di sconnecti ng the refri gerant l i nes or di s-
chargi ng the refri gerant system. Di schargi ng i s not
necessary i f servi ci ng the compressor cl utch or cl utch
coi l , the engi ne, the cyl i nder head, or the generator.
(1) Recover the refri gerant from the system. (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/PLUMB-
I NG - STANDARD PROCEDURE - REFRI GERANT
RECOVERY)
cabl e.
(3) Remove the serpenti ne dri ve bel t. Refer to
(4) Unpl ug the compressor cl utch coi l wi re harness
connector.
24 - 58 PLUMBING WJ
A/C COMPRESSOR (Continued)
(5) Remove the (2) refri gerant l i ne retai ni ng bol ts
that secure the sucti on l i ne and di scharge l i ne to the
compressor. I nstal l pl ugs i n, or tape over al l of the
opened refri gerant fi tti ngs.
(6) Remove the bol ts that secure the compressor
(Fi g. 2) or (Fi g. 3) and (Fi g. 4).
(7) Remove the compressor.
Fig. 2 COMPRESSOR REMOVE/INSTALL - 4.0L
ENGINE
1 - POWER STEERING PUMP MOUNTING BRACKET
2 - BOLT
3 - BRACE
4 - BOLT
5 - BOLT
6 - A/C COMPRESSOR
7 - BOLT
Fig. 3 COMPRESSOR AND A/C LINES - V8
1 - DISCHARGE LINE
2 - A/C COMPRESSOR
3 - SUCTION LINE
4 - A/C/ CONDENSOR
5 - DISCHARGE LINE TO CONDENSOR
6 - A/C PRESSURE TRANSDUCER SWITCH
7 - A/C/ SERVICE PORT
8 - RECEIVER DRIER
Fig. 4 COMPRESSOR REMOVE/INSTALL - V8
ENGINE - RIGHT VIEW
1 - BOLT
2 - A/C COMPRESSOR
3 - BOLT
WJ PLUMBING 24 - 59
REMOVAL - 2. 7L TURBO DIESEL
(3) Remove the accessory dri ve bel t from the com-
pressor cl utch. Refer to Cool i ng for the procedure
(Fi g. 5).
(5) Remove the front spl ash shi el d (i f equi pped).
(6) Remove the (2) refri gerant l i ne retai ni ng bol ts
from the compressor. Remove both l i nes from the
compressor and cover al l openi ngs.
(7) Di sconnect the compressor cl utch el ectri cal con-
nector.
(8) Remove the compressor mounti ng bol ts and
remove the compressor from the vehi cl e.
Fig. 5 2.7L Diesel Compressor-RHD (LHD typical)
1 - SUCTION LINE MOUNTING SCREW
2 - SUCTION LINE TO H-BLOCK
3 - H-BLOCK
4 - RECEIVER DRIER
5 - LIQUID LINE SERVICE PORT
6 - LIQUID LINE AND RECEIVER DRIER
7 - A/C COMPRESSOR
8 - A/C COMPRESSOR DRIVE BELT
9 - RADIATOR - CONDENSOR ASSEMBLY
24 - 60 PLUMBING WJ
INSTALLATION
INSTALLATION
properl y routed.
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - STANDARD PRO-
CEDURE) Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
(1) I nstal l the compressor. Ti ghten the 4.0L
mounti ng bol ts fasteni ng the compressor to the bl ock
to 45-65 Nm (35-50 ft. l bs.). Ti ghten the mounti ng
bol ts hol di ng the rear brace to the compressor and
bl ock to 40-55 Nm (30-40 ft. l bs.). Ti ghten the 4.7L
compressor front mounti ng screws to 45-65 Nm
(35-50 ft. l bs.), and the rear mounti ng screws to
35-45 Nm (25-35 ft. l bs.).
(2) Remove the tape or pl ugs from al l of the
opened refri gerant l i ne fi tti ngs. I nstal l the sucti on
l i ne and di scharge l i ne fi tti ngs to the mani fol d on the
compressor. Ti ghten the mounti ng bol ts to 25.4 Nm
(225 i n. l bs.).
(3) I nstal l the serpenti ne dri ve bel t. Refer to Cool -
i ng for the procedures.
(4) Pl ug i n the compressor cl utch coi l wi re harness
connector.
TEM EVACUATE)
TEM CHARGE)
INSTALLATION - 2. 7L TURBO DIESEL
CAUTION: Check the oil level before installing the
new compressor. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT OIL -
STANDARD PROCEDURE)
properl y routed.
(1) Li ft the compressor i nto posi ti on and i nstal l
the (4) mounti ng bol ts. Torque the bol ts to 41 Nm
(30 ft. l bs.).
(2) Connect the compressor cl utch el ectri cal con-
nector.
(3) I nstal l both refri gerant l i nes on the compressor.
Make certai n the seal i ng 0-ri ngs are free of tears and
wel l l ubri cated wi th R-134a refri gerant oi l . Torque
the l i ne retai ni ng bol ts to 22 Nm (200 i n. l bs.).
(4) I nstal l the front spl ash shi el d (i f equi pped).
(5) Lower the vehi cl e from the hoi st.
(6) I nstal l the accessory dri ve bel t on the compres-
sor cl utch. Refer to Cool i ng for the procedure.
WJ PLUMBING 24 - 61
TEM EVACUATE)
TEM CHARGE)
A/C CONDENSER
DESCRIPTION
The condenser i s l ocated i n the ai r fl ow i n front of
the engi ne cool i ng radi ator. The condenser i s a heat
exchanger that al l ows the hi gh-pressure refri gerant
gas bei ng di scharged by the compressor to gi ve up i ts
heat to the ai r passi ng over the condenser fi ns.
OPERATION
When the refri gerant gas gi ves up i ts heat, i t con-
denses. When the refri gerant l eaves the condenser, i t
has become a hi gh-pressure l i qui d refri gerant. The
vol ume of ai r fl owi ng over the condenser fi ns i s cri t-
i cal to the proper cool i ng performance of the ai r con-
di ti oni ng system. Therefore, i t i s i mportant that
there are no objects pl aced i n front of the radi ator
gri l l e openi ngs i n the front of the vehi cl e or forei gn
materi al on the condenser fi ns that mi ght obstruct
proper ai r fl ow. Al so, any factory-i nstal l ed ai r seal s or
shrouds must be properl y rei nstal l ed fol l owi ng radi a-
tor or condenser servi ce.
The condenser cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
REMOVAL
TIONS IN THE FRONT OF THIS GROUP BEFORE
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
cabl e.
(3) Remove the screws attachi ng the gri l l e and
headl amp mounti ng modul e to the upper crossmem-
ber of the vehi cl e. Refer to Body for thi s and further
steps i n the procedure.
(4) Remove the headl amps from thei r mounts.
(5) Remove the nuts that secure the hood l atch
and brace to the upper crossmember.
(6) The radi ator upper crossmember can be
adjusted l eft or ri ght through the use of i ts sl otted
mounti ng hol es. Before removal , mark the ori gi nal
posi ti on of the crossmember.
(7) Remove the bol ts that secure the radi ator to
the upper crossmember and set i t asi de (Fi g. 6).
(8) Remove the engi ne ai r fi l ter i nl et duct secured
at the headl amp mounti ng modul e.
(9) Remove the headl amp mounti ng modul e and
front fasci a for access to the condenser and fi tti ngs.
(10) Di sconnect the di scharge l i ne and l i qui d l i ne
refri gerant l i ne fi tti ngs from the condenser. I nstal l
pl ugs i n, or tape over al l of the opened refri gerant
l i ne fi tti ngs.
Fig. 6 CONDENSER MOUNTING - TYPICAL
1 - CONDENSER-TO-RADIATOR MOUNTING BRACKETS (2)
2 - UPPER CROSSMEMBER
3 - FAN SHROUD
4 - ALIGNMENT TABS
5 - RADIATOR
6 - ALIGNMENT DOWELS (2)
7 - RUBBER ISOLATORS (2)
8 - RUBBER GROMMETS (2)
9 - LOWER CROSSMEMBER
10 - CONDENSER
24 - 62 PLUMBING WJ
(11) Remove the bol ts that secure the upper con-
denser and transmi ssi on cool er.
(12) Careful l y l i ft the condenser out of the vehi cl e.
INSTALLATION
properl y routed.
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
(1) Careful l y posi ti on the condenser i n the vehi cl e.
(2) I nstal l the bol ts that secure the upper con-
denser and transmi ssi on cool er.
(3) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the condenser i nl et and the di scharge
l i ne. Connect the di scharge l i ne to the condenser
i nl et. Ti ghten the retai ni ng nut to 28 Nm (250 i n.
l bs.).
l i ne fi tti ngs on the condenser outl et and the l i qui d
l i ne. Connect the l i qui d l i ne to the condenser outl et.
Ti ghten the retai ni ng nut to 28 Nm (250 i n. l bs.).
(5) I nstal l the headl amp mounti ng modul e and
front fasci a. Refer to Body for the procedure.
(6) I nstal l the engi ne ai r fi l ter i nl et duct.
(7) I nstal l the bol ts that secure the radi ator to the
upper crossmember.
(8) I nstal l the nuts that secure the hood l atch and
brace to the upper crossmember.
(9) I nstal l the headl amps i n thei r mounts.
(10) I nstal l the screws attachi ng the gri l l e and
headl amp mounti ng modul e to the upper crossmem-
ber of the vehi cl e. Refer to Body for thi s and further
steps i n the procedure.
(11) Evacuate and Recharge the refri gerant sys-
tem. (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE -
REFRI GERANT SYSTEM EVACUATE) (Refer to 24 -
TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
A/C DISCHARGE LINE
REMOVAL
cabl e.
(2) Recover the refri gerant system. (Refer to 24 -
STANDARD PROCEDURE - REFRI GERANT
RECOVERY)
(3) Remove both headl amps from the vehi cl e. Refer
to Lamps/Li ghti ng for the procedure.
(4) Remove the a/c hi gh pressure transducer(Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/CON-
TROLS/A/C PRESSURE TRANSDUCER - REMOV-
AL).
(5) Remove the front fasci a from the vehi cl e. Refer
to Front Fasci a for the procedure (Fi g. 7).
(6) Remove the refri gerant l i ne retai ni ng fastener
from the condenser i nl et fi tti ng. Remove the l i ne and
cap the condenser i nl et tube to prevent contami na-
ti on of the system.
WJ PLUMBING 24 - 63
A/C CONDENSER (Continued)
(8) Remove the front spl ash shi el d (i f equi pped).
from the compressor outl et fi tti ng. Remove the l i ne
and cap the compressor outl et openi ng to prevent
contami nati on of the system.
(10) Uncl i p and remove the di scharge l i ne from the
vehi cl e.
REMOVAL
TIONS IN THE FRONT OF THIS GROUP BEFORE
cabl e.
(3) Remove the a/c hi gh pressure transducer(Refer
TROLS/A/C PRESSURE TRANSDUCER - REMOV-
AL).
(4) Di sconnect the di scharge l i ne from the con-
denser i nl et. I nstal l pl ugs i n, or tape over al l of the
opened refri gerant l i ne fi tti ngs.
(5) Remove the bol t that secures the di scharge l i ne
fi tti ng to compressor. I nstal l pl ugs i n, or tape over al l
of the opened refri gerant l i ne fi tti ngs.
(6) Remove the di scharge l i ne assembl y from the
vehi cl e.
INSTALLATION
properl y routed.
(1) Careful l y posi ti on the di scharge l i ne i n the
vehi cl e.
(2) Remove the cap and i nstal l the di scharge l i ne
on the compressor. Be certai n the seal i ng o-ri ng i s
wel l l ubri cated wi th PAG oi l and free of tears. Torque
the retai ni ng fastener to 22 Nm (200 i n. l bs.).
(3) I nstal l the front spl ash shi el d (i f equi pped).
(4) Lower the vehi cl e from the hoi st.
(5) Remove the cap and i nstal l the di scharge l i ne
on the condenser. Be certai n the seal i ng o-ri ng i s wel l
l ubri cated wi th PAG oi l and free of tears. Torque the
retai ni ng fastener to 28 Nm (21 ft. l bs.).
(6) I nstal l the front fasci a on the vehi cl e. Refer to
Front Fasci a for the procedure.
(7) I nstal l both headl amps i n the vehi cl e. Refer to
Lamps/Li ghti ng for the procedure.
(8) I nstal l the a/c hi gh pressure transducer, and
connect the el ectri cal connector(Refer to 24 - HEAT-
Fig. 7 Suction-Discharge Lines- RHD (LHD-typical)
1 - SUCTION LINE
2 - H-BLOCK
3 - RECEIVER DRIER
4 - DISCHARGE LINE & SERVICE PORT
5 - A/C COMPRESSOR
6 - DISCHARGE LINE & CONDENSOR CONNECTION
24 - 64 PLUMBING WJ
A/C DISCHARGE LINE (Continued)
I NG & AI R CONDI TI ONI NG/CONTROLS/A/C
PRESSURE TRANSDUCER - I NSTALLATI ON).
TEM EVACUATE)
TEM CHARGE)
INSTALLATION
properl y routed.
(1) Remove the tape or pl ugs from the di scharge
l i ne bl ock fi tti ng and the mani fol d on the compressor.
I nstal l the di scharge l i ne bl ock fi tti ng to the mani fol d
on the compressor. Ti ghten the mounti ng bol t to 25.4
Nm (225 i n. l bs.).
l i ne fi tti ngs on the condenser i nl et and the di scharge
l i ne. Connect the di scharge l i ne to the condenser
i nl et. Ti ghten the retai ni ng nut to 28 Nm (250 i n.
l bs.).
(3) I nstal l the a/c hi gh pressure transducer(Refer
TROLS/A/C PRESSURE TRANSDUCER - I NSTAL-
LATI ON).
TEM EVACUATE)
TEM CHARGE)
A/C EXPANSION VALVE
DESCRIPTION
The H val ve type thermal expansi on val ve (TXV)
i s l ocated at the front of the heater-A/C housi ng
between the l i qui d and sucti on l i nes and the evapo-
rator coi l .
The expansi on val ve i s a factory cal i brated uni t
and cannot be adjusted or repai red. I f faul ty or dam-
aged, the expansi on val ve must be repl aced.
OPERATION
Hi gh-pressure, hi gh temperature l i qui d refri gerant
from the l i qui d l i ne passes through the expansi on
val ve ori fi ce, converti ng i t i not a l ow-pressure, l ow-
temperature mi xture of l i qui d and gas before i t
enters the evaporator coi l . A temperature sensor i n
the expansi on val ve control head moni tors the tem-
perature of the refri gerant l eavi ng the evaporator coi l
throught the sucti on l i ne, and adjusts the ori fi ce si ze
at the l i qui d l i ne to l et the proper amoount of refri g-
erant i nto the evaporator coi l to meet the vehi cl e
cool i ng requi rements. Control l i ng the refri gerant fl ow
through the evaporator ensures that none of the
refri gerant l eavi ng the evaporator i s sti l l i n a l i qui d
state, whi ch coul d damage the compressor.
DIAGNOSIS AND TESTING - A/C EXPANSION
VALVE
The expansi on val ve i s l ocated on the engi ne si de
of the dash panel near the shock tower.
The expansi on val ve can fai l i n three di fferent
posi ti ons (open, cl osed or restri cted).
I n an Open Posi ti on: thi s wi l l resul t i n a noi sy
compressor or no cool i ng. The cause can be broken
spri ng, broken bal l or excessi ve moi sture i n the A/C
system. I f the spri ng or bal l are found to be defecti ve,
repl ace the expansi on val ve. I f excessi ve moi sture i s
found i n the A/C system, recycl e the refri gerant.
I n a Cl osed Posi ti on: There wi l l be l ow sucti on
pressure and no cool i ng. Thi s may be caused by a
fai l ed power dome or excessi ve moi sture i n the A/C
system. I f the power dome on the expansi on val ve i s
found to be defecti ve repl ace the expansi on val ve. I f
excessi ve moi sture i s found recycl e the refri gerant.
A Restri cted Ori fi ce: There wi l l be l ow sucti on
pressure and no cool i ng. Thi s may be caused by
debri s i n the refri gerant system. I f debri s i s bel i eved
to be the cause, recycl e the refri gerant and repl ace
the expansi on val ve and the recei ver/dri er.
WJ PLUMBING 24 - 65
A/C DISCHARGE LINE (Continued)
REMOVAL
cabl e.
(2) Recover the refri gerant from the A/C system-
PLUMBI NG - STANDARD PROCEDURE).
(3) Di sconnect the the A/C l i nes from the expan-
si on val ve. Cap or tape over the open A/C l i nes.
(4) Remove the l i nes from the expansi on val ve(Re-
fer to 24 - HEATI NG & AI R CONDI TI ONI NG/
PLUMBI NG/LI QUI D LI NE - REMOVAL), (Refer to
24 - HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
LI QUI D LI NE - REMOVAL), (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
DI SCHARGE LI NE - REMOVAL) and (Refer to 24 -
DI SCHARGE LI NE - REMOVAL).
(5) Remove the expansi on val ve retai ner screw
from the expansi on val ve.
(6) Remove the expansi on val ve.
(7) Remove the expansi on val ve gasket.
INSTALLATION
(1) I nstal l a NEW gasket and i nstal l the eapansi on
val ve to the evaporator.
(2) I nstal l the expansi on val ve bol ts and ti ghten to
11 Nm (100 i n. l bs.).
(3) I nstal l NEW seal s on the A/C l i nes and i nstal l
the l i nes to the expansi on val ve(Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C DI S-
CHARGE LI NE - I NSTALLATI ON), (Refer to 24 -
DI SCHARGE LI NE - I NSTALLATI ON), (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
LI QUI D LI NE - I NSTALLATI ON) and (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
LI QUI D LI NE - I NSTALLATI ON).
(4) Evacuate the A/C system(Refer to 24 - HEAT-
DARD PROCEDURE).
(5) Recharge the A/C system(Refer to 24 - HEAT-
DARD PROCEDURE).
LIQUID LINE
REMOVAL
REMOVAL
(1) The l i qui d l i ne i s servi ced as an i ntegral part of
the recei ver/dri er assembl y(Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG/RECEI VER /
DRI ER - REMOVAL) or (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG/RECEI VER /
DRI ER - REMOVAL).
(1) The l i qui d l i ne i s servi ce as an i ntegral part of
DRI ER - REMOVAL).
INSTALLATION
INSTALLATION
properl y routed.
DRI ER - I NSTALLATI ON) or (Refer to 24 - HEAT-
24 - 66 PLUMBING WJ
A/C EXPANSION VALVE (Continued)
I NG & AI R CONDI TI ONI NG/PLUMBI NG/RE-
CEI VER / DRI ER - I NSTALLATI ON).
properl y routed.
the recei ver/dri er bottl e assembl y(Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/RE-
CEI VER / DRI ER - I NSTALLATI ON).
SUCTION LINE
REMOVAL
REMOVAL
cabl e.
(3) Remove the retai ner nut from the evaporator
connecti on (Fi g. 8) or (Fi g. 9).
(4) Sl i de the sucti on l i ne off the stud and l i qui d
l i ne. I nstal l pl ugs i n, or tape over al l the opened
refri gerant l i ne fi tti ngs. Remove from cl i p.
(5) Remove the bol t that secures the sucti on l i ne
fi tti ng to compressor. I nstal l pl ugs i n, or tape over al l
of the opened refri gerant l i ne fi tti ngs.
(6) Remove the sucti on l i ne assembl y from the
vehi cl e.
Fig. 8 SUCTION LINE - I-6
1 - SUCTION LINE
2 - RECEIVER DRIER- LIQUID LINE
3 - H-BLOCK
Fig. 9 V-8 Suction Line
2 - A/C COMPRESSOR
3 - SUCTION LINE TO COMPRESSOR
4 - RECEIVER DRIER ASSEMBLY
5 - H-BLOCK
WJ PLUMBING 24 - 67
LIQUID LINE (Continued)
(2) Recover the refri gerant system. (Refer to 24 -
STANDARD PROCEDURE - REFRI GERANT
RECOVERY)
from the H-Val ve Bl ock (Fi g. 10). Remove the l i ne
and gasket from the H-Val ve bl ock and cap or tape
over both ends.
(4) Remove the refri gerant l i ne support bracket
bol t from the cyl i nder head cap.
from the compressor i nl et fi tti ng. Remove the l i ne
and cap the compressor outl et tube to prevent con-
tami nati on of the system.
(6) Uncl i p and remove the sucti on l i ne from the
vehi cl e.
INSTALLATION
INSTALLATION
properl y routed.
(1) Remove the tape or pl ugs from the sucti on l i ne
bl ock fi tti ng and the mani fol d on the compressor.
I nstal l the sucti on l i ne bl ock fi tti ng to the mani fol d
on the compressor. Ti ghten the mounti ng bol t to 25.4
Nm (225 i n. l bs.).
l i ne fi tti ngs on the evaporator outl et and the sucti on
l i ne. Sl i de the sucti on l i ne copnnecti on bl ock over the
l i qui d l i ne and evaporator stud. Ti ghten the retai ni ng
nut to 28 Nm (250 i n. l bs.).
TEM EVACUATE)
TEM CHARGE)
Fig. 10 Suction-Discharge Lines- RHD (LHD-typical)
1 - SUCTION LINE
2 - H-BLOCK
3 - RECEIVER DRIER
4 - DISCHARGE LINE & SERVICE PORT
5 - A/C COMPRESSOR
6 - DISCHARGE LINE & CONDENSOR CONNECTION
24 - 68 PLUMBING WJ
SUCTION LINE (Continued)
properl y routed.
(1) Careful l y posi ti on the sucti on l i ne i n the vehi -
cl e.
(2) Remove the cap or tape and i nstal l the sucti on
l i ne on the compressor. Be certai n the seal i ng o-ri ng
i s wel l l ubri cated wi th PAG oi l and free of tears.
Torque the retai ni ng fastener to 22 Nm (200 i n. l bs.).
(3) Posi ti on and i nstal l the refri gerant l i ne support
bracket bol t on the cyl i nder head cap. Torque the bol t
to 20 Nm (177 i n. l bs.).
(4) Remove the cap or tape and i nstal l the sucti on
l i ne on the H-Val ve Bl ock. Be certai n the seal i ng
O-ri ng i s wel l l ubri cated wi th PAG oi l and free of
tears. Torque the retai ni ng fastener to 28 Nm (21 ft.
l bs.).
(5) I nstal l the ti e-straps retai ni ng the wi re har-
ness on the sucti on l i ne.
TEM EVACUATE)
TEM CHARGE)
A/C EVAPORATOR
DESCRIPTION
The evaporator coi l i s l ocated i n the HVAC hous-
i ng, under the i nstrument panel . The evaporator coi l
i s posi ti oned i n the HVAC housi ng so that al l ai r that
enters the housi ng must pass over the fi ns of the
evaporator before i t i s di stri buted through the sys-
tem ducts and outl ets. However, ai r passi ng over the
evaporator coi l fi ns wi l l onl y be condi ti oned when the
compressor i s engaged and ci rcul ati ng refri gerant
through the evaporator coi l tubes.
OPERATION
Refri gerant enters the evaporator from the ori fi ce
tube as a l ow-temperature, l ow-pressure l i qui d. As
ai r fl ows over the fi ns of the evaporator, the humi di ty
i n the ai r condenses on the fi ns, and the heat from
the ai r i s absorbed by the refri gerant. Heat absorp-
ti on causes the refri gerant to boi l and vapori ze. The
refri gerant becomes a l ow-pressure gas before i t
l eaves the evaporator.
The evaporator coi l cannot be repai red and, i f
REMOVAL
INJURY.
(2) Li ft the evaporator coi l uni t out of the l ower
hal f of the HVAC housi ng (Fi g. 11).
WJ PLUMBING 24 - 69
SUCTION LINE (Continued)
INSTALLATION
properl y routed.
(1) I nstal l the evaporator coi l i n the bottom hal f of
the HVAC housi ng. Be certai n that the evaporator
foam i nsul ator wrap i s rei nstal l ed.
I NSTALLATI ON)
NOTE: If the evaporator is replaced, add 60 millili-
ters (2 fluid ounces) of refrigerant oil to the refrig-
erant system.
Fig. 11 HVAC HOUSING- CASE SEPARATED
1 - ELECTRICIAL CONNECTORS
2 - VACUUM ACTUATOR
3 - RECIRCULATION DOOR
4 - THERMAL EXPANSION VALVE
6 - BLOWER WHEEL
7 - EVAPORATOR AND TUBES
8 - FIN SENSOR PROBE
9 - BLEND DOOR
10 - PIVOT SHAFT (MOTOR REMOVED)
12 - LOWER HOUSING
14 - UPPER HOUSING
15 - VACUUM HARNESS
24 - 70 PLUMBING WJ
A/C EVAPORATOR (Continued)
HEATER CORE
DESCRIPTION
The heater core i s l ocated i n the HVAC housi ng,
under the i nstrument panel . I t i s a heat exchanger
made of rows of tubes and fi ns.
OPERATION
Engi ne cool ant i s ci rcul ated through heater hoses
to the heater core at al l ti mes. As the cool ant fl ows
through the heater core, heat removed from the
engi ne i s transferred to the heater core fi ns and
tubes. Ai r di rected through the heater core pi cks up
the heat from the heater core fi ns. The temperature
control door al l ows control of the heater output ai r
temperature by control l i ng how much of the ai r fl ow-
i ng through the HVAC housi ng i s di rected through
the heater core. The bl ower motor speed control s the
vol ume of ai r fl owi ng through the HVAC housi ng.
The heater core cannot be repai red and, i f faul ty or
damaged, i t must be repl aced. Refer to Cool i ng for
more i nformati on on the engi ne cool i ng system, the
engi ne cool ant and the heater hoses.
REMOVAL
INJURY.
(2) Remove the foam gasket surroundi ng the core
tubes.
NOTE: Notice the orientation of the irregularly
shaped gasket on the tubes. The gasket must be
placed correctly to ensure proper sealing against
the body during reinstallation.
(3) Remove the screws and retai ners that secure the
heater core and tubes to the HVAC housi ng (Fi g. 12).
(4) Remove the mode door actuator i f necessary,
for cl earance to remove the core.
(5) Li ft the heater core strai ght up and out of the
(6) When repl aci ng i ndi vi dual tubes, l oosen and
remove the round tube-to-core cl amp, and pul l tube
from core.
INSTALLATION
Fig. 12 HEATER CORE, TUBES, AND RETAINERS
1 - TUBE-TO-CORE CLAMPS
2 - GROUND STRAP
3 - HVAC HOUSING
4 - TUBE RETAINERS AND SCREWS
5 - HEATER CORE
WJ PLUMBING 24 - 71
properl y routed.
(1) When i nstal l i ng i ndi vi dual tubes, i nsert tube
i nto core ensuri ng that tube O-ri ng i s seated i n core
and not pi nched. Hol d tube i n seated posi ti on whi l e
i nstal l i ng the round tube-to-core cl amp (Fi g. 14).
NOTE: The round tube-to-heater-core clamp should
be left loose enough to turn the tube in the core.
Position the core in the housing, and then tighten
the tube-to-heater-core clamp after orienting the
tubes to the molded HVAC housing.
(2) Lower the heater core i nto the HVAC housi ng.
(3) I nstal l the mode door actuator, i f removed from
housi ng for core removal .
(4) Posi ti on the retai ners over the heater core
tubes. I nstal l and ti ghten the screws that secure the
heater core and retai ners to the HVAC housi ng.
NOTE: The grounding strap is to be attached to the
lower heater core tube retainer.
(5) Rei nstal l the HVAC housi ng to the vehi cl e.
DI STRI BUTI ON/HVAC HOUSI NG - I NSTALLA-
TI ON)
RECEIVER / DRIER
DESCRIPTION
The recei ver/dri er i s mounted i n the engi ne com-
partment between the condenser and i s part of the
l i qui d l i ne assembl y. The fi l ter/dri er cannot be
repai red, i f the fi l ter/dri er i s faul ty, damaged, l eft
open to the atmosphere or contami nated the l i ne
assembl y must be repl aced.
OPERATION
The fi l ter-dri er performs a fi l teri ng acti on to pre-
vent forei gn materi al i n the refri gerant from contam-
i nati ng the expansi on val ve. A desi ccant bag i s
mounted i nsi de the fi l ter-dri er cani ster to absorb any
Fig. 13 HEATER CORE AND TUBES - (Typical)
2 - EXPANSION VALVE
4 - OUTLET TO DEFROSTER DUCTS
6 - FLOOR DUCT
7 - TO REAR PASSENGER FLOOR AIR DUCTS
8 - FLOOR DUCT
9 - HEATER CORE AND TUBES
10 - HOUSING DRAIN
12 - BLOWER MOTOR
13 - GROUND STRAP
24 - 72 PLUMBING WJ
HEATER CORE (Continued)
moi sture whi ch may have netered and become
trapped wi thi n the refri gerant system. I n addi ti on,
duri ng peri ods of hi gh demand ai r condi ti oner opera-
ti on, the fi l ter-dri er acts as a reservoi r to store sur-
pl us refri gerant. Refri gerant enters the fi l ter-dri er as
a hi gh-pressure, l ow-temperature l i qui d.
REMOVAL
system(Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE).
(2) Remove the battery and the battery tray(Refer
to 8 - ELECTRI CAL/BATTERY SYSTEM/BATTERY -
REMOVAL) and (Refer to 8 - ELECTRI CAL/BAT-
TERY SYSTEM/TRAY - REMOVAL).
(3) Remove the screw from the recei ver/dri er
bracket (Fi g. 15) or (Fi g. 16).
(4) Remove the retai ni ng nut from the evaporator
connecti on and then sl i de the sucti on l i ne off the
stud and l i qui d l i ne.
(5) Remove the recei ver/dri er bracket from the
stud and di sconnect the l i qui d l i ne from the evapora-
tor i nl et. I nstal l pl ugs i n or tape over al l of the evap-
orator connecti on openi ngs and opened refri gerant
l i ne fi tti ngs.
(6) Di sconnect the l i qui d l i ne from the condenser
outl et. I nstal l pl ugs i n, or tape over al l of the opened
(7) Remove l i qui d l i ne assembl y.
INSTALLATION
Fig. 14 HEATER CORE, TUBES, AND O-RINGS
2 - TUBE-TO-CORE CLAMPS
3 - SCREWS
4 - O-RINGS
5 - HEATER CORE
Fig. 15 COMPRESSOR AND A/C LINES - V8
1 - DISCHARGE LINE
2 - A/C COMPRESSOR
3 - SUCTION LINE
4 - A/C/ CONDENSOR
5 - DISCHARGE LINE TO CONDENSOR
6 - A/C PRESSURE TRANSDUCER SWITCH
7 - A/C/ SERVICE PORT
8 - RECEIVER DRIER
WJ PLUMBING 24 - 73
RECEIVER / DRIER (Continued)
properl y routed.
l i ne fi tti ngs on the condenser outl et and the con-
denser end of the l i qui d l i ne. Connect the l i qui d l i ne
to the condenser outl et. Ti ghten the retai ni ng nut to
20.16 Nm (180 i n. l bs.).
l i ne fi tti ngs on the evaporator end of the l i qui d l i ne
and the evaporator i nl et. Pl ace the recei ver/dri er
bracket on the stud and connect the l i qui d l i ne to the
evaporator i nl et.
(3) Remove the tape or pl ugs from the sucti on l i ne
and evaporator outl et. Sl i de the sucti on l i ne connec-
ti on bl ock on the l i qui d l i ne on the evaporator con-
necti on stud. Ti ghten the retai ni ng nut to 20.16 Nm
( 180 i n. l bs.).
(4) I nsert a screw for the recei ver/dri er bracket
and hand turn three turns. Ti ghten the screw to
10.64 Nm (95 i n. l bs.).
(5) I nstal l the battery tray and the battery(Refer
to 8 - ELECTRI CAL/BATTERY SYSTEM/TRAY -
I NSTALLATI ON) and (Refer to 8 - ELECTRI CAL/
BATTERY SYSTEM/BATTERY - I NSTALLATI ON).
TEM EVACUATE)
TEM CHARGE)
NOTE: If the receiver/drier is replaced, add 120 mil-
liliters (4 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle. (Refer to 24 - HEATING & AIR CONDITIONING/
Fig. 16 2.7L Diesel Compressor-RHD (LHD typical)
1 - SUCTION LINE MOUNTING SCREW
3 - H-BLOCK
4 - RECEIVER DRIER
5 - LIQUID LINE SERVICE PORT
6 - LIQUID LINE AND RECEIVER DRIER
7 - A/C COMPRESSOR
8 - A/C COMPRESSOR DRIVE BELT
9 - RADIATOR - CONDENSOR ASSEMBLY
24 - 74 PLUMBING WJ
RECEIVER / DRIER (Continued)
REFRIGERANT
DESCRIPTION
The refri gerant used i n thi s ai r condi ti oni ng sys-
tem i s a HydroFl uoroCarbon (HFC), type R-134a.
Unl i ke R-12, whi ch i s a Chl oroFl uoroCarbon (CFC),
R-134a refri gerant does not contai n ozone-depl eti ng
chl ori ne. R-134a refri gerant i s a non-toxi c, non-fl am-
mabl e, cl ear, and col orl ess l i quefi ed gas.
Even though R-134a does not contai n chl ori ne, i t
must be recl ai med and recycl ed just l i ke CFC-type
refri gerants. Thi s i s because R-134a i s a greenhouse
gas and can contri bute to gl obal warmi ng.
OPERATION
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 added to an R-134a refri gerant
system wi l l cause compressor fai l ure, refri gerant oi l
sl udge or poor ai r condi ti oni ng system performance.
I n addi ti on, the Pol yAl kyl ene Gl ycol (PAG) syntheti c
refri gerant oi l s used i n an R-134a refri gerant system
are not compati bl e wi th the mi neral -based refri ger-
ant oi l s used i n an R-12 refri gerant system.
R-134a refri gerant system servi ce ports, servi ce
tool coupl ers and refri gerant di spensi ng bottl es have
al l been desi gned wi th uni que fi tti ngs to ensure that
an R-134a system i s not acci dental l y contami nated
wi th the wrong refri gerant (R-12). There are al so
l abel s posted i n the engi ne compartment of the vehi -
cl e and on the compressor i denti fyi ng to servi ce tech-
ni ci ans that the ai r condi ti oni ng system i s equi pped
wi th R-134a.
REFRIGERANT OIL
DESCRIPTION
The refri gerant oi l used i n R-134a refri gerant sys-
tems i s a syntheti c-based, Pol yAl kyl ene Gl ycol (PAG),
wax-free l ubri cant. Mi neral -based R-12 refri gerant
oi l s are not compati bl e wi th PAG oi l s, and shoul d
never be i ntroduced to an R-134a refri gerant system.
There are di fferent PAG oi l s avai l abl e, and each
contai ns a di fferent addi ti ve package. The 10PA17
compressor used i n thi s vehi cl e i s desi gned to use an
ND8 PAG refri gerant oi l . Use onl y refri gerant oi l of
thi s same type to servi ce the refri gerant system.
OPERATION
After performi ng any refri gerant recovery or recy-
cl i ng operati on, al ways repl eni sh the refri gerant sys-
tem wi th the same amount of the recommended
refri gerant oi l as was removed. Too l i ttl e refri gerant
oi l can cause compressor damage, and too much can
reduce ai r condi ti oni ng system performance.
PAG refri gerant oi l i s much more hygroscopi c than
mi neral oi l , and wi l l absorb any moi sture i t comes
i nto contact wi th, even moi sture i n the ai r. The PAG
oi l contai ner shoul d al ways be kept ti ghtl y capped
unti l i t i s ready to be used. After use, recap the oi l
contai ner i mmedi atel y to prevent moi sture contami -
nati on.
STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL
When an ai r condi ti oni ng system i s assembl ed at
the factory, al l components except the compressor are
refri gerant oi l free. After the refri gerant system has
been charged and operated, the refri gerant oi l i n the
compressor i s di spersed throughout the refri gerant
system. The accumul ator, evaporator, condenser, and
compressor wi l l each retai n a si gni fi cant amount of
the needed refri gerant oi l .
I t i s i mportant to have the correct amount of oi l i n
the refri gerant system. Thi s ensures proper l ubri ca-
ti on of the compressor. Too l i ttl e oi l wi l l resul t i n
damage to the compressor. Too much oi l wi l l reduce
the cool i ng capaci ty of the ai r condi ti oni ng system.
I t wi l l not be necessary to check the oi l l evel i n the
compressor or to add oi l , unl ess there has been an oi l
l oss. An oi l l oss may occur due to a rupture or l eak
from a refri gerant l i ne, a connector fi tti ng, a compo-
nent, or a component seal . I f a l eak occurs, add 30
mi l l i l i ters (1 fl ui d ounce) of refri gerant oi l to the
refri gerant system after the repai r has been made.
Refri gerant oi l l oss wi l l be evi dent at the l eak poi nt
by the presence of a wet, shi ny surface around the
l eak.
Refri gerant oi l must be added when a accumul ator,
evaporator coi l , or condenser are repl aced. See the
Refri gerant Oi l Capaci ti es chart. When a compressor
i s repl aced, the refri gerant oi l must be drai ned from
the ol d compressor and measured. Drai n al l of the
refri gerant oi l from the new compressor, then fi l l the
new compressor wi th the same amount of refri gerant
oi l that was drai ned out of the ol d compressor.
Refrigerant Oil Capacities
Component ml fl oz
A/C System 130 4.40
Receiver Drier 70 2.37
Condenser 10 0.34
Evaporator 50 1.69
Compressor
drain and measure
the oil from the old
compressor - see
text.
WJ PLUMBING 24 - 75
VISCOUS HEATER
DESCRIPTION
DESCRIPTION
The di esel engi ne has an engi ne mounted mechan-
i cal devi ce cal l ed a Vi scous Heater that i s used to
heat the cool ant comi ng from the engi ne to the
heater core. The Vi scous Heater i s dri ven by the
engi ne fan bel t and has a el ectro-mechani cal cl utch
whi ch i s control l ed by the HVAC control uni t.
DESCRIPTION - VISCOUS HEATER CLUTCH
The basi c vi scous heater cl utch assembl y consi sts
of a stati onary el ectromagneti c coi l , a hub beari ng
and pul l ey assembl y and a cl utch pl ate. The el ectro-
magneti c coi l uni t and the hub beari ng and pul l ey
assembl y are each retai ned on the nose of the com-
pressor front housi ng wi th snap ri ngs (Fi g. 17). The
cl utch pl ate i s keyed to the vi scous heater shaft and
secured wi th a nut. These components provi de the
means to engage and di sengage the vi scous heater
from the engi ne accessory dri ve bel t.
OPERATION
OPERATION - VISCOUS HEATER
The Vi scous Heater i s dri ven by the engi ne fan
bel t. The Vi scous Heater has an el ectro-mechani cal
cl utch that recei ves a si gnal from the HVAC control
head and the Vi scous Heater control l er that ener-
gi zes and engages the cl utch. Once engaged the
cl utch al l ows the Vi scous Heater to i ncrease the tem-
perature of the cool ant fl owi ng to the heater core,
whi ch provi des heat the passenger compartment
qui cker than normal engi nes wi thout the Vi scous
Heater. The Vi scous Heater generates heat by means
of fri cti on whi ch heats a speci al Si l i con Oi l wi thi n i ts
housi ng whi ch i s then transferred to the engi ne cool -
ant when the cool ant passes over fi ns wi thi n the
pump. Pl ease note that the cool ant i s i sol ated from
the si l i con oi l wi thi n the pump housi ng. When
demand for passenger compartment heat decreases
the Vi scous Heater cl utch wi l l recei ve an i nput from
the Vi scous heater control l er to di sengage.
OPERATION - VISCOUS HEATER CLUTCH
When the cl utch coi l i s energi zed, i t magneti cal l y
draws the cl utch i nto contact wi th the pul l ey and
dri ves the vi scous heater shaft. When the coi l i s not
energi zed the pul l ey freewheel s on the cl utch hub
beari ng, whi ch i s part of the pul l ey. The vi scous
heater cl utch and coi l are the onl y servi ced parts on
the vi scous heater assembl y. I f the vi scous heater i s
i noperati ve or damaged the enti re assembl y must be
repl aced. The vi scous heater cl utch engagement i s
control l ed by several components: the vi scous heater
control l er, the engi ne powertrai n control modul e and
the HVAC control head.
REMOVAL
REMOVAL - VISCOUS HEATER
(1) Drai n the engi ne cool ant(Refer to 7 - COOL-
I NG/ENGI NE - STANDARD PROCEDURE).
(2) Remove the engi ne accessory dri ve bel t(Refer to
7 - COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(3) Remove the heater hose cl amps at the Vi scous
Heater.
(4) Remove the heater hoses from the Vi scous
Heater.
(5) Unpl ug the Vi scous Heater cl utch el ectri cal
connector.
(6) Remove the bol ts hol di ng the Vi scous Heater to
the mounti ng bracket.
(7) Remove the Vi scous Heater from the vehi cl e.
REMOVAL - VISCOUS HEATER CLUTCH
(1) The vi scous heater cl utch can be servi ced i n
the vehi cl e and the cool i ng system does not have to
be drai ned.
cabl e.
(3) Remove the serpenti ne dri ve bel t(Refer to 7 -
REMOVAL).
Fig. 17 CLUTCH ASSEMBLY- typical
1 - CLUTCH PLATE
2 - SHAFT KEY
3 - PULLEY
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 76 PLUMBING WJ
(4) Unpl ug the cl utch coi l wi re harness connector.
(5) Remove the bol ts that secure the vi scous
heater to the mounti ng bracket.
(6) Remove the vi scous heater from the mounti ng
bracket. Support the vi scous heater i n the engi ne
compartment whi l e servi ci ng the cl utch.
(7) I nsert the two pi ns of the spanner wrench (spe-
ci al Tool C-4489 or equi val ent) i nto the hol es of the
cl utch pl ate. Hol d the cl utch pl ate stati onary and
remove the hex nut (Fi g. 18).
(8) Remove the cl utch pl ate.
(9) Remove the cl utch shi ms.
(10) Remove the external front housi ng snap ri ng
(11) I nstal l the l i p of the rotor pul l er (Speci al Tool
C-61411 or equi val ent) i nto the snap ri ng groove
exposed i n the previ ous step, and i nstal l the shaft
protector (Speci al Tool C-61412 or equi val ent) (Fi g.
20).
(12) I nstal l the pul l er through bol ts (Speci al Tool
C-6461 or equi val ent) through the pul l er fl ange and
i nto the jaws of the rotor pul l er and ti ghten. Turn
the pul l er center bol t cl ockwi se unti l the rotor i s free
(Fi g. 21).
(13) Remove the screw and retai ner from the
cl utch coi l l ead wi re harness on the vi scous heater
housi ng.
Fig. 18 CLUTCH NUT REMOVE-typical
1 - CLUTCH PLATE
2 - SPANNER
Fig. 19 EXTERNAL SNAP RING REMOVE- typical
1 - PULLEY
Fig. 20 SHAFT PROTECTOR AND PULLER- typical
1 - PULLER JAW
2 - SHAFT PROTECTOR
Fig. 21 INSTALL PULLER PLATE- typical
1 - PULLER JAW
2 - PULLER
WJ PLUMBING 24 - 77
VISCOUS HEATER (Continued)
(14) Remove the snap ri ng from the hub and
remove the cl utch fi el d coi l (Fi g. 22). Sl i de the cl utch
fi el d coi l off of the hub.
INSTALLATION
INSTALLATION
(1) I nstal l Vi scous Heater to engi ne mounti ng
bracket.
(2) I nstal l the Vi scous Heater mounti ng bol ts and
ti ghten to 33 Nm ( 25 ft. l bs.).
(3) Pl ug the wi ri ng harness el ectri cal connector to
the Vi scous Heater cl utch.
(4) I nstal l heater hoses to the Vi scous Heater con-
necti ons.
(5) I nstal l heater hose cl amps to Vi scous Heater
connecti ons.
(6) I nstal l the engi ne accessory dri ve bel t(Refer to
7 - COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON).
(7) Refi l l the engi ne cool i ng system(Refer to 7 -
COOLI NG/ENGI NE - STANDARD PROCEDURE).
(9) Operate vehi cl e and check for any cool ant
l eaks, repai r as requi red.
INSTALLATION - VISCOUS HEATER CLUTCH
(1) I nstal l the cl utch fi el d coi l and snap ri ng.
(2) I nstal l the screw and retai ner on the cl utch coi l
l ead wi re harness on the vi scous heater housi ng.
Ti ghten the screw to 2.2 Nm (20 i n. l bs.)
(3) Al i gn the rotor assembl y squarel y on the front
housi ng hub.
(4) I nstal l the rotor beari ng asembl y wi th the
i nstal l er (Speci al Tool C-6871 or equal i vent). Thread
the i nstal l er on the shaft, then turn the nut unti l the
rotor asembl y i s seated.
(5) I nstal l the external front housi ng snap ri ng
wi th snap ri ng pl i ers. The bevel si de of the snap ri ng
must be faci ng outward. Press the snap ri ng to make
sure i t i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(6) I nstal l the ori gi nal cl utch shi ms on the shaft.
(7) I nstal l the cl utch pl ate. I nstal l the shaft hex
nut and ti ghten to 1520 Nm (1115 ft. l bs.).
(8) Check the cl utch ai r gap wi th a feel er gauge
(Fi g. 23). I f the gap does not meet speci fi cati on, add
or substract shi ms as requi red. The ai r gap speci fi ca-
ti on i f 0.41 to 0.79 mi l l i meters (0.016 to 0.031 i nch-
es).
NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch (and not having the old shims
available) use a 1.0, 0.50 and 0.13 millimeter (0.040,
0.020 and 0.005 inch) shim from the new clutch
hardware package that is provided with the new
clutch.
(9) Rei nstal l the vi scous heater to the mounti ng
bracket. Ti ghten the mounti ng screws to 33 Nm (25
ft. l bs.).
(10) Rei nstal l the battery negati ve cabl e.
Fig. 22 CLUTCH FIELD COIL SNAP RING REMOVE-
typical
1 - COIL
Fig. 23 CHECK CLUTCH AIR GAP-typical
1 - FEELER GAUGE
24 - 78 PLUMBING WJ
VISCOUS HEATER (Continued)
EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - STATE DISPLAY TEST
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - DIAGNOSTIC TROUBLE
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - TASK MANAGER . . . . . . . . . 17
DESCRIPTION - MONITORED SYSTEMS . . . 17
DESCRIPTION - TRIP DEFINITION . . . . . . . . 19
DESCRIPTION - COMPONENT MONITORS . . 19
DESCRIPTION - NON-MONITORED
CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION - HIGH AND LOW LIMITS . . . 20
DESCRIPTION - LOAD VALUE . . . . . . . . . . . 20
OPERATION - TASK MANAGER . . . . . . . . . . . . 21
EVAPORATIVE EMISSIONS . . . . . . . . . . . . . . . . 24
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - EMISSION CONTROL SYSTEM
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a prob-
l em wi th a moni tored ci rcui t often enough to i ndi cate an
actual probl em, i t stores a Di agnosti c Troubl e Code
(DTC) i n the PCMs memory. I f the code appl i es to a
non-emi ssi ons rel ated component or system, and the
probl em i s repai red or ceases to exi st, the PCM cancel s
the code after 40 warm-up cycl es. Di agnosti c troubl e
codes that affect vehi cl e emi ssi ons i l l umi nate the Mal -
functi on I ndi cator (check engi ne) Lamp. Refer to Mal -
functi on I ndi cator Lamp i n thi s secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored ci r-
cui t even though a mal functi on has occurred. Thi s may
happen because one of the DTC cri teri a for the ci rcui t
has not been met. For example, assume the di agnosti c
troubl e code cri teri a requi res the PCM to moni tor the
ci rcui t onl y when the engi ne operates between 750 and
2000 RPM. Suppose the sensors output ci rcui t shorts to
ground when engi ne operates above 2400 RPM (resul t-
i ng i n 0 vol t i nput to the PCM). Because the condi ti on
happens at an engi ne speed above the maxi mum thresh-
ol d (2000 rpm), the PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTCs. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
Techni ci ans must retri eve stored DTCs by connect-
i ng the DRB scan tool (or an equi val ent scan tool ) to
the 16way data l i nk connector (Fi g. 1).
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, connect the DRB scan
tool to the 16way data link connector to erase all
DTCs and extinguish the MIL (check engine lamp).
Fig. 1 Data Link (Diagnostic) Connector Location
1 - INSTRUMENT PANEL LOWER/LEFT EDGE
2 - DATA LINK CONNECTOR
WJ EMISSIONS CONTROL 25 - 1
DESCRIPTION - STATE DISPLAY TEST MODE
The swi tch i nputs to the Powertrai n Control Mod-
ul e (PCM) have two recogni zed states; HI GH and
LOW. For thi s reason, the PCM cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus
an open ci rcui t, a short ci rcui t, or a defecti ve swi tch.
I f the State Di spl ay screen shows the change from
HI GH to LOW or LOW to HI GH, assume the enti re
swi tch ci rcui t to the PCM functi ons properl y. Connect
the DRB scan tool to the data l i nk connector and
access the state di spl ay screen. Then access ei ther
State Di spl ay I nputs and Outputs or State Di spl ay
Sensors.
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE
The Ci rcui t Actuati on Test Mode checks for proper
operati on of output ci rcui ts or devi ces the Powertrai n
Control Modul e (PCM) may not i nternal l y recogni ze.
The PCM attempts to acti vate these outputs and
al l ow an observer to veri fy proper operati on. Most of
the tests provi de an audi bl e or vi sual i ndi cati on of
devi ce operati on (cl i ck of rel ay contacts, fuel spray,
etc.). Except for i ntermi ttent condi ti ons, i f a devi ce
functi ons properl y duri ng testi ng, assume the devi ce,
i ts associ ated wi ri ng, and dri ver ci rcui t work cor-
rectl y. Connect the DRB scan tool to the data l i nk
connector and access the Actuators screen.
DESCRIPTION - DIAGNOSTIC TROUBLE CODES
A Di agnosti c Troubl e Code (DTC) i ndi cates the
PCM has recogni zed an abnormal condi ti on i n the
system.
Remember that DTCs are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTCs, refer to the charts in this
section.
BULB CHECK
Each ti me the i gni ti on key i s turned to the ON
posi ti on, the mal functi on i ndi cator (check engi ne)
l amp on the i nstrument panel shoul d i l l umi nate for
approxi matel y 2 seconds then go out. Thi s i s done for
a bul b check.
OBTAINING DTCS USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data l i nk
(di agnosti c) connector. Thi s connector i s l ocated i n
the passenger compartment; at the l ower edge of
i nstrument panel ; near the steeri ng col umn.
(2) Turn the i gni ti on swi tch on and access the
Read Faul t screen.
(3) Record al l the DTCs and freeze frame i nfor-
mati on shown on the DRB scan tool .
(4) To erase DTCs, use the Erase Troubl e Code
data screen on the DRB scan tool . Do not erase any
DTCs until problems have been investigated
and repairs have been performed.
(M) Mal functi on I ndi cator Lamp (MI L) i l l umi nated duri ng engi ne operati on i f thi s DTC was recorded
(dependi ng i f requi red by CARB and/or EPA). MI L i s di spl ayed as an engi ne i con on i nstrument panel .
(G) Generator l amp i l l umi nated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0030 (M) 1/1 O2 Sensor Heater Circuit
Malfunction
Problem detected in oxygen sensor heater relay circuit.
P0031 (M) 1/1 O2 Sensor Heater Circuit Low Problem detected in oxygen sensor heater relay circuit.
P0032 (M) 1/1 O2 Sensor Heater Circuit High Problem detected in oxygen sensor heater relay circuit.
Malfunction
Problem detected in oxygen sensor heater relay circuit.
25 - 2 EMISSIONS CONTROL WJ
EMISSIONS CONTROL (Continued)
Generic Scan
Tool P-Code
P0071 (M) Amb/Bat Temp Sensor Performance
P0106 Barometric Pressure Out of Range MAP sensor input voltage out of an acceptable range
detected during reading of barometric pressure at key-on.
P0107 (M) Map Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage.
P0108 (M) Map Sensor Voltage Too High MAP sensor input above maximum acceptable voltage.
PO111 (M) Intake Air Temp Sensor Performance
P0112 (M) Intake Air Temp Sensor Voltage Low Intake air (charge) temperature sensor input below the
minimum acceptable voltage.
P0113 (M) Intake Air Temp Sensor Voltage High Intake air (charge) temperature sensor input above the
maximum acceptable voltage.
P0116 Coolant Temp Sensor Performance A rationatilty error has been detected in the coolant temp
sensor.
P0117 (M) ECT Sensor Voltage Too Low Engine coolant temperature sensor input below the
P0118 (M) ECT Sensor Voltage Too High Engine coolant temperature sensor input above the
P0121 (M) TPS Voltage Does Not Agree With
MAP
TPS signal does not correlate to MAP sensor signal.
P0121 (M) Accelerator Position Sensor (APPS)
Signal Voltage Too Low
APPS voltage input below the minimum acceptable
voltage.
P0122 (M) Throttle Position Sensor Voltage Low Throttle position sensor input below the acceptable
voltage range.
Signal Voltage Too Low
APPS voltage input below the minimum acceptable
voltage.
P0123 (M) Throttle Position Sensor Voltage
High
Throttle position sensor input above the maximum
acceptable voltage.
Signal Voltage Too High
APPS voltage input above the maximum acceptable
voltage.
P0125 (M) Closed Loop Temp Not Reached Time to enter Closed Loop Operation (Fuel Control) is
excessive.
P0125 (M) Engine is Cold Too Long Engine does not reach operating temperature.
Malfunction
Oxygen sensor heater element malfunction.
P0131 (M) 1/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0132 (M) 1/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0133 (M) 1/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0134 (M) 1/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor input.
Generic Scan
Tool P-Code
P0135 (M) 1/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
Malfunction
Oxygen sensor heater element malfunction.
operating range.
operating range.
P0139 (M) 1/2 O2 Sensor Slow Response Oxygen sensor response not as expected.
sensor.
operating range.
operating range.
sensor.
operating range.
P0152 (M) 2/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage sustained above normal
operating range.
sensor.
operating range.
operating range.
P0159 2/2 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
sensor.
PO165 Starter Relay Circuit Problem detected in starter relay circuit.
P0168 Decreased Engine Performance Due
To High Injection Pump Fuel Temp
Fuel temperature is above the engine protection limit.
Engine power will be derated.
P0171 (M) 1/1 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
Generic Scan
Tool P-Code
P0172 (M) 1/1 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
P0174 (M) 2/1 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
P0175 (M) 2/1 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
P0176 Loss of Flex Fuel Calibration Signal No calibration voltage present from flex fuel sensor.
P0177 Water In Fuel Excess water found in fuel by water-in-fuel sensor.
P0178 Flex Fuel Sensor Volts Too Low Flex fuel sensor input below minimum acceptable voltage.
P0178 Water In Fuel Sensor Voltage Too
Low
Loss of water-in-fuel circuit or sensor.
P0179 Flex Fuel Sensor Volts Too High Flex fuel sensor input above maximum acceptable
voltage.
P0181 Fuel Injection Pump Failure Low power, engine derated, or engine stops.
P0182 (M) CNG Temp Sensor Voltage Too Low Compressed natural gas temperature sensor voltage
below acceptable voltage.
P0183 (M) CNG Temp Sensor Voltage Too High Compressed natural gas temperature sensor voltage
above acceptable voltage.
P0201 (M) Injector #1 Control Circuit An open or shorted condition detected in control circuit for
injector #1 or the INJ 1 injector bank.
P0204 (M) Injector #4 Control Circuit Injector #4 or INJ 4 injector bank output driver stage does
not respond properly to the control signal.
P0205 (M) Injector #5 Control Circuit Injector #5 output driver stage does not respond properly
to the control signal.
P0215 Fuel Injection Pump Control Circuit Failure in fuel pump relay control circuit.
P0216 (M) Fuel Injection Pump Timing Failure High fuel supply restriction, low fuel pressure or possible
wrong or incorrectly installed pump keyway.
To Engine Overheat Condition
Engine overheating. ECM will derate engine performance.
Generic Scan
Tool P-Code
P0219 Crankshaft Position Sensor
Overspeed Signal
Engine has exceeded rpm limits.
P0222 (M) Idle Validation Signals Both Low Problem detected with idle validation circuits within APPS.
P0223 (M) Idle Validation Signals Both High
(Above 5 Volts)
Problem detected with idle validation circuits within APPS.
P0230 Transfer Pump (Lift Pump) Circuit
Out of Range
Problem detected in fuel transfer pump circuits.
P0232 Fuel Shutoff Signal Voltage Too High Fuel shut-off signal voltage too high from ECM to fuel
injection pump.
P0234 (M) Turbo Boost Limit Exceeded Problem detected in turbocharger wastegate.
P0236 (M) Map Sensor Too High Too Long Problem detected in turbocharger wastegate.
P0237 (M) Map Sensor Voltage Too Low MAP sensor voltage input below the minimum acceptable
voltage.
P0238 (M) Map Sensor Voltage Too High MAP sensor voltage input above the maximum
acceptable voltage.
PO243 Wastegate Solenoid Circuit
P0251 (M) Fuel Inj. Pump Mech. Failure Fuel
Valve Feedback Circuit
Problem sensed with fuel circuit internal to fuel injection
pump.
P0253 (M) Fuel Injection Pump Fuel Valve
Open Circuit
Problem sensed with fuel circuit internal to fuel injection
pump.
P0254 Fuel Injection Pump Fuel Valve
Current Too High
Problem caused by internal fuel injection pump failure.
P0300 (M) Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
P0301 (M) CYLINDER #1 MISFIRE Misfire detected in cylinder #1.
P0307 (M) CYLINDER #7 MISFIRE Misfire detected in cylinder #7
P0320 (M) No Crank Referance Signal at PCM No reference signal (crankshaft position sensor) detected
during engine cranking.
P0320 (M) No RPM Signal to PCM (Crankshaft
Position Sensor Signal to JTEC)
A CKP signal has not been detected at the PCM.
P0325 Knock Sensor #1 Circuit Knock sensor (#1) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0330 Knock Sensor #2 Circuit Knock sensor (#2) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
Generic Scan
Tool P-Code
P0336 (M) Crankshaft Position (CKP) Sensor
Signal
Problem with voltage signal from CKP.
P0340 (M) No Cam Signal At PCM No fuel sync
P0341 (M) Camshaft Position (CMP) Sensor
Signal
Problem with voltage signal from CMP.
P0350 Ignition Coil Draws Too Much
Current
A coil (1-5) is drawing too much current.
P0351 (M) Ignition Coil # 1 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time.
dwell time.
dwell time.
dwell time (High Impedance).
dwell time (High Impedance).
dwell time (high impedance).
P0370 Fuel Injection Pump Speed/Position
Sensor Sig Lost
Problem caused by internal fuel injection pump failure.
P0380 (M) Intake Air Heater Relay #1 Control
Circuit
Problem detected in #1 air heater solenoid/relay circuit
(not heater element)
P0381 (M) Wait To Start Lamp Inoperative Problem detected in wait-to-start bulb circuit.
P0382 (M) Intake Air Heater Relay #2 Control
Circuit
Problem detected in #2 air heater solenoid/relay circuit
(not heater element)
P0387 Crankshaft Position Sensor Supply
Voltage Too Low
CKP sensor voltage input below the minimum acceptable
voltage.
P0388 Crankshaft Position Sensor Supply
Voltage Too High
CKP sensor voltage input above the maximum acceptable
voltage.
PO0400 Diesel EGR System Failure
P0401 EGR System Failure Required change in air/fuel ration not detected during
diagnostic test.
P0403 EGR Solenoid Circuit An open or shorted condition detected in the EGR
solenoid control circuit.
P0404 EGR Position Sensor Rationality EGR position sensor signal does not correlate to EGR
duty cycle.
P0405 EGR Position Sensor Volts Too Low EGR position sensor input below the acceptable voltage
range.
Generic Scan
Tool P-Code
P0406 EGR Position Sensor Volts Too High EGR position sensor input above the acceptable voltage
range.
P0412 Secondary Air Solenoid Circuit An open or shorted condition detected in the secondary
air (air switching/aspirator) solenoid control circuit.
P0420 (M) 1/1 Catalytic Converter Efficiency Catalyst 1/1 efficiency below required level.
P0432 (M) 1/2 Catalytic Converter Efficiency Catalyst 2/1 efficiency below required level.
P0441 (M) Evap Purge Flow Monitor Insufficient or excessive vapor flow detected during
evaporative emission system operation.
P0442 (M) Evap Leak Monitor Medium Leak
Detected
A small leak has been detected in the evaporative
system.
P0443 (M) Evap Purge Solenoid Circuit An open or shorted condition detected in the EVAP purge
solenoid control circuit.
P0455 (M) Evap Leak Monitor Large Leak
Detected
A large leak has been detected in the evaporative system.
P0456 (M) Evap Leak Monitor Small Leak
Detected
Leak has been detected in the evaporative system.
P0460 Fuel Level Unit No Change Over
Miles
During low fuel
P0460 Fuel Level Unit No Change Over
Miles
Fuel level sending unit voltage does not change for more
than 40 miles.
PO061 Fuel Level Unit No Change Over
Time
P0462 Fuel Level Sending Unit Volts Too
Low
Fuel level sensor input below acceptable voltage.
P0462 (M) Fuel Level Sending Unit Volts Too
Low
Open circuit between PCM and fuel gauge sending unit.
P0463 Fuel Level Sending Unit Volts Too
High
Fuel level sensor input above acceptable voltage.
P0463 (M) Fuel Level Sending Unit Volts Too
High
Circuit shorted to voltage between PCM and fuel gauge
sending unit.
P0500 (M) No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load
conditions.
P0500 (M) No Vehicle Speed Sensor Signal A vehicle speed signal was not detected.
P0505 (M) Idle Air Control Motor Circuits
P0508 (M) IAC Motor Sense Circuit Low
P0509 (M) IAC Motor Sense Circuit High
P0521 Oil Pressure Switch Rationality
P0522 Oil Pressure Voltage Too Low Oil pressure sending unit (sensor) voltage input below the
P0523 Oil Pressure Voltage Too High Oil pressure sending unit (sensor) voltage input above the
P0524 Oil Pressure Too Low Engine oil pressure is low. Engine power derated.
Generic Scan
Tool P-Code
P0545 A/C Clutch Relay Circuit Problem detected in air conditioning clutch relay control
circuit.
P0551 Power Steering Switch Failure Incorrect input state detected for the power steering
switch circuit. PL: High pressure seen at high speed.
P0562 Charging System Voltage Too Low Supply voltage sensed at ECM too low.
P0563 Charging System Voltage Too High Supply voltage sensed at ECM too high.
P0572 Brake Switch Input #1 Signal
Missing
P0573 Brake Switch Input #2 Signal
Missing
P0575 Cruise Control Switch Voltage Low
P0576 Cruise Control Switch Voltage High
P0577 Cruise Control Switch Voltage High
P0600 PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum)
detected.
P0602 (M) ECM Fueling Calibration Error ECM Internal fault condition detected.
P0604 RAM Check Failure Transmission control module RAM self test fault detected.
-Aisin transmission
P0605 ROM Check Falure Transmission control module ROM self test fault detected
-Aisin transmission
P0606 (M) ECM Failure ECM Internal fault condition detected.
P0615 Starter Relay Control Circuit An open or shorted condition detected in the starter relay
control circuit.
P0622 (G) Generator Field Not Switching
Properly
An open or shorted condition detected in the generator
field control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch
relay control circuit.
P0700 EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or
Aisin controller has an active fault and has illuminated the
MIL via a CCD (EATX) or SCI (Aisin) message. The
specific fault must be acquired from the EATX via CCD or
from the Aisin via ISO-9141.
P0703 Brake Switch Stuck Pressed or
Released
Incorrect input state detected in the brake switch circuit.
(Changed from P1595)
P0703 Brake Switch Sense Circuit
P0711 (M) Trans Temp Sensor, No Temp Rise
After Start
Relationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a
failure of the Transmission Temperature Sensor. OBD II
Rationality. Was MIL code 37.
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage. Was MIL code 37.
Generic Scan
Tool P-Code
P0712 (M) Trans Temp Sensor Voltage Too Low Voltage less than 1.55 volts (4-speed auto. trans. only).
P0713 Trans Temp Sensor Voltage Too
High
Transmission fluid temperature sensor input above
acceptable voltage. Was MIL code 37.
P0713 (M) Trans Temp Sensor Voltage Too
High
Voltage greater than 3.76 volts (4-speed auto. trans.
only).
P0720 (M) Low Output SPD Sensor RPM,
Above 15 MPH
The relationship between the Output Shaft Speed Sensor
and vehicle speed is not within acceptable limits.
P0720 (M) Low Output Spd Sensor RPM Above
15 mph
Output shaft speed is less than 60 rpm with vehicle speed
above 15 mph (4-speed auto. trans. only).
P0740 (M) Torq Con Clu, No RPM Drop at
Lockup
Relationship between engine and vehicle speeds
indicated failure of torque convertor clutch lock-up system
(TCC/PTU solenoid)
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay Circuits
An open or shorted condition detected in the torque
converter clutch (part throttle unlock) solenoid control
circuit. Shift solenoid C electrical fault - Aisin transmission
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay Circuits
An open or shorted condition detected in the torque
converter part throttle unlock solenoid control circuit (3 or
4-speed auto. trans. only).
P0748 (M) Governor Pressur Sol Control/Trans
Relay Circuits
An open or shorted condition detected in the Governor
Pressure Solenoid circuit or Trans Relay Circuit in JTEC
RE transmissions.
P0748 (M) Governor Pressure Sol Control/Trans
Relay Circuits
An open or shorted condition detected in the governor
pressure solenoid or relay circuits (4-speed auto. trans.
only).
P0751 (M) O/D Switch Pressed (Lo) More Than
5 Minutes
Overdrive override switch input is in a prolonged
depressed state.
P0751 (M) O/D Switch Pressed (LO) More Than
5 Min
Overdrive Off switch input too low for more than 5
minutes (4-speed auto. trans. only).
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
Circuits
An open or shorted condition detected in the overdrive
solenoid control circuit or Trans Relay Circuit in JTEC RE
transmissions. Was MIL code 45.
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
Circuits
An open or shorted condition detected in the transmission
2-4 shift solenoid circuit (4-speed auto. trans. only).
P0756 AW4 Shift Sol B (2-3) Functional
Failure
Shift solenoid B (2-3) functional fault - Aisin transmission
P0783 (M) 3-4 Shift Sol, No RPM Drop at
Lockup
The overdrive solenoid is unable to engage the gear
change from 3rd gear to the overdrive gear.
P0801 Reverse Gear Lockout Circuit Open
or Short
An open or shorted condition detected in the transmission
reverse gear lock-out solenoid control circuit.
P0830 Clutch Depressed Switch Circuit Problem detected in clutch switch circuit.
P0833 Clutch Released Switch Circuit Problem detected in clutch switch circuit.
P0836 4WD Mux Switch Circuit
P0837 4WD Mux Switch Performance
Generic Scan
Tool P-Code
P1110 Decrease Engine Performance Due
To High Intake Air Temperature
Intake manifold air temperature is above the engine
protection limit. Engine power will be derated.
To High Injection Pump Fuel Temp
Fuel temperature is above the engine protection limit.
P1192 Intake Air Temp Sensor Voltage Low
P1193 Intake Air Temp Sensor Voltage High
P1194 O2 Heater Performance
P1195 (M) 1/1 O2 Sensor Slow During Catalyst
Monitor
A slow switching oxygen sensor has been detected in
bank 1/1 during catalyst monitor test. (Also see SCI DTC
$66) (was P0133)
P1196 (M) 2/1 O2 Sensor Slow During Catalyst
Monitor
$7A) (was P0153)
P1197 1/2 O2 Sensor Slow During Catalyst
Monitor
$68) (was P0139)
P1198 Radiator Temperature Sensor Volts
Too High
Radiator coolant temperature sensor input above the
P1199 Radiator Temperature Sensor Volts
Too Low
Radiator coolant temperature sensor input below the
P1280 Fuel System Relay Circuit
P1281 Engine is Cold Too Long Engine coolant temperature remains below normal
operating temperatures during vehicle travel (Thermostat).
P1282 Fuel Pump/System Relay Control
Circuit
An open or shorted condition detected in the fuel pump
relay control circuit.
P1283 Idle Select Signal Invalid ECM or fuel injection pump module internal fault condition
detected.
P1284 (M) Fuel Injection Pump Battery Voltage
Out-Of-Range
Fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1285 (M) Fuel Injection Pump Controller
Always On
Fuel injection pump module relay circuit failure detected.
P1286 Accelerator Position Sensor (APPS)
Supply Voltage Too High
High voltage detected at APPS.
P1287 Fuel Injection Pump Controller
Supply Voltage Low
ECM or fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1288 Intake Manifold Short Runner
Solenoid Circuit
An open or shorted condition detected in the short runner
tuning valve circuit.
P1289 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold
tuning valve solenoid control circuit.
P1290 High Pressure Solenoid Relay Ckt. CNG Fuel System Pressure Too HighCompressed
natural gas system pressure above normal operating
range.
P1291 No Temp Rise Seen From Intake
Heaters
Energizing Heated Air Intake does not change intake air
temperature sensor an acceptable amount.
Generic Scan
Tool P-Code
P1291 (M) No Temperature Rise Seen From
Intake Air Heaters
Problem detected in intake manifold air heating system.
P1292 CNG Pressure Sensor Voltage Too
High
Compressed natural gas pressure sensor reading above
acceptable voltage.
P1293 CNG Pressure Sensor Voltage Too
Low
Compressed natural gas pressure sensor reading below
acceptable voltage.
P1294 (M) Target Idle Not Reached Target RPM not achieved during drive idle condition.
Possible vacuum leak or IAC (AIS) lost steps.
P1295 (M) No 5 Volts to TP Sensor Loss of a 5 volt feed to the Throttle Position Sensor has
been detected.
Supply Voltage Too Low
APPS supply voltage input below the minimum
acceptable voltage.
P1296 No 5 Volts to MAP Sensor Loss of a 5 volt feed to the MAP Sensor has been
detected.
P1297 (M) No Change in MAP From Start To
Run
No difference is recognized between the MAP reading at
engine idle and the stored barometric pressure reading.
P1298 Lean Operation at Wide Open
Throttle
A prolonged lean condition is detected during Wide Open
Throttle
P1299 Vacuum Leak Found (IAC Fully
Seated)
MAP Sensor signal does not correlate to Throttle Position
Sensor signal. Possible vacuum leak.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the ASD or CNG
shutoff relay control ckt.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the auto
shutdown relay circuit.
P1389 No ASD Relay Output Voltage At
PCM
No Z1 or Z2 voltage sensed when the auto shutdown
relay is energized.
P1389 (M) No ASD Relay Output Voltage at
PCM
An open condition detected In the ASD relay output
circuit.
P1390 Timing Belt Skipped 1 Tooth or More Relationship between Cam and Crank signals not correct
P1391 (M) Intermittent Loss of CMP or CKP Loss of the Cam Position Sensor or Crank Position
sensor has occurred. For PL 2.0L
P1398 (M) Mis-Fire Adaptive Numerator at Limit PCM is unable to learn the Crank Sensors signal in
preparation for Misfire Diagnostics. Probable defective
Crank Sensor
P1399 Wait To Start Lamp Cicuit An open or shorted condition detected in the Wait to Start
Lamp circuit.
P1403 No 5V to EGR Sensor Loss of 5v feed to the EGR position sensor.
P01475 Aux 5 Volt Supply Voltage High Sensor supply voltage for ECM sensors is too high.
P1476 Too Little Secondary Air Insufficient flow of secondary air injection detected during
aspirator test (was P0411)
P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during
aspirator test (was P0411).
Generic Scan
Tool P-Code
P1478 Battery Temp Sensor Volts Out of
Limit
Internal temperature sensor input voltage out of an
acceptable range.
P1479 Transmission Fan Relay Circuit An open or shorted condition detected in the transmission
fan relay circuit.
P1480 PCV Solenoid Circuit An open or shorted condition detected in the PCV
solenoid circuit.
P1481 EATX RPM Pulse Perf EATX RPM pulse generator signal for misfire detection
does not correlate with expected value.
P1482 Catalyst Temperature Sensor Circuit
Shorted Low
Catalyst temperature sensor circuit shorted low.
P1483 Catalyst Temperature Sensor Circuit
Shorted High.
Catalyst temperature sensor circuit shorted high.
P1484 Catalytic Converter Overheat
Detected
A catalyst overheat condition has been detected by the
catalyst temperature sensor.
P1485 Air Injection Solenoid Circuit An open or shorted condition detected in the air assist
solenoid circuit.
P1486 Evap Leak Monitor Pinched Hose
Found
LDP has detected a pinched hose in the evaporative hose
system.
P1487 Hi Speed Rad Fan CTRL Relay
Circuit
An open or shorted condition detected in the control
circuit of the #2 high speed radiator fan control relay.
P1488 Auxiliary 5 Volt Supply Output Too
Low
Auxiliary 5 volt sensor feed is sensed to be below an
acceptable limit.
P1488 5 Volt Supply Voltage Low Sensor supply voltage for ECM sensors is too low.
P1489 High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control
circuit of the high speed radiator fan control relay.
P1490 Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of
the low speed radiator fan control relay.
P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan
control relay control circuit. This includes PWM solid state
relays.
P1492 Ambient/Batt Temp Sen Volts Too
High
External temperature sensor input above acceptable
voltage.
P1492 (M) Ambient/Batt Temp Sensor Volts Too
High
Battery temperature sensor input voltage above an
acceptable range.
P1493 (M) Ambient/Batt Temp Sen Volts Too
Low
External temperature sensor input below acceptable
voltage.
P1493 (M) Ambient/Batt Temp Sen Volts Too
Low
Battery temperature sensor input voltage below an
acceptable range.
P1494 (M) Leak Detection Pump Sw or
Mechanical Fault
Incorrect input state detected for the Leak Detection
Pump (LDP) pressure switch.
P1495 Leak Detection Pump Solenoid
Circuit
An open or shorted condition detected in the Leak
Detection Pump (LDP) solenoid circuit.
P1496 5 Volt Supply, Output Too Low 5 volt sensor feed is sensed to be below an acceptable
limit. ( less than 4v for 4 sec )
Generic Scan
Tool P-Code
P1498 High Speed Rad Fan Ground CTRL
Rly Circuit
An open or shorted condition detected in the control
circuit of the #3 high speed radiator fan control relay.
P1499 Hydraulic cooling fan solenoid circuit An open or shorted condition detected in the cooling fan
control solenoid circuit.
P1594 (G) Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1594 Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the
speed control vacuum or vent solenoid control circuits.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in the speed
control vacuum or vent solenoid circuits.
P1596 Speed Control Switch Always High Speed control switch input above maximum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below minimum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below the minimum acceptable
voltage.
P1598 A/C Pressure Sensor Volts Too High A/C pressure sensor input above maximum acceptable
voltage.
P1598 A/C Sensor Input Hi Problem detected in air conditioning electrical circuit.
P1599 A/C Pressure Sensor Volts Too Low A/C pressure sensor input below minimum acceptable
voltage.
P1599 A/C Sensor Input Lo Problem detected in air conditioning electrical circuit.
P1602 PCM not programmed
P1680 Clutch Released Switch Circuit Problem detected in clutch switch electrical circuit.
P1681 No I/P Cluster CCD/J1850
Messages Received
No CCD/J1850 messages received from the cluster
control module.
P1682 (G) Charging System Voltage Too Low Battery voltage sense input below target charging voltage
during engine operation and no significant change in
voltage detected during active test of generator output
circuit.
P1682 Charging System Voltage Too Low Charging system output voltage low.
P1683 SPD CTRL PWR Relay; or S/C 12v
Driver CKT
An open or shorted condition detected in the speed
control servo power control circuit.
P1683 Spd ctrl pwr rly, or s/c 12v driver
circuit
An open or shorted condition detected in the speed
control servo power control circuit.
P1684 Batt Loss (disconnected) in last 50
Starts
The battery has been disconnected within the last 50
starts
P1685 SKIM Invalid Key - (Wrong or Invalid
Key MSG Received From SKIM)
The engine controler has received an invalid key from the
SKIM.
P1686 No SKIM BUS Messages Received No CCD/J1850 messages received from the Smart Key
Immobilizer Module (SKIM).
Generic Scan
Tool P-Code
P1687 No MIC BUS Message (No Cluster
BUS Message)
No CCD/J1850 messages received from the Mechanical
Instrument Cluster (MIC) module.
P1688 (M) Internal Fuel Injection Pump
Controller Failure
Internal problem within the fuel injection pump. Low
power, engine derated, or engine stops.
P1689 (M) No Communication Between ECM
and Injection Pump Module
Data link circuit failure between ECM and fuel injection
pump. Low power, engine derated, or engine stops.
P1690 (M) Fuel Injection Pump CKP Sensor
Does Not Agree With ECM CKP
Sensor
Problem in fuel sync signal. Possible injection pump
timing problem. Low power, engine derated, or engine
stops.
P1691 Fuel Injection Pump Controller
Calibration Error
Internal fuel injection pump failure. Low power, engine
derated, or engine stops.
P1692 DTC Set In ECM A Companion DTC was set in both the ECM and PCM.
P1693 (M) DTC Detected in Companion Module A fault has been generated in the companion engine
control module.
P1693 (M) DTC Detected in PCM/ECM or DTC
Detected in ECM
A Companion DTC was set in both the ECM and PCM.
P1694 Fault In Companion Module No CCD/J1850 messages received from the powertrain
control module-Aisin transmission
P1694 (M) No BUS (CCD) Messages received
from ECM
Bus communication failure to PCM.
P1695 No CCD/J1850 Message From Body
Control Module
No CCD/J1850 messages received from the body control
module.
P1696 PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by
the control module.
P1697 PCM Failure SRI Mile Not Stored Unsuccessful attempt to update Service Reminder
Indicator (SRI or EMR) mileage in the control module
EEPROM.
P1698 No CCD/J1850 Message From TCM No CCD/J1850 messages received from the electronic
transmission control module (EATX) or the Aisin
transmission controller.
P1698 No CCD Messages received from
PCM
Bus communication failure to PCM. A Companion DTC
was set in both the ECM and PCM.
P1699 No Climate Control Bus Messages
P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission
2-3 gear lock-out solenoid control circuit.
P1740 TCC or OD Sol Perf A rationality error has been detected in either the TCC
solenoid or overdrive solenoid systems.
P1740 (M) TCC OR O/D Solenoid Performance Problem detected in transmission convertor clutch and/or
overdrive circuits (diesel engine with 4-speed auto. trans.
only).
Generic Scan
Tool P-Code
P1756 (M) GOV Press Not Equal to Target @
15-20 PSI
The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear. (Mid Pressure
Malfunction)
P1756 (M) Governor Pressure Not Equal to
Target @ 15-20 PSI
Governor sensor input not between 10 and 25 psi when
requested (4-speed auto. trans. only).
P1757 GOV Press Not Equal to Target @
15-20 PSI
The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear (Zero Pressure
Malfunction)
P1757 (M) Governor Pressure Above 3 PSI In
Gear With 0 MPH
Governor pressure greater than 3 psi when requested to
be 0 psi (4-speed auto. trans. only).
P1762 (M) Gov Press Sen Offset Volts Too Lo
or High
The Governor Pressure Sensor input is greater than a
calibration limit or is less than a calibration limit for 3
consecutive park/neutral calibrations.
P1762 (M) Governor Press Sen Offset Volts Too
Low or High
Sensor input greater or less than calibration for 3
consecutive Neutral/Park occurrences (4-speed auto.
trans. only).
P1763 Governor Pressure Sensor Volts Too
Hi
The Governor Pressure Sensor input is above an
acceptable voltage level.
P1763 (M) Governor Pressure Sensor Volts Too
HI
Voltage greater than 4.89 volts (4-speed auto. trans.
only).
Low
The Governor Pressure Sensor input is below an
acceptable voltage level.
Low
Voltage less than .10 volts (4-speed auto. trans. only).
P1765 (M) Trans 12 Volt Supply Relay CTRL
Circuit
An open or shorted condition is detected in the
Transmission Relay control circuit. This relay supplies
power to the TCC
P1765 (M) Trans 12 Volt Supply Relay Ctrl
Circuit
Current state of solenoid output port is different than
expected (4-speed auto. trans. only).
P1830 Clutch Override Relay Circuit Problem detected in clutch pedal switch override relay
circuit.
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch.
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch
(3 or 4-speed auto. trans. only).
DESCRIPTION - TASK MANAGER
The PCM i s responsi bl e for effi ci entl y coordi nati ng
the operati on of al l the emi ssi ons-rel ated compo-
nents. The PCM i s al so responsi bl e for determi ni ng i f
the di agnosti c systems are operati ng properl y. The
software desi gned to carry out these responsi bi l i ti es
i s referred to as the Task Manager.
DESCRIPTION - MONITORED SYSTEMS
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated. These moni tors generate
Di agnosti c Troubl e Codes that can be di spl ayed wi th
the MI L or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
Mi sfi re Moni tor
Fuel System Moni tor
Oxygen Sensor Moni tor
Oxygen Sensor Heater Moni tor
Catal yst Moni tor
Leak Detecti on Pump Moni tor (i f equi pped)
Al l these system moni tors requi re two consecuti ve
tri ps wi th the mal functi on present to set a faul t.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
The fol l owi ng i s an operati on and descri pti on of
each system moni tor:
OXYGEN SENSOR (O2S) MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
Catal yst and Fuel Moni tors.
The O2S can fai l i n any or al l of the fol l owi ng
manners:
sl ow response rate
reduced output vol tage
dynami c shi ft
shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
OXYGEN SENSOR HEATER MONITOR
I f there i s an oxygen sensor (O2S) shorted to vol t-
age DTC, as wel l as a O2S heater DTC, the O2S
faul t MUST be repai red fi rst. Before checki ng the
O2S faul t, veri fy that the heater ci rcui t i s operati ng
correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S sensor
are very temperature sensi ti ve. The readi ngs are not
accurate bel ow 300C. Heati ng of the O2S sensor i s
done to al l ow the engi ne control l er to shi ft to cl osed
l oop control as soon as possi bl e. The heati ng el ement
used to heat the O2S sensor must be tested to ensure
that i t i s heati ng the sensor properl y.
The O2S sensor ci rcui t i s moni tored for a drop i n
vol tage. The sensor output i s used to test the heater
by i sol ati ng the effect of the heater el ement on the
O2S sensor output vol tage from the other effects.
LEAK DETECTION PUMP MONITOR (IF EQUIPPED)
The l eak detecti on assembl y i ncorporates two pri -
mary functi ons: i t must detect a l eak i n the evapora-
ti ve system and seal the evaporati ve system so the
l eak detecti on test can be run.
The pri mary components wi thi n the assembl y are:
A three port sol enoi d that acti vates both of the func-
ti ons l i sted above; a pump whi ch contai ns a swi tch,
two check val ves and a spri ng/di aphragm, a cani ster
vent val ve (CVV) seal whi ch contai ns a spri ng l oaded
vent seal val ve.
I mmedi atel y after a col d start, between predeter-
mi ned temperature threshol ds l i mi ts, the three port
sol enoi d i s bri efl y energi zed. Thi s i ni ti al i zes the
pump by drawi ng ai r i nto the pump cavi ty and al so
cl oses the vent seal . Duri ng non test condi ti ons the
vent seal i s hel d open by the pump di aphragm
assembl y whi ch pushes i t open at the ful l travel posi -
ti on. The vent seal wi l l remai n cl osed whi l e the
pump i s cycl i ng due to the reed swi tch tri ggeri ng of
the three port sol enoi d that prevents the di aphragm
assembl y from reachi ng ful l travel . After the bri ef
i ni ti al i zati on peri od, the sol enoi d i s de-energi zed
al l owi ng atmospheri c pressure to enter the pump
cavi ty, thus permi tti ng the spri ng to dri ve the di a-
phragm whi ch forces ai r out of the pump cavi ty and
i nto the vent system. When the sol enoi d i s energi zed
and de energi zed, the cycl e i s repeated creati ng fl ow
i n typi cal di aphragm pump fashi on. The pump i s con-
trol l ed i n 2 modes:
Pump Mode: The pump i s cycl ed at a fi xed rate to
achi eve a rapi d pressure bui l d i n order to shorten the
overal l test l ength.
Test Mode: The sol enoi d i s energi zed wi th a fi xed
durati on pul se. Subsequent fi xed pul ses occur when
the di aphragm reaches the Swi tch cl osure poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5
water. The cycl e rate of pump strokes i s qui te rapi d
as the system begi ns to pump up to thi s pressure. As
the pressure i ncreases, the cycl e rate starts to drop
off. I f there i s no l eak i n the system, the pump woul d
eventual l y stop pumpi ng at the equal i zed pressure. I f
there i s a l eak, i t wi l l conti nue to pump at a rate rep-
resentati ve of the fl ow characteri sti c of the si ze of the
l eak. From thi s i nformati on we can determi ne i f the
l eak i s l arger than the requi red detecti on l i mi t (cur-
rentl y set at .040 ori fi ce by CARB). I f a l eak i s
reveal ed duri ng the l eak test porti on of the test, the
test i s termi nated at the end of the test mode and no
further system checks wi l l be performed.
After passi ng the l eak detecti on phase of the test,
system pressure i s mai ntai ned by turni ng on the
LDPs sol enoi d unti l the purge system i s acti vated.
Purge acti vati on i n effect creates a l eak. The cycl e
rate i s agai n i nterrogated and when i t i ncreases due
to the fl ow through the purge system, the l eak check
porti on of the di agnosti c i s compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
Evaporati ve system functi onal i ty wi l l be veri fi ed by
usi ng the stri cter evap purge fl ow moni tor. At an
appropri ate warm i dl e the LDP wi l l be energi zed to
seal the cani ster vent. The purge fl ow wi l l be cl ocked
up from some smal l val ue i n an attempt to see a
shi ft i n the 02 control system. I f fuel vapor, i ndi cated
by a shi ft i n the 02 control , i s present the test i s
passed. I f not, i t i s assumed that the purge system i s
not functi oni ng i n some respect. The LDP i s agai n
turned off and the test i s ended.
MISFIRE MONITOR
Excessi ve engi ne mi sfi re resul ts i n i ncreased cata-
l yst temperature and causes an i ncrease i n HC emi s-
si ons. Severe mi sfi res coul d cause catal yst damage.
To prevent catal yti c convertor damage, the PCM
moni tors engi ne mi sfi re.
for mi sfi re duri ng most engi ne operati ng condi ti ons
(posi ti ve torque) by l ooki ng at changes i n the crank-
shaft speed. I f a mi sfi re occurs the speed of the
crankshaft wi l l vary more than normal .
FUEL SYSTEM MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the Ai r Fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S sensor output. The programmed
memory acts as a sel f cal i brati on tool that the engi ne
control l er uses to compensate for vari ati ons i n engi ne
speci fi cati ons, sensor tol erances and engi ne fati gue
over the l i fe span of the engi ne. By moni tori ng the
actual fuel -ai r rati o wi th the O2S sensor (short term)
and mul ti pl yi ng that wi th the program l ong-term
(adapti ve) memory and compari ng that to the l i mi t,
i t can be determi ned whether i t wi l l pass an emi s-
si ons test. I f a mal functi on occurs such that the PCM
cannot mai ntai n the opti mum A/F rati o, then the
MI L wi l l be i l l umi nated.
CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. Thi s can i ncrease vehi cl e emi ssi ons
and deteri orate engi ne performance, dri veabi l i ty and
fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2Ss) to moni tor the effi ci ency of the converter. The
dual O2Ss sensor strategy i s based on the fact that
as a catal yst deteri orates, i ts oxygen storage capaci ty
and i ts effi ci ency are both reduced. By moni tori ng
the oxygen storage capaci ty of a catal yst, i ts effi -
ci ency can be i ndi rectl y cal cul ated. The upstream
O2S i s used to detect the amount of oxygen i n the
exhaust gas before the gas enters the catal yti c con-
verter. The PCM cal cul ates the A/F mi xture from the
output of the O2S. A l ow vol tage i ndi cates hi gh oxy-
gen content (l ean mi xture). A hi gh vol tage i ndi cates a
l ow content of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstream O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2Ss.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2Ss i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L wi l l be i l l u-
mi nated.
DESCRIPTION - TRIP DEFINITION
The term Tri p has di fferent meani ngs dependi ng
on what the ci rcumstances are. I f the MI L (Mal func-
ti on I ndi cator Lamp) i s OFF, a Tri p i s defi ned as
when the Oxygen Sensor Moni tor and the Catal yst
Moni tor have been compl eted i n the same dri ve cycl e.
When any Emi ssi on DTC i s set, the MI L on the
dash i s turned ON. When the MI L i s ON, i t takes 3
good tri ps to turn the MI L OFF. I n thi s case, i t
depends on what type of DTC i s set to know what a
Tri p i s.
For the Fuel Moni tor or Mi s-Fi re Moni tor (conti n-
uous moni tor), the vehi cl e must be operated i n the
Si mi l ar Condi ti on Wi ndow for a speci fi ed amount of
ti me to be consi dered a Good Tri p.
I f a Non-Conti uous OBDI I Moni tor fai l s twi ce i n a
row and turns ON the MI L, re-runni ng that moni tor
whi ch previ ousl y fai l ed, on the next start-up and
passi ng the moni tor, i s consi dered to be a Good Tri p.
These wi l l i ncl ude the fol l owi ng:
Oxygen Sensor
Catal yst Moni tor
Purge Fl ow Moni tor
Leak Detecti on Pump Moni tor (i f equi pped)
EGR Moni tor (i f equi pped)
Oxygen Sensor Heater Moni tor
I f any other Emi ssi on DTC i s set (not an OBDI I
Moni tor), a Good Tri p i s consi dered to be when the
Oxygen Sensor Moni tor and Catal yst Moni tor have
been compl eted; or 2 Mi nutes of engi ne run ti me i f
the Oxygen Sensor Moni tor or Catal yst Moni tor have
been stopped from runni ng.
I t can take up to 2 Fai l ures i n a row to turn on the
MI L. After the MI L i s ON, i t takes 3 Good Tri ps to
turn the MI L OFF. After the MI L i s OFF, the PCM
wi l l sel f-erase the DTC after 40 Warm-up cycl es. A
Warm-up cycl e i s counted when the ECT (Engi ne
Cool ant Temperature Sensor) has crossed 160F and
has ri sen by at l east 40F si nce the engi ne has been
started.
DESCRIPTION - COMPONENT MONITORS
There are several components that wi l l affect vehi -
cl e emi ssi ons i f they mal functi on. I f one of these com-
ponents mal functi ons the Mal functi on I ndi cator
Lamp (MI L) wi l l i l l umi nate.
Some of the component moni tors are checki ng for
proper operati on of the part. El ectri cal l y operated
components now have i nput (rati onal i ty) and output
(functi onal i ty) checks. Previ ousl y, a component l i ke
the Throttl e Posi ti on sensor (TPS) was checked by
the PCM for an open or shorted ci rcui t. I f one of
these condi ti ons occurred, a DTC was set. Now there
i s a check to ensure that the component i s worki ng.
Thi s i s done by watchi ng for a TPS i ndi cati on of a
greater or l esser throttl e openi ng than MAP and
engi ne rpm i ndi cate. I n the case of the TPS, i f engi ne
vacuum i s hi gh and engi ne rpm i s 1600 or greater
and the TPS i ndi cates a l arge throttl e openi ng, a
DTC wi l l be set. The same appl i es to l ow vacuum i f
the TPS i ndi cates a smal l throttl e openi ng.
Al l open/short ci rcui t checks or any component that
has an associ ated l i mp i n wi l l set a faul t after 1 tri p
wi th the mal functi on present. Components wi thout
an associ ated l i mp i n wi l l take two tri ps to i l l umi -
nate the MI L.
Refer to the Di agnosti c Troubl e Codes Descri pti on
Charts i n thi s secti on and the appropri ate Power-
trai n Di agnosti c Procedure Manual for di agnosti c
procedures.
DESCRIPTION - NON-MONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems and condi ti ons that coul d have mal functi ons
causi ng dri veabi l i ty probl ems. The PCM mi ght not
store di agnosti c troubl e codes for these condi ti ons.
However, probl ems wi th these systems may cause the
PCM to store di agnosti c troubl e codes for other sys-
tems or components. For exampl e, a fuel pressure
probl em wi l l not regi ster a faul t di rectl y, but coul d
cause a ri ch/l ean condi ti on or mi sfi re. Thi s coul d
cause the PCM to store an oxygen sensor or mi sfi re
di agnosti c troubl e code
FUEL PRESSURE
The fuel pressure regul ator control s fuel system
pressure. The PCM cannot detect a cl ogged fuel
pump i nl et fi l ter, cl ogged i n-l i ne fuel fi l ter, or a
pi nched fuel suppl y or return l i ne. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng the
PCM to store an oxygen sensor or fuel system di ag-
nosti c troubl e code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an i noperati ve i gni ti on coi l ,
foul ed or worn spark pl ugs, i gni ti on cross fi ri ng, or
open spark pl ug cabl es.
CYLINDER COMPRESSION
The PCM cannot detect uneven, l ow, or hi gh engi ne
cyl i nder compressi on.
EXHAUST SYSTEM
The PCM cannot detect a pl ugged, restri cted or
l eaki ng exhaust system, al though i t may set a fuel
system faul t.
FUEL INJECTOR MECHANICAL MALFUNCTIONS
The PCM cannot determi ne i f a fuel i njector i s
cl ogged, the needl e i s sti cki ng or i f the wrong i njector
i s i nstal l ed. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng the PCM to store a di agnosti c
troubl e code for ei ther mi sfi re, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Al though the PCM moni tors engi ne exhaust oxygen
content when the system i s i n cl osed l oop, i t cannot
determi ne excessi ve oi l consumpti on.
THROTTLE BODY AIRFLOW
The PCM cannot detect a cl ogged or restri cted ai r
cl eaner i nl et or fi l ter el ement.
VACUUM ASSIST
The PCM cannot detect l eaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces. However, these coul d cause the PCM
to store a MAP sensor di agnosti c troubl e code and
cause a hi gh i dl e condi ti on.
PCM SYSTEM GROUND
The PCM cannot determi ne a poor system ground.
However, one or more di agnosti c troubl e codes may
be generated as a resul t of thi s condi ti on. The mod-
ul e shoul d be mounted to the body at al l ti mes, al so
duri ng di agnosti c.
PCM CONNECTOR ENGAGEMENT
The PCM may not be abl e to determi ne spread or
damaged connector pi ns. However, i t mi ght store
di agnosti c troubl e codes as a resul t of spread connec-
tor pi ns.
DESCRIPTION - HIGH AND LOW LIMITS
The PCM compares i nput si gnal vol tages from each
i nput devi ce wi th establ i shed hi gh and l ow l i mi ts for
the devi ce. I f the i nput vol tage i s not wi thi n l i mi ts
and other cri teri a are met, the PCM stores a di agnos-
ti c troubl e code i n memory. Other di agnosti c troubl e
code cri teri a mi ght i ncl ude engi ne RPM l i mi ts or
i nput vol tages from other sensors or swi tches that
must be present before veri fyi ng a di agnosti c troubl e
code condi ti on.
DESCRIPTION - LOAD VALUE
ENGINE IDLE/NEUTRAL 2500 RPM/NEUTRAL
All Engines 2% to 8% of Maximum Load 9% to 17% of Maximum Load
OPERATION - TASK MANAGER
The Task Manager determi nes whi ch tests happen
when and whi ch functi ons occur when. Many of the
di agnosti c steps requi red by OBD I I must be per-
formed under speci fi c operati ng condi ti ons. The Task
Manager software organi zes and pri ori ti zes the di ag-
nosti c procedures. The job of the Task Manager i s to
determi ne i f condi ti ons are appropri ate for tests to be
run, moni tor the parameters for a tri p for each test,
and record the resul ts of the test. Fol l owi ng are the
responsi bi l i ti es of the Task Manager software:
Test Sequence
MI L I l l umi nati on
Di agnosti c Troubl e Codes (DTCs)
Tri p I ndi cator
Freeze Frame Data Storage
Si mi l ar Condi ti ons Wi ndow
Test Sequence
I n many i nstances, emi ssi ons systems must fai l
di agnosti c tests more than once before the PCM i l l u-
mi nates the MI L. These tests are know as two tri p
moni tors. Other tests that turn the MI L l amp on
after a si ngl e fai l ure are known as one tri p moni -
tors. A tri p i s defi ned as start the vehi cl e and oper-
ate i t to meet the cri teri a necessary to run the gi ven
moni tor.
Many of the di agnosti c tests must be performed
under certai n operati ng condi ti ons. However, there
are ti mes when tests cannot be run because another
test i s i n progress (confl i ct), another test has fai l ed
(pendi ng) or the Task Manager has set a faul t that
may cause a fai l ure of the test (suspend).
Pendi ng
Under some si tuati ons the Task Manager wi l l not
run a moni tor i f the MI L i s i l l umi nated and a faul t i s
stored from another moni tor. I n these si tuati ons, the
Task Manager postpones moni tors pending resol u-
ti on of the ori gi nal faul t. The Task Manager does not
run the test unti l the probl em i s remedi ed.
For exampl e, when the MI L i s i l l umi nated for an
Oxygen Sensor faul t, the Task Manager does not run
the Catal yst Moni tor unti l the Oxygen Sensor faul t i s
remedi ed. Si nce the Catal yst Moni tor i s based on si g-
nal s from the Oxygen Sensor, runni ng the test woul d
produce i naccurate resul ts.
Confl i ct
There are si tuati ons when the Task Manager does
not run a test i f another moni tor i s i n progress. I n
these si tuati ons, the effects of another moni tor run-
ni ng coul d resul t i n an erroneous fai l ure. I f thi s con-
flict i s present, the moni tor i s not run unti l the
confl i cti ng condi ti on passes. Most l i kel y the moni tor
wi l l run l ater after the confl i cti ng moni tor has
passed.
For exampl e, i f the Fuel System Moni tor i s i n
progress, the Task Manager does not run the EGR
Moni tor. Si nce both tests moni tor changes i n ai r/fuel
rati o and adapti ve fuel compensati on, the moni tors
wi l l confl i ct wi th each other.
Suspend
Occasi onal l y the Task Manager may not al l ow a two
tri p faul t to mature. The Task Manager wi l l sus-
pend the maturi ng of a faul t i f a condi ti on exi sts
that may i nduce an erroneous fai l ure. Thi s prevents
i l l umi nati ng the MI L for the wrong faul t and al l ows
more preci s di agnosi s.
For exampl e, i f the PCM i s stori ng a one tri p faul t
for the Oxygen Sensor and the EGR moni tor, the
Task Manager may sti l l run the EGR Moni tor but
wi l l suspend the resul ts unti l the Oxygen Sensor
Moni tor ei ther passes or fai l s. At that poi nt the Task
Manager can determi ne i f the EGR system i s actu-
al l y fai l i ng or i f an Oxygen Sensor i s fai l i ng.
MIL Illumination
The PCM Task Manager carri es out the i l l umi na-
ti on of the MI L. The Task Manager tri ggers MI L i l l u-
mi nati on upon test fai l ure, dependi ng on moni tor
fai l ure cri teri a.
The Task Manager Screen shows both a Requested
MI L state and an Actual MI L state. When the MI L i s
i l l umi nated upon compl eti on of a test for a thi rd tri p,
the Requested MI L state changes to OFF. However,
the MI L remai ns i l l umi nated unti l the next key
cycl e. (On some vehi cl es, the MI L wi l l actual l y turn
OFF duri ng the thi rd key cycl e) Duri ng the key cycl e
for the thi rd good tri p, the Requested MI L state i s
OFF, whi l e the Actual MI L state i s ON. After the
next key cycl e, the MI L i s not i l l umi nated and both
MI L states read OFF.
Diagnostic Trouble Codes (DTCs)
Wi th OBD I I , di fferent DTC faul ts have di fferent
pri ori ti es accordi ng to regul ati ons. As a resul t, the
pri ori ti es determi ne MI L i l l umi nati on and DTC era-
sure. DTCs are entered accordi ng to i ndi vi dual pri or-
i ty. DTCs wi th a hi gher pri ori ty overwri te l ower
pri ori ty DTCs.
Priorities
Pri ori ty 0 Non-emi ssi ons rel ated troubl e codes
Pri ori ty 1 One tri p fai l ure of a two tri p faul t
for non-fuel system and non-mi sfi re.
Pri ori ty 2 One tri p fai l ure of a two tri p faul t
for fuel system (ri ch/l ean) or mi sfi re.
Pri ori ty 3 Two tri p fai l ure for a non-fuel sys-
tem and non-mi sfi re or matured one tri p comprehen-
si ve component faul t.
Pri ori ty 4 Two tri p fai l ure or matured faul t
for fuel system (ri ch/l ean) and mi sfi re or one tri p cat-
al yst damagi ng mi sfi re.
Non-emi ssi ons rel ated fai l ures have no pri ori ty.
One tri p fai l ures of two tri p faul ts have l ow pri ori ty.
Two tri p fai l ures or matured faul ts have hi gher pri -
ori ty. One and two tri p fai l ures of fuel system and
mi sfi re moni tor take precedence over non-fuel system
and non-mi sfi re fai l ures.
DTC Self Erasure
Wi th one tri p components or systems, the MI L i s
i l l umi nated upon test fai l ure and DTCs are stored.
Two tri p moni tors are components requi ri ng fai l ure
i n two consecuti ve tri ps for MI L i l l umi nati on. Upon
fai l ure of the fi rst test, the Task Manager enters a
maturi ng code. I f the component fai l s the test for a
second ti me the code matures and a DTC i s set.
After three good tri ps the MI L i s exti ngui shed and
the Task Manager automati cal l y swi tches the tri p
counter to a warm-up cycl e counter. DTCs are auto-
mati cal l y erased fol l owi ng 40 warm-up cycl es i f the
component does not fai l agai n.
For mi sfi re and fuel system moni tors, the compo-
nent must pass the test under a Si mi l ar Condi ti ons
Wi ndow i n order to record a good tri p. A Si mi l ar Con-
di ti ons Wi ndow i s when engi ne RPM i s wi thi n 375
RPM and l oad i s wi thi n 10% of when the faul t
occurred.
NOTE: It is important to understand that a compo-
nent does not have to fail under a similar window of
operation to mature. It must pass the test under a
Similar Conditions Window when it failed to record
a Good Trip for DTC erasure for misfire and fuel
system monitors.
DTCs can be erased anyti me wi th a DRB I I I . Eras-
i ng the DTC wi th the DRB I I I erases al l OBD I I
i nformati on. The DRB I I I automati cal l y di spl ays a
warni ng that erasi ng the DTC wi l l al so erase al l
OBD I I moni tor data. Thi s i ncl udes al l counter i nfor-
mati on for warm-up cycl es, tri ps and Freeze Frame.
Trip Indicator
The Trip i s essenti al for runni ng moni tors and
exti ngui shi ng the MI L. I n OBD I I terms, a tri p i s a
set of vehi cl e operati ng condi ti ons that must be met
for a speci fi c moni tor to run. Al l tri ps begi n wi th a
key cycl e.
Good Trip
The Good Tri p counters are as fol l ows:
Speci fi c Good Tri p
Fuel System Good Tri p
Mi sfi re Good Tri p
Al ternate Good Tri p (appears as a Gl obal Good
Tri p on DRB I I I )
Comprehensi ve Components
Major Moni tor
Warm-Up Cycl es
Specific Good Trip
The term Good Tri p has di fferent meani ngs
dependi ng on the ci rcumstances:
I f the MI L i s OFF, a tri p i s defi ned as when the
Oxygen Sensor Moni tor and the Catal yst Moni tor
have been compl eted i n the same dri ve cycl e.
I f the MI L i s ON and a DTC was set by the Fuel
Moni tor or Mi sfi re Moni tor (both conti nuous moni -
tors), the vehi cl e must be operated i n the Si mi l ar
Condi ti on Wi ndow for a speci fi ed amount of ti me.
I f the MI L i s ON and a DTC was set by a Task
Manager commanded once-per-tri p moni tor (such as
the Oxygen Sensor Moni tor, Catal yst Moni tor, Purge
Fl ow Moni tor, Leak Detecti on Pump Moni tor, EGR
Moni tor or Oxygen Sensor Heater Moni tor), a good
tri p i s when the moni tor i s passed on the next start-
up.
I f the MI L i s ON and any other emi ssi ons DTC
was set (not an OBD I I moni tor), a good tri p occurs
when the Oxygen Sensor Moni tor and Catal yst Mon-
i tor have been compl eted, or two mi nutes of engi ne
run ti me i f the Oxygen Sensor Moni tor and Catal yst
Moni tor have been stopped from runni ng.
Fuel System Good Trip
To count a good tri p (three requi red) and turn off
the MI L, the fol l owi ng condi ti ons must occur:
Engi ne i n cl osed l oop
Operati ng i n Si mi l ar Condi ti ons Wi ndow
Short Term mul ti pl i ed by Long Term l ess than
threshol d
Less than threshol d for a predetermi ned ti me
I f al l of the previ ous cri teri a are met, the PCM wi l l
count a good tri p (three requi red) and turn off the
MI L.
Misfire Good Trip
I f the fol l owi ng condi ti ons are met the PCM wi l l
count one good tri p (three requi red) i n order to turn
off the MI L:
Operati ng i n Si mi l ar Condi ti on Wi ndow
1000 engi ne revol uti ons wi th no mi sfi re
Warm-Up Cycles
Once the MI L has been exti ngui shed by the Good
Tri p Counter, the PCM automati cal l y swi tches to a
Warm-Up Cycl e Counter that can be vi ewed on the
DRB I I I . Warm-Up Cycl es are used to erase DTCs
and Freeze Frames. Forty Warm-Up cycl es must
occur i n order for the PCM to sel f-erase a DTC and
Freeze Frame. A Warm-Up Cycl e i s defi ned as fol -
l ows:
Engi ne cool ant temperature must start bel ow
and ri se above 160 F
Engi ne cool ant temperature must ri se by 40 F
No further faul ts occur
Freeze Frame Data Storage
Once a fai l ure occurs, the Task Manager records
several engi ne operati ng condi ti ons and stores i t i n a
Freeze Frame. The Freeze Frame i s consi dered one
frame of i nformati on taken by an on-board data
recorder. When a faul t occurs, the PCM stores the
i nput data from vari ous sensors so that techni ci ans
can determi ne under what vehi cl e operati ng condi -
ti ons the fai l ure occurred.
The data stored i n Freeze Frame i s usual l y
recorded when a system fai l s the fi rst ti me for two
tri p faul ts. Freeze Frame data wi l l onl y be overwri t-
ten by a di fferent faul t wi th a hi gher pri ori ty.
CAUTION: Erasing DTCs, either with the DRB III or
by disconnecting the battery, also clears all Freeze
Frame data.
Similar Conditions Window
The Si mi l ar Condi ti ons Wi ndow di spl ays i nforma-
ti on about engi ne operati on duri ng a moni tor. Abso-
l ute MAP (engi ne l oad) and Engi ne RPM are stored
i n thi s wi ndow when a fai l ure occurs. There are two
di fferent Si mi l ar condi ti ons Wi ndows: Fuel System
and Mi sfi re.
FUEL SYSTEM
Fuel System Similar Conditions Window
An i ndi cator that Absol ute MAP When Fuel Sys Fai l
and RPM When Fuel Sys Fai l ed are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from NO to YES.
Absolute MAP When Fuel Sys Fail The
stored MAP readi ng at the ti me of fai l ure. I nforms
the user at what engi ne l oad the fai l ure occurred.
Absolute MAP A l i ve readi ng of engi ne l oad
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
RPM When Fuel Sys Fail The stored RPM
readi ng at the ti me of fai l ure. I nforms the user at
what engi ne RPM the fai l ure occurred.
Engine RPM A l i ve readi ng of engi ne RPM
Wi ndow.
Adaptive Memory Factor The PCM uti l i zes
both Short Term Compensati on and Long Term Adap-
ti ve to cal cul ate the Adapti ve Memory Factor for
total fuel correcti on.
Upstream O2S Volts A l i ve readi ng of the
Oxygen Sensor to i ndi cate i ts performance. For
exampl e, stuck l ean, stuck ri ch, etc.
SCW Time in Window (Similar Conditions
Window Time in Window) A ti mer used by the
PCM that i ndi cates that, after al l Si mi l ar Condi ti ons
have been met, i f there has been enough good engi ne
runni ng ti me i n the SCW wi thout fai l ure detected.
Thi s ti mer i s used to i ncrement a Good Tri p.
Fuel System Good Trip Counter A Tri p
Counter used to turn OFF the MI L for Fuel System
DTCs. To i ncrement a Fuel System Good Tri p, the
engi ne must be i n the Si mi l ar Condi ti ons Wi ndow,
Adapti ve Memory Factor must be l ess than cal i -
brated threshol d and the Adapti ve Memory Factor
must stay bel ow that threshol d for a cal i brated
amount of ti me.
Test Done This Trip I ndi cates that the
moni tor has al ready been run and compl eted duri ng
the current tri p.
MISFIRE
Same Misfire Warm-Up State I ndi cates i f
the mi sfi re occurred when the engi ne was warmed up
(above 160 F).
In Similar Misfire Window An i ndi cator
that Absol ute MAP When Mi sfi re Occurred and
RPM When Mi sfi re Occurred are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from NO to YES.
Absolute MAP When Misfire Occurred
The stored MAP readi ng at the ti me of fai l ure.
I nforms the user at what engi ne l oad the fai l ure
occurred.
Absolute MAP A l i ve readi ng of engi ne l oad
Wi ndow.
RPM When Misfire Occurred The stored
RPM readi ng at the ti me of fai l ure. I nforms the user
at what engi ne RPM the fai l ure occurred.
Engine RPM A l i ve readi ng of engi ne RPM
Wi ndow.
Adaptive Memory Factor The PCM uti l i zes
both Short Term Compensati on and Long Term Adap-
ti ve to cal cul ate the Adapti ve Memory Factor for
total fuel correcti on.
200 Rev Counter Counts 0100 720 degree
cycl es.
SCWCat 200 Rev Counter Counts when i n
si mi l ar condi ti ons.
SCW FTP 1000 Rev Counter Counts 04
when i n si mi l ar condi ti ons.
Misfire Good Trip Counter Counts up to
three to turn OFF the MI L.
Misfire Data Data col l ected duri ng test.
Test Done This Trip I ndi cates YES when the
test i s done.
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
DESCRIPTION
DESCRIPTION - EVAPORATION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION - CCV SYSTEM . . . . . . . . . . . 25
DESCRIPTION - PCV SYSTEM . . . . . . . . . . . 25
OPERATION
OPERATION - 4.0L CCV SYSTEM . . . . . . . . . 26
OPERATION - 4.7L PCV SYSTEM . . . . . . . . . 26
SPECIFICATIONS
TORQUE - EVAPORATION SYSTEM . . . . . . . 27
CCV HOSE
DIAGNOSIS AND TESTING - CCV SYSTEM -
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL - FIXED ORIFICE FITTING . . . . . . . . 28
INSTALLATION - FIXED ORIFICE FITTING . . . . 29
EVAP/PURGE SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
FUEL FILLER CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LEAK DETECTION PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING - ENABLING
CONDITIONS TO RUN EVAP LEAK
DETECTION TEST . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
ORVR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
PCV VALVE
DIAGNOSIS AND TESTING - PCV VALVE/PCV
SYSTEM - 4.7L . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL - PCV VALVE - 4.7L . . . . . . . . . . . . . 39
INSTALLATION - PCV VALVE - 4.7L . . . . . . . . . 39
VACUUM LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
VAPOR CANISTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION
DESCRIPTION - EVAPORATION CONTROL
SYSTEM
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When
fuel evaporates i n the fuel tank, the vapors pass
through the control val ve, through the fuel manage-
ment val ve, and through vent hoses and tubes to a
charcoal fi l l ed evaporati ve cani ster. The cani ster tem-
porari l y hol ds the vapors. The Powertrai n Control
Modul e (PCM) al l ows i ntake mani fol d vacuum to
draw vapors i nto the combusti on chambers duri ng
certai n operati ng condi ti ons.
Gas powered engi nes use a duty cycl e purge sys-
tem. The PCM control s vapor fl ow by operati ng the
duty cycl e EVAP purge sol enoi d. Refer to Duty Cycl e
EVAP Cani ster Purge Sol enoi d.
When equi pped wi th certai n emi ssi ons packages, a
Leak Detecti on Pump (LDP) wi l l be used as part of
the evaporati ve system for OBD I I requi rements.
Al so refer to Leak Detecti on Pump.
Vehi cl es powered wi th gasol i ne engi nes are al so
equi pped wi th ORVR (On-Board Refuel i ng Vapor
Recovery). Refer to ORVR for addi ti onal i nformati on.
25 - 24 EVAPORATIVE EMISSIONS WJ
NOTE: The evaporative system uses specially man-
ufactured lines/hoses. If replacement becomes nec-
essary, only use fuel resistant, low permeation
hose.
Certai n components can be found i n (Fi g. 1).
DESCRIPTION - CCV SYSTEM
The 4.0L 6cyl i nder engi ne i s equi pped wi th a
Crankcase Venti l ati on (CCV) system. The system
consi sts of:
A fi xed ori fi ce fi tti ng of a cal i brated si ze. Thi s
fi tti ng i s pressed i nto a rubber grommet l ocated on
the top/rear of cyl i nder head (val ve) cover (Fi g. 2).
a pai r of breather tubes (l i nes) to connect the
system components.
the ai r cl eaner housi ng.
an ai r i nl et fi tti ng (Fi g. 2).
DESCRIPTION - PCV SYSTEM
The 4.7L V-8 engi ne i s equi pped wi th a cl osed
crankcase venti l ati on system and a Posi ti ve Crank-
case Venti l ati on (PCV) val ve.
Thi s system consi sts of:
Fig. 1 ORVR / LDP COMPONENTS
1 - FUEL TANK (LEFT SIDE) 6 - EVAP CANISTER
2 - FRAME RAIL (LEFT-REAR OUTSIDE) 7 - LDP FILTER
3 - FUEL VENT TUBE 8 - TWO-PIECE SUPPORT BRACKET
4 - FUEL FILL TUBE 9 - LEAK DETECTION PUMP (LDP)
5 - CONTROL VALVE
Fig. 2 CCV System4.0L Engine
1 - AIR INLET FITTING
2 - FIXED ORIFICE FITTING
3 - CCV BREATHER TUBE (REAR)
4 - INT. MAN. FITTING
5 - CCV BREATHER TUBE (FRONT)
WJ EVAPORATIVE EMISSIONS 25 - 25
EVAPORATIVE EMISSIONS (Continued)
a PCV val ve mounted to the oi l fi l l er housi ng
(Fi g. 3). The PCV val ve i s seal ed to the oi l fi l l er
housi ng wi th an o-ri ng.
the ai r cl eaner housi ng
two i nterconnected breathers threaded i nto the
rear of each cyl i nder head (Fi g. 4).
tubes and hose to connect the system compo-
nents.
OPERATION
OPERATION - 4. 0L CCV SYSTEM
The CCV system performs the same functi on as a
conventi onal PCV system, but does not use a vacuum
control l ed PCV val ve.
The fi xed ori fi ce fi tti ng meters the amount of
crankcase vapors drawn out of the engi ne.
When the engi ne i s operati ng, fresh ai r enters the
engi ne and mi xes wi th crankcase vapors. Engi ne vac-
uum draws the vapor/ai r mi xture through the fi xed
ori fi ce and i nto the i ntake mani fol d. The vapors are
then consumed duri ng engi ne combusti on.
OPERATION - 4. 7L PCV SYSTEM
The PCV system operates by engi ne i ntake mani -
fol d vacuum. Fi l tered ai r i s routed i nto the crankcase
through the ai r cl eaner hose and crankcase breath-
ers. The metered ai r, al ong wi th crankcase vapors,
are drawn through the PCV val ve and i nto a passage
i n the i ntake mani fol d. The PCV system manages
crankcase pressure and meters bl ow-by gases to the
i ntake system, reduci ng engi ne sl udge formati on.
The PCV val ve contai ns a spri ng l oaded pl unger.
Thi s pl unger meters the amount of crankcase vapors
routed i nto the combusti on chamber based on i ntake
mani fol d vacuum.
TYPICAL PCV val ves are shown i n (Fi g. 5), (Fi g.
6) and (Fi g. 7).
When the engi ne i s not operati ng, or duri ng an
engi ne pop-back, the spri ng forces the pl unger back
agai nst the seat (Fi g. 5). Thi s wi l l prevent vapors
from fl owi ng through the val ve.
Fig. 3 PCV Valve/Oil Filler Tube (Housing)4.7L
Engine
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - PCV VALVE
Fig. 4 PCV System Hoses/Tubes4.7L Engine
1 - FRESH AIR FITTING
2 - CONNECTING TUBES/HOSES
3 - CRANKCASE BREATHERS (2)
4 - RUBBER HOSE
5 - AIR CLEANER RESONATOR
Duri ng peri ods of hi gh mani fol d vacuum, such as
i dl e or crui si ng speeds, vacuum i s suffi ci ent to com-
pl etel y compress spri ng. I t wi l l then pul l the pl unger
to the top of the val ve (Fi g. 6). I n thi s posi ti on there
i s mi ni mal vapor fl ow through the val ve.
Duri ng peri ods of moderate mani fol d vacuum, the
pl unger i s onl y pul l ed part way back from i nl et. Thi s
resul ts i n maxi mum vapor fl ow through the val ve
(Fi g. 7).
SPECIFICATIONS
TORQUE - EVAPORATION SYSTEM
Crankcase Breathers - 3.7L /
4.7L
12 - 106
EVAP Canister Mounting 11 - 100
EVAP Canister Purge
Solenoid Mounting Nuts
9 - 80
LDP Pump-to-Support Bracket 2 - 20
LDP Pump Support
Bracket-to-Frame
28 - 250
Fig. 5 Engine Off or Engine Pop-BackNo Vapor
Flow
Fig. 6 High Intake Manifold VacuumMinimal Vapor
Flow
Fig. 7 Moderate Intake Manifold VacuumMaximum
Vapor Flow
CCV HOSE
DIAGNOSIS AND TESTING - CCV SYSTEM -
4. 0L
Before attempti ng di agnosi s, be sure l ocati ons of
fi xed ori fi ce fi tti ng and ai r i nl et fi tti ng (Fi g. 8) have
not been i nadvertentl y exchanged. The fi xed ori fi ce
fi tti ng i s l i ght grey i n col or and i s l ocated at rear of
val ve cover. The ai r i nl et fi tti ng i s bl ack i n col or and
i s l ocated at front of val ve cover.
(1) Pul l fi xed ori fi ce fi tti ng (Fi g. 8) from val ve
cover and l eave tube attached.
(2) Start engi ne and bri ng to i dl e speed.
(3) I f fi tti ng i s not pl ugged, a hi ssi ng noi se wi l l be
heard as ai r passes through fi tti ng ori fi ce. Al so, a
strong vacuum shoul d be fel t wi th a fi nger pl aced at
fi tti ng i nl et.
(4) I f vacuum i s not present, remove fi tti ng ori fi ce
fi tti ng from tube. Start engi ne. I f vacuum can now be
fel t, repl ace fi xed ori fi ce fi tti ng. Do not attempt to
cl ean pl asti c fi tti ng.
(5) I f vacuum i s sti l l not fel t at hose, check l i ne/
hose for ki nks or for obstructi on. I f necessary, cl ean
out i ntake mani fol d fi tti ng at i ntake mani fol d. Do
thi s by turni ng a 1/4 i nch dri l l (by hand) through the
fi tti ng to di sl odge any sol i d parti cl es. Bl ow out the
fi tti ng wi th shop ai r. I f necessary, use a smal l er dri l l
to avoi d removi ng any metal from the fi tti ng.
(6) Return fi xed ori fi ce fi tti ng to val ve cover and
l eave tube attached.
(7) Di sconnect ai r i nl et fi tti ng and i ts attached
hose at front of val ve cover (Fi g. 8). Start engi ne and
bri ng to i dl e speed. Hol d a pi ece of sti ff paper (such
as a parts tag) l oosel y over the rubber grommet
(openi ng) of the di sconnected ai r i nl et fi tti ng.
(8) The paper shoul d be drawn agai nst the rubber
grommet wi th noti ceabl e force. Thi s wi l l be after
al l owi ng approxi matel y one mi nute for crankcase
pressure to reduce.
(9) I f vacuum i s not present, check breather hoses/
tubes/l i nes for obstructi ons or restri cti ons.
(10) After testi ng, reconnect al l system hoses/
tubes/l i nes.
REMOVAL - FIXED ORIFICE FITTING
When i nstal l i ng fi xed ori fi ce fi tti ng, be sure l oca-
ti ons of fi xed ori fi ce fi tti ng and ai r i nl et fi tti ng (Fi g.
9) have not been i nadvertentl y exchanged. The fi xed
ori fi ce fi tti ng i s l i ght grey i n col or and i s l ocated at
rear of val ve cover. The ai r i nl et fi tti ng i s bl ack i n
col or and i s l ocated at front of val ve cover.
(1) Pul l fi xed ori fi ce fi tti ng (Fi g. 9) from val ve
cover grommet.
(2) Separate fi tti ng from CCV breather tube.
Fig. 8 Fixed Orifice Fitting and CCV System4.0L
Engine
Fig. 9 FIXED ORIFICE FITTING - 4.0L
INSTALLATION - FIXED ORIFICE FITTING
When i nstal l i ng fi xed ori fi ce fi tti ng, be sure l oca-
ti ons of fi xed ori fi ce fi tti ng and ai r i nl et fi tti ng (Fi g.
9) have not been i nadvertentl y exchanged. The fi xed
ori fi ce fi tti ng i s l i ght grey i n col or and i s l ocated at
rear of val ve cover. The ai r i nl et fi tti ng i s bl ack i n
col or and i s l ocated at front of val ve cover.
(1) Connect fi tti ng to CCV breather tube.
(2) Return fi xed ori fi ce fi tti ng to val ve cover grom-
met.
EVAP/PURGE SOLENOID
DESCRIPTION
The duty cycl e EVAP cani ster purge sol enoi d (DCP)
regul ates the rate of vapor fl ow from the EVAP can-
i ster to the i ntake mani fol d. The Powertrai n Control
Modul e (PCM) operates the sol enoi d.
OPERATION
Duri ng the col d start warm-up peri od and the hot
start ti me del ay, the PCM does not energi ze the sol e-
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The engi ne enters cl osed l oop operati on after i t
reaches a speci fi ed temperature and the ti me del ay
ends. Duri ng cl osed l oop operati on, the PCM cycl es
(energi zes and de-energi zes) the sol enoi d 5 or 10
ti mes per second, dependi ng upon operati ng condi -
ti ons. The PCM vari es the vapor fl ow rate by chang-
i ng sol enoi d pul se wi dth. Pul se wi dth i s the amount
of ti me that the sol enoi d i s energi zed. The PCM
adjusts sol enoi d pul se wi dth based on engi ne operat-
i ng condi ti on.
REMOVAL
The duty cycl e evaporati ve (EVAP) cani ster purge
sol enoi d i s l ocated i n the engi ne compartment near
the brake master cyl i nder (Fi g. 10).
(1) Di sconnect el ectri cal connector at sol enoi d.
(2) Di sconnect vacuum l i nes at sol enoi d.
(3) Li ft sol enoi d sl ot (Fi g. 10) from mounti ng
bracket for removal .
INSTALLATION
(1) Posi ti on sol enoi d sl ot to mounti ng bracket.
(2) Connect vacuum l i nes to sol enoi d. Be sure vac-
uum l i nes are fi rml y connected and not l eaki ng or
damaged. I f l eaki ng, a Di agnosti c Troubl e Code
(DTC) may be set wi th certai n emi ssi on packages.
(3) Connect el ectri cal connector to sol enoi d.
FUEL FILLER CAP
DESCRIPTION
The pl asti c fuel tank fi l l er tube cap i s threaded
onto the end of the fuel fi l l tube. Certai n model s are
equi pped wi th a 1/4 turn cap.
OPERATION
The l oss of any fuel or vapor out of fuel fi l l er tube
i s prevented by the use of a pressure-vacuum fuel fi l l
cap. Rel i ef val ves i nsi de the cap wi l l rel ease fuel tank
pressure at predetermi ned pressures. Fuel tank vac-
uum wi l l al so be rel eased at predetermi ned val ues.
Thi s cap must be repl aced by a si mi l ar uni t i f
repl acement i s necessary. Thi s i s i n order for the sys-
tem to remai n effecti ve.
CAUTION: Remove fill cap before servicing any fuel
system component to relieve tank pressure. If
equipped with a California emissions package and a
Leak Detection Pump (LDP), the cap must be tight-
ened securely. If cap is left loose, a Diagnostic
Trouble Code (DTC) may be set.
REMOVAL
I f repl acement of the 1/4 turn fuel tank fi l l er tube
cap i s necessary, i t must be repl aced wi th an i denti -
cal cap to be sure of correct system operati on.
Fig. 10 EVAP/PURGE SOLENOID LOCATION
1 - BRAKE MASTER CYLINDER
2 - EVAP SOLENOID
3 - SLOT
4 - ELEC. CONNEC.
5 - VACUUM LINE CONNEC.
6 - TEST PORT
CCV HOSE (Continued)
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
LEAK DETECTION PUMP
DESCRIPTION
The evaporati ve emi ssi on system i s desi gned to
prevent the escape of fuel vapors from the fuel sys-
tem (Fi g. 11). Leaks i n the system, even smal l ones,
can al l ow fuel vapors to escape i nto the atmosphere.
Government regul ati ons requi re onboard testi ng to
make sure that the evaporati ve (EVAP) system i s
functi oni ng properl y. The l eak detecti on system tests
for EVAP system l eaks and bl ockage. I t al so performs
sel f-di agnosti cs. Duri ng sel f-di agnosti cs, the Power-
trai n Control Modul e (PCM) fi rst checks the Leak
Detecti on Pump (LDP) for el ectri cal and mechani cal
faul ts. I f the fi rst checks pass, the PCM then uses
the LDP to seal the vent val ve and pump ai r i nto the
system to pressuri ze i t. I f a l eak i s present, the PCM
wi l l conti nue pumpi ng the LDP to repl ace the ai r
that l eaks out. The PCM determi nes the si ze of the
l eak based on how fast/l ong i t must pump the LDP
as i t tri es to mai ntai n pressure i n the system.
EVAP LEAK DETECTION SYSTEM COMPONENTS
Servi ce Port: Used wi th speci al tool s l i ke the Mi l l er
Evaporati ve Emi ssi ons Leak Detector (EELD) to test
for l eaks i n the system.
EVAP Purge Sol enoi d: The PCM uses the EVAP
purge sol enoi d to control purgi ng of excess fuel
vapors stored i n the EVAP cani ster. I t remai ns cl osed
duri ng l eak testi ng to prevent l oss of pressure.
EVAP Cani ster: The EVAP cani ster stores fuel
vapors from the fuel tank for purgi ng.
EVAP Purge Ori fi ce: Li mi ts purge vol ume.
EVAP System Ai r Fi l ter: Provi des ai r to the LDP
for pressuri zi ng the system. I t fi l ters out di rt whi l e
al l owi ng a vent to atmosphere for the EVAP system.
Fig. 11 TYPICAL SYSTEM COMPONENTS
1 - Throttle Body
2 - Service Vacuum Supply Tee (SVST)
3 - LDP Solenoid
4 - EVAP System Air Filter
5 - LDP Vent Valve
6 - EVAP Purge Orifice
7 - EVAP Purge Solenoid
8 - Service Port
9 - To Fuel Tank
10 - EVAP Canister
11 - LDP
12 - Intake Air Plenum
FUEL FILLER CAP (Continued)
OPERATION
The mai n purpose of the LDP i s to pressuri ze the
fuel system for l eak checki ng. I t cl oses the EVAP sys-
tem vent to atmospheri c pressure so the system can
be pressuri zed for l eak testi ng. The di aphragm i s
powered by engi ne vacuum. I t pumps ai r i nto the
EVAP system to devel op a pressure of about 7.5
H2O (1/4) psi . A reed swi tch i n the LDP al l ows the
PCM to moni tor the posi ti on of the LDP di aphragm.
The PCM uses the reed swi tch i nput to moni tor how
fast the LDP i s pumpi ng ai r i nto the EVAP system.
Thi s al l ows detecti on of l eaks and bl ockage. The LDP
assembl y consi sts of several parts (Fi g. 12). The sol e-
noi d i s control l ed by the PCM, and i t connects the
upper pump cavi ty to ei ther engi ne vacuum or atmo-
spheri c pressure. A vent val ve cl oses the EVAP sys-
tem to atmosphere, seal i ng the system duri ng l eak
testi ng. The pump secti on of the LDP consi sts of a
di aphragm that moves up and down to bri ng ai r i n
through the ai r fi l ter and i nl et check val ve, and
pump i t out through an outl et check val ve i nto the
EVAP system. The di aphragm i s pul l ed up by engi ne
vacuum, and pushed down by spri ng pressure, as the
LDP sol enoi d turns on and off. The LDP al so has a
magneti c reed swi tch to si gnal di aphragm posi ti on to
the PCM. When the di aphragm i s down, the swi tch i s
cl osed, whi ch sends a 12 V (system vol tage) si gnal to
the PCM. When the di aphragm i s up, the swi tch i s
open, and there i s no vol tage sent to the PCM. Thi s
al l ows the PCM to moni tor LDP pumpi ng acti on as i t
turns the LDP sol enoi d on and off.
LDP AT REST (NOT POWERED)
When the LDP i s at rest (no el ectri cal /vacuum) the
di aphragm i s al l owed to drop down i f the i nternal
(EVAP system) pressure i s not greater than the
return spri ng. The LDP sol enoi d bl ocks the engi ne
vacuum port and opens the atmospheri c pressure
port connected through the EVAP system ai r fi l ter.
The vent val ve i s hel d open by the di aphragm. Thi s
al l ows the cani ster to see atmospheri c pressure (Fi g.
13).
DIAPHRAGM UPWARD MOVEMENT
When the PCM energi zes the LDP sol enoi d, the
sol enoi d bl ocks the atmospheri c port l eadi ng through
the EVAP ai r fi l ter and at the same ti me opens the
engi ne vacuum port to the pump cavi ty above the
di aphragm. The di aphragm moves upward when vac-
uum above the di aphragm exceeds spri ng force. Thi s
upward movement cl oses the vent val ve. I t al so
causes l ow pressure bel ow the di aphragm, unseati ng
the i nl et check val ve and al l owi ng ai r i n from the
EVAP ai r fi l ter. When the di aphragm compl etes i ts
upward movement, the LDP reed swi tch turns from
cl osed to open (Fi g. 14).
DIAPHRAGM DOWNWARD MOVEMENT
Based on reed swi tch i nput, the PCM de-energi zes
the LDP sol enoi d, causi ng i t to bl ock the vacuum
port, and open the atmospheri c port. Thi s connects
the upper pump cavi ty to atmosphere through the
EVAP ai r fi l ter. The spri ng i s now abl e to push the
di aphragm down. The downward movement of the
di aphragm cl oses the i nl et check val ve and opens the
outl et check val ve pumpi ng ai r i nto the evaporati ve
system. The LDP reed swi tch turns from open to
cl osed, al l owi ng the PCM to moni tor LDP pumpi ng
(di aphragm up/down) acti vi ty (Fi g. 15). Duri ng the
pumpi ng mode, the di aphragm wi l l not move down
far enough to open the vent val ve. The pumpi ng cycl e
i s repeated as the sol enoi d i s turned on and off.
When the evaporati ve system begi ns to pressuri ze,
the pressure on the bottom of the di aphragm wi l l
begi n to oppose the spri ng pressure, sl owi ng the
pumpi ng acti on. The PCM watches the ti me from
when the sol enoi d i s de-energi zed, unti l the di a-
phragm drops down far enough for the reed swi tch to
Fig. 12 EVAP LEAK DETECTION SYSTEM
COMPONENTS
1 - Reed Switch
2 - Solenoid
3 - Spring
4 - Pump Cavity
5 - Diaphragm
6 - Inlet Check Valve
7 - Vent Valve
8 - From Air Filter
9 - To Canister
10 - Outlet Check Valve
11 - Engine Vacuum
LEAK DETECTION PUMP (Continued)
change from opened to cl osed. I f the reed swi tch
changes too qui ckl y, a l eak may be i ndi cated. The
l onger i t takes the reed swi tch to change state, the
ti ghter the evaporati ve system i s seal ed. I f the sys-
tem pressuri zes too qui ckl y, a restri cti on somewhere
i n the EVAP system may be i ndi cated.
PUMPING ACTION
Acti on : Duri ng porti ons of thi s test, the PCM uses
the reed swi tch to moni tor di aphragm movement.
The sol enoi d i s onl y turned on by the PCM after the
reed swi tch changes from open to cl osed, i ndi cati ng
that the di aphragm has moved down. At other ti mes
duri ng the test, the PCM wi l l rapi dl y cycl e the LDP
sol enoi d on and off to qui ckl y pressuri ze the system.
Duri ng rapi d cycl i ng, the di aphragm wi l l not move
enough to change the reed swi tch state. I n the state
of rapi d cycl i ng, the PCM wi l l use a fi xed ti me i nter-
val to cycl e the sol enoi d. I f the system does not pass
the EVAP Leak Detecti on Test, the fol l owi ng DTCs
may be set:
P0442 - EVAP LEAK MONI TOR 0.040 LEAK
DETECTED
P0455 - EVAP LEAK MONI TOR LARGE LEAK
DETECTED
P0456 - EVAP LEAK MONI TOR 0.020 LEAK
DETECTED
P1486 - EVAP LEAK MON PI NCHED HOSE
FOUND
P1494 - LEAK DETECTI ON PUMP SW OR
MECH FAULT
P1495 - LEAK DETECTI ON PUMP SOLENOI D
CI RCUI T
DIAGNOSIS AND TESTING - ENABLING
CONDITIONS TO RUN EVAP LEAK DETECTION
TEST
Col d start: wi th ambi ent temperature (obtai ned
from model i ng the i nl et ai r temperature sensor on
passenger vehi cl es and the battery temperature sen-
sor on Jeep & Dodge Truck vehi cl es) between 4 C
(40 F) and 32 C (90 F) for 0.040 l eak. Between 4
C (40 F) and 29 C (85 F) for 0.020 l eak.
Engi ne cool ant temperature wi thi n:-12 to -8 C
(10 to 18 F) of battery/ambi ent.
Battery vol tage between 10 and 15 vol ts.
Low fuel warni ng l i ght off (fuel l evel must be
between 15% and 85%.
MAP sensor readi ng 22 i n Hg or above (Thi s i s
the mani fol d absol ute pressure, not vacuum).
Fig. 13 LDP AT REST
1 - Diaphragm
2 - Inlet Check Valve (Closed)
3 - Vent Valve (Open)
4 - From Air Filter
5 - To Canister
6 - Outlet Check Valve (Closed)
7 - Engine Vacuum (Closed)
Fig. 14 DIAPHRAGM UPWARD MOVEMENT
1 - Diaphragm
2 - Inlet Check Valve (Open)
3 - Vent Valve (Closed)
4 - From Air Filter
5 - To Canister
6 - Outlet Check Valve (Closed)
7 - Engine Vacuum (Open)
No engi ne stal l duri ng test.
NOTE: IF BATTERY VOLTAGE DROPS BELOW 10
VOLTS FOR MORE THAN 5 SECONDS DURING
ENGINE CRANKING, THE EVAP LEAK DETECTION
TEST WILL NOT RUN.
NOTE: THE FOLLOWING VALUES ARE APPROXI-
MATE AND VEHICLE SPECIFIC. USE THE VALUES
SEEN IN PRE TEST/MONITOR TEST SCREEN ON
THE DRB III. SEE TSB 25-02-98 FOR MORE
DETAIL.
A DTC wi l l not be set i f a one-tri p faul t i s set or i f
the MI L i s i l l umi nated for any of the fol l owi ng:
Purge Sol enoi d El ectri cal Faul t
Al l TPS Faul ts
Al l Engi ne Control l er Sel f Test Faul ts
LDP Pressure Swi tch Faul t
Al l Cam and/or Crank Sensor Faul t
EGR Sol enoi d El ectri cal Faul t
Al l MAP Sensor Faul ts
Al l I njector Faul ts
Ambi ent/Battery Temperature Sensor El ectri cal
Faul ts
Baro Out of Range
Vehi cl e Speed Faul ts
Al l Cool ant Sensor Faul ts
LDP Sol enoi d Ci rcui t
NOTE: IF BATTERY TEMPERATURE IS NOT WITHIN
RANGE, OR IF THE ENGINE COOLANT TEMPERA-
TURE IS NOT WITHIN A SPECIFIED RANGE OF THE
BATTERY TEMPERATURE, THE PCM WILL NOT
RUN TESTS FOR DTC P1494, P1486, P0442, P0455
AND P0441. THESE TEMPERATURE CALIBRATIONS
MAY BE DIFFERENT BETWEEN MODELS.
SECTION 1 - P1495 Leak Detection Pump
Solenoid Circuit- When the i gni ti on key i s turned
to ON, the LDP di aphragm shoul d be i n the down
posi ti on and the LDP reed swi tch shoul d be cl osed. I f
the EVAP system has resi dual pressure, the LDP di a-
phragm may be up. Thi s coul d resul t i n the LDP reed
swi tch bei ng open when the key i s turned to ON
and a P1494 faul t coul d be set because the PCM i s
expecti ng the reed swi tch to be cl osed.
After the key i s turned ON, the PCM i mmedi -
atel y tests the LDP sol enoi d ci rcui t for el ectri cal
faul ts. I f a faul t i s detected, DTC P1495 wi l l set, the
Fig. 15 DIAPHRAGM DOWNWARD MOVEMENT
1 - Diaphragm
2 - Inlet Check Valve (Closed)
3 - Vent Valve (Closed)
4 - From Air Filter
5 - To Canister
6 - Outlet Check Valve (Open)
7 - Engine Vacuum (Closed)
EVAP LDP TEST SEQUENCE
1 - IGNITION SWITCH
2 - LDP DIAPHRAM
3 - LDP SWITCH
4 - LDP SOLENOID
5 - SECTION 1
6 - SECTION 2
7 - SECTION 3
8 - SECTION 4
9 - SECTION 5
10 - 3 TEST CYCLES TO TEST FOR BLOCKAGE
11- RAPID PUMP CYCLING FOR 70 CYCLES
MI L wi l l i l l umi nate, and the remai ni ng EVAP Leak
Detecti on Test i s cancel ed.
SECTION 2 - P1494 Leak Detection Pump
Switch or Mechanical Fault- I f DTC P1495 i s not
set, the PCM wi l l check for DTC P1494. I f the LDP
reed swi tch was cl osed when the key was turned to
ON, the PCM energi zes the LDP sol enoi d for up to
8 seconds and moni tors the LDP swi tch. As the LDP
di aphragm i s pul l ed up by engi ne vacuum, the LDP
reed swi tch shoul d change from cl osed to open. I f i t
does not, the PCM sets a temporary faul t (P1494) i n
memory, and wai ts unti l the next ti me the Enabl i ng
Condi ti ons are met to run the test agai n. I f thi s i s
agai n detected, P1494 i s stored and the MI L i s i l l u-
mi nated. I f the probl em i s not detected duri ng the
next enabl i ng cycl e, the temporary faul t wi l l be
cl eared.
However, i f the PCM detects the reed swi tch open
when the key i s turned to ON, the PCM must deter-
mi ne i f thi s condi ti on i s due to resi dual pressure i n
the EVAP system, or an actual faul t. The PCM stores
i nformati on i n memory on EVAP system purgi ng
from previ ous engi ne run or dri ve cycl es.
I f l i ttl e or no purgi ng took pl ace, resi dual pressure
coul d be hol di ng the LDP di aphragm up, causi ng the
LDP swi tch to be open. Si nce thi s i s not a mal func-
ti on, the PCM cancel s the EVAP Leak Detecti on Test
wi thout setti ng the temporary faul t.
I f there was suffi ci ent purgi ng duri ng the previ ous
cycl e to el i mi nate EVAP system pressure, the PCM
judges that thi s i s a mal functi on and sets a tempo-
rary faul t i n memory. The next ti me that the
Enabl i ng Condi ti ons are met, the test wi l l run agai n.
I f the faul t i s agai n detected, the MI L wi l l i l l umi nate
and DTC P1494 wi l l be stored. I f the faul t i s not
detected, the temporary faul t wi l l be cl eared.
SECTION 3 - P1486 EVAP Leak Monitor
Pinched Hose Found- I f no faul t has been detected
so far, the PCM begi ns testi ng for possi bl e bl ockage
i n the EVAP system between the LDP and the fuel
tank. Thi s i s done by moni tori ng the ti me requi red
for the LDP to pump ai r i nto the EVAP system dur-
i ng two to three pump cycl es. I f no bl ockage i s
present, the LDP di aphragm i s abl e to qui ckl y pump
ai r out of the LDP each ti me the PCM turns off the
LDP sol enoi d. I f a bl ockage i s present, the PCM
detects that the LDP takes l onger to compl ete each
pump cycl e. I f the pump cycl es take l onger than
expected (approxi matel y 6 to 10 seconds) the PCM
wi l l suspect a bl ockage. On the next dri ve when
Enabl i ng Condi ti ons are met, the test wi l l run agai n.
I f bl ockage i s agai n detected, P1486 i s stored, and
the MI L i s i l l umi nated.
SECTION 4 - No DTC Can Be Set During This
Time- After the LDP bl ockage tests are compl eted,
the PCM then tests for EVAP system l eakage. Fi rst,
the PCM commands the LDP to rapi dl y pump for 20
to 50 seconds (dependi ng on fuel l evel ) to bui l d pres-
sure i n the EVAP system. Thi s eval uates the system
J18-24-0 to see i f i t can be suffi ci entl y pressuri zed.
Thi s eval uati on (rapi d pump cycl i ng) may occur sev-
eral ti mes pri or to l eak checki ng. The LDP reed
swi tch does not cl ose and open duri ng rapi d pumpi ng
because the di aphragm does not travel through i ts
ful l range duri ng thi s part of the test.
SECTION 5 - P0456, P0442, P0455 EVAP Leak
Monitor and Leak Detected- Next, the PCM per-
forms one or more test cycl es by moni tori ng the ti me
requi red for the LDP reed swi tch to cl ose (di aphragm
to drop) after the LDP sol enoi d i s turned off.
I f the swi tch does not cl ose, or cl oses after a l ong
del ay, i t means that the system does not have any
si gni fi cant l eakage and the EVAP Leak Detecti on
Test i s compl ete.
However, i f the LDP reed swi tch cl oses qui ckl y,
there may be a l eak or the fuel l evel may be l ow
enough that the LDP must pump more to fi ni sh pres-
suri zi ng the EVAP system. I n thi s case, the PCM wi l l
rapi dl y pump the LDP agai n to bui l d pressure i n the
EVAP system, and fol l ow that by moni tori ng the ti me
needed for several LDP test cycl es. Thi s process of
rapi d pumpi ng fol l owed by several LDP test cycl es
may repeat several ti mes before the PCM judges that
a l eak i s present.
When l eaks are present, the LDP test cycl e ti me
wi l l be i nversel y proporti onal to the si ze of the l eak.
The l arger the l eak, the shorter the test cycl e ti me.
The smal l er the l eak, the l onger the test cycl e ti me.
DTCs may be set when a l eak as smal l as 0.5 mm
(0.020) di ameter i s present.
I f the system detects a l eak, a temporary faul t wi l l
be stored i n PCM memory. The ti me i t takes to detect
a .020, .040, or Large l eak i s based on cal i brati ons
that vary from model to model . The i mportant poi nt
to remember i s i f a l eak i s agai n detected on the next
EVAP Leak Detecti on Test, the MI L wi l l i l l umi nate
and a DTC wi l l be stored based on the si ze of l eak
detected. I f no l eak i s detected duri ng the next test,
the temporary faul t wi l l be cl eared.
DI AGNOSTI C TI PS Duri ng di agnosi s, you can
compare the LDP sol enoi d acti vi ty wi th the moni tor
sequence i n Fi gure 6. I f the PCM detects a probl em
that coul d set a DTC, the testi ng i s hal ted and LDP
sol enoi d acti vi ty wi l l stop. As each secti on of the test
begi ns, i t i ndi cates that the previ ous secti on passed
successful l y. By watchi ng to see whi ch tests compl ete,
you can see i f any condi ti ons are present that the
PCM consi ders abnormal .
For exampl e, i f the LDP sol enoi d i s energi zed for
the test cycl es to test for bl ockage (P1486), i t means
that the LDP has al ready passed i ts test for P1494.
Then, i f the PCM detects a possi bl e bl ockage, i t wi l l
set a temporary faul t wi thout turni ng on the MI L
and conti nue the l eak porti on of the test. However,
the PCM wi l l assume that the system i s al ready
pressuri zed and ski p the rapi d pump cycl es.
Al ways di agnose l eaks, i f possi bl e, before di scon-
necti ng connecti ons. Di sconnecti ng connecti ons may
mask a l eak condi ti on.
Keep i n mi nd that i f the purge sol enoi d seat i s
l eaki ng, i t coul d go undetected si nce the l eak woul d
end up i n the i ntake mani fol d. Di sconnect the purge
sol enoi d at the mani fol d when l eak checki ng. I n addi -
ti on, a pi nched hose faul t (P1486) coul d set i f the
purge sol enoi d does not purge the fuel system prop-
erl y (bl ocked seat). The purge sol enoi d must vent the
fuel system pri or to the LDP system test. I f the
purge sol enoi d cannot properl y vent the system the
LDP cannot properl y compl ete the test for P1486 and
thi s faul t can set due to pressure bei ng i n the EVAP
system duri ng the test sequence.
Mul ti pl e actuati ons of the DRB I I I Leak Detec-
ti on Pump (LDP) Moni tor Test can hi de a 0.020 l eak
because of excess vapor generati on. Addi ti onal l y, any
source for addi ti onal vapor generati on can hi de a
smal l l eak i n the EVAP system. Excess vapor gener-
ati on can del ay the fal l of the LDP di aphragm thus
hi di ng the smal l l eak. An exampl e of thi s condi ti on
coul d be bri ngi ng a col d vehi cl e i nto a warm shop for
testi ng or hi gh ambi ent temperatures.
Ful l y pl ugged and parti al l y pl ugged underhood
vacuum l i nes have been known to set MI L condi -
ti ons. P1494 and P0456 can be set for thi s reason.
Al ways, thoroughl y, check pl umbi ng for pi nches or
bl ockage before condemni ng components.
TEST EQUI PMENT The Evaporati ve Emi ssi on
Leak Detector (EELD) Mi l l er Speci al Tool 8404 i s
capabl e of vi sual l y detecti ng l eaks i n the evaporati ve
system and wi l l take the pl ace of the ul trasoni c l eak
detector 6917A. The EELD uti l i zes shop ai r and a
smoke generator to vi sual l y detect l eaks down to
0.020 or smal l er. The food grade oi l used to make the
smoke i ncl udes an UV trace dye that wi l l l eave tel l -
tal e si gns of the l eak under a bl ack l i ght. Thi s i s
hel pful when components have to be removed to
determi ne the exact l eak l ocati on. For detai l ed test
i nstructi ons, fol l ow the operators manual packaged
wi th the EELD.
NOTE: Be sure that the PCM has the latest software
update. Reprogram as indicated by any applicable
Technical Service Bulletin. After LDP repairs are
completed, verify the repair by running the DRB III
Leak Detection Pump (LDP) Monitor Test as
described in Technical Service Bulletin 18-12-99.
REMOVAL
The Leak Detecti on Pump (LDP) i s l ocated under
the l eft quarter panel behi nd the l eft/rear wheel (Fi g.
16). I t i s attached to a two-pi ece support bracket
(Fi g. 17). The LDP and LDP fi l ter are repl aced (ser-
vi ced) as one uni t.
(1) Remove stone shi el d behi nd l eft/rear wheel
(Fi g. 18). Dri l l out pl asti c ri vets for removal .
(2) Remove 3 LDP mounti ng bol ts (Fi g. 19).
(3) Remove support bracket brace bol t (Fi g. 17).
nuts at frame rai l (Fi g. 19).
(5) To separate and l ower front secti on of two-pi ece
support bracket, remove 3 attachi ng bol ts on bottom
of support bracket (Fi g. 17). Whi l e l oweri ng support
bracket, di sconnect LDP wi ri ng cl i p (Fi g. 20).
(6) Di sconnect el ectri cal connector at LDP (Fi g.
20).
(7) Careful l y remove vapor/vacuum l i nes at LDP
(Fi g. 20).
(8) Remove LDP.
INSTALLATION
The LDP i s l ocated i n the l eft quarter panel behi nd
the l eft/rear wheel . I t i s attached to a two-pi ece sup-
port bracket (Fi g. 17). The LDP and LDP fi l ter are
repl aced (servi ced) as one uni t.
(1) Posi ti on LDP and careful l y i nstal l vapor/vac-
uum l i nes to LDP and LDP fi l ter. The vapor/vac-
uum lines and hoses must be firmly connected.
Fig. 16 LOCATION, LDP / EVAP CANISTER
1 - LEAK DETECTION PUMP
2 - EVAP CANISTER
Fig. 18 STONE SHIELD
1 - LEFT-REAR WHEELHOUSE
2 - STONE SHIELD
3 - PLASTIC RIVETS
Fig. 19 LDP MOUNTING BOLTS
Fig. 20 LDP REMOVAL / INSTALLATION
1 - LDP
2 - ELEC. CONNECT.
3 - VAPOR / VACUUM LINES
4 - WIRING CLIP
Check the vapor/vacuum lines at the LDP, LDP
filter and EVAP canister purge solenoid for
damage or leaks. If a leak is present, a Diagnos-
tic Trouble Code (DTC) may be set.
(2) Connect el ectri cal connector to LDP.
(3) Whi l e rai si ng front secti on of support bracket,
connect LDP wi ri ng cl i p (Fi g. 20).
(4) I nstal l 3 LDP mounti ng bol ts (Fi g. 19). Refer to
Torque Speci fi cati ons.
(5) Joi n front and rear secti ons of two-pi ece sup-
port bracket by i nstal l i ng 3 bol ts on bottom of sup-
port bracket (Fi g. 17). Do not ti ghten bol ts at thi s
ti me.
(6) I nstal l support bracket brace bol t (Fi g. 17). Do
not ti ghten bol t at thi s ti me.
(7) Ti ghten 2 support bracket nuts at frame rai l
(Fi g. 19). Refer to Torque Speci fi cati ons.
(8) Ti ghten 3 support bracket bol ts and brace bol t.
Refer to Torque Speci fi cati ons.
(9) Posi ti on stone shi el d behi nd l eft/rear wheel
(Fi g. 18). I nstal l new pl asti c ri vets.
ORVR
DESCRIPTION
The ORVR (On-Board Refuel i ng Vapor Recovery)
system consi sts of a uni que fuel tank, fl ow manage-
ment val ve, fl ui d control val ve, one-way check val ve
and vapor cani ster. Certai n ORVR components can be
found i n (Fi g. 1).
OPERATION
The ORVR (On-Board Refuel i ng Vapor Recovery)
system i s used to remove excess fuel tank vapors.
Thi s i s done whi l e the vehi cl e i s bei ng refuel ed. Cer-
tai n ORVR components can be found i n (Fi g. 1).
Fuel fl owi ng i nto the fuel fi l l er tube (approx. 1
I .D.) creates an aspi rati on effect drawi ng ai r i nto the
fuel fi l l tube. Duri ng refuel i ng, the fuel tank i s
vented to the EVAP cani ster to capture escapi ng
vapors. Wi th ai r fl owi ng i nto the fi l l er tube, there are
no fuel vapors escapi ng to the atmosphere. Once the
refuel i ng vapors are captured by the EVAP cani ster,
the vehi cl es computer control l ed purge system draws
vapor out of the cani ster for the engi ne to burn. The
vapor fl ow i s metered by the purge sol enoi d so that
there i s no, or mi ni mal i mpact on dri veabi l i ty or
tai l pi pe emi ssi ons.
As fuel starts to fl ow through the fuel fi l l tube, i t
opens the normal l y cl osed check val ve and enters the
fuel tank. Vapor or ai r i s expel l ed from the tank
through the control val ve and on to the vapor cani s-
ter. Vapor i s absorbed i n the EVAP cani ster unti l
vapor fl ow i n the l i nes stops. Thi s stoppage occurs
fol l owi ng fuel shut-off, or by havi ng the fuel l evel i n
the tank ri se hi gh enough to cl ose the control val ve.
Thi s control val ve contai ns a fl oat that ri ses to seal
the l arge di ameter vent path to the EVAP cani ster.
At thi s poi nt i n the refuel i ng process, fuel tank pres-
sure i ncreases, the check val ve cl oses (preventi ng l i q-
ui d fuel from spi ti ng back at the operator), and fuel
then ri ses up the fuel fi l l er tube to shut off the di s-
pensi ng nozzl e.
PCV VALVE
DIAGNOSIS AND TESTING - PCV VALVE/PCV
SYSTEM - 4. 7L
(1) Di sconnect PCV l i ne/hose (Fi g. 21) by di scon-
necti ng rubber connecti ng hose at PCV val ve fi tti ng.
(2) Remove PCV val ve at oi l fi l l er tube by rotati ng
PCV val ve downward unti l l ocati ng tabs have been
freed at cam l ock (Fi g. 21). After tabs have cl eared,
pul l val ve strai ght out from fi l l er tube. To prevent
damage to PCV valve locating tabs, valve must
be pointed downward for removal. Do not force
valve from oil filler tube.
(3) After val ve i s removed, check condi ti on of val ve
o-ri ng (Fi g. 21). Al so, PCV val ve shoul d rattl e when
shaken.
(4) Reconnect PCV val ve to i ts connecti ng l i ne/
hose.
(5) Start engi ne and bri ng to i dl e speed.
(6) I f val ve i s not pl ugged, a hi ssi ng noi se wi l l be
heard as ai r passes through val ve. Al so, a strong vac-
uum shoul d be fel t wi th a fi nger pl aced at val ve
i nl et.
(7) I f vacuum i s not fel t at val ve i nl et, check l i ne/
hose for ki nks or for obstructi on. I f necessary, cl ean
out i ntake mani fol d fi tti ng at rear of mani fol d. Do
thi s by turni ng a 1/4 i nch dri l l (by hand) through the
fi tti ng to di sl odge any sol i d parti cl es. Bl ow out the
fi tti ng wi th shop ai r. I f necessary, use a smal l er dri l l
to avoi d removi ng any metal from the fi tti ng.
(8) Do not attempt to clean the old PCV valve.
(9) Return PCV val ve back to oi l fi l l er tube by
pl aci ng val ve l ocati ng tabs (Fi g. 21) i nto cam l ock.
Press PCV val ve i n and rotate val ve upward. A sl i ght
cl i ck wi l l be fel t when tabs have engaged cam l ock.
Val ve shoul d be poi nted towards rear of vehi cl e.
(10) Connect PCV l i ne/hose and connecti ng rubber
hose to PCV val ve.
(11) Di sconnect rubber hose from fresh ai r fi tti ng
at l eft si de of ai r cl eaner resonator box (Fi g. 22).
Start engi ne and bri ng to i dl e speed. Hol d a pi ece of
sti ff paper (such as a parts tag) l oosel y over the
openi ng of the di sconnected rubber hose.
(12) The paper shoul d be drawn agai nst the hose
openi ng wi th noti ceabl e force. Thi s wi l l be after
al l owi ng approxi matel y one mi nute for crankcase
pressure to reduce.
(13) I f vacuum i s not present, di sconnect each PCV
system hose at top of each breather (Fi g. 22). Check
for obstructi ons or restri cti ons.
(14) I f vacuum i s sti l l not present, remove each
PCV system breather (Fi g. 22) from each cyl i nder
head. Check for obstructi ons or restri cti ons. I f
pl ugged, repl ace breather. Ti ghten breather to 12
Nm (106 i n. l bs.) torque. Do not attempt to cl ean
breather
(15) I f vacuum i s sti l l not present, di sconnect each
PCV system hose at each fi tti ng and check for
obstructi ons or restri cti ons.
Fig. 21 PCV Valve/Oil Filler Tube4.7L V-8 Engine
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - PCV VALVE
Fig. 22 PCV Breathers/Tubes/Hoses4.7L V-8
Engine
1 - FRESH AIR FITTING
2 - CONNECTING TUBES/HOSES
3 - CRANKCASE BREATHERS (2)
4 - RUBBER HOSE
5 - AIR CLEANER RESONATOR
PCV VALVE (Continued)
REMOVAL - PCV VALVE - 4. 7L
The PCV val ve i s l ocated on the oi l fi l l er tube (Fi g.
23). Two l ocati ng tabs are l ocated on the si de of the
val ve (Fi g. 23). These 2 tabs fi t i nto a cam l ock i n the
oi l fi l l er tube. An o-ri ng seal s the val ve to the fi l l er
tube.
(1) Di sconnect PCV l i ne/hose (Fi g. 23) by di scon-
necti ng rubber hose at PCV val ve fi tti ng.
(2) Remove PCV val ve at oi l fi l l er tube by rotati ng
PCV val ve downward (counter-cl ockwi se) unti l l ocat-
i ng tabs have been freed at cam l ock (Fi g. 23). After
tabs have cl eared, pul l val ve strai ght out from fi l l er
tube. To prevent damage to PCV valve locating
tabs, valve must be pointed downward for
removal. Do not force valve from oil filler tube.
(3) After val ve i s removed, check condi ti on of val ve
o-ri ng (Fi g. 23).
INSTALLATION - PCV VALVE - 4. 7L
The PCV val ve i s l ocated on the oi l fi l l er tube (Fi g.
23). Two l ocati ng tabs are l ocated on the si de of the
val ve (Fi g. 23). These 2 tabs fi t i nto a cam l ock i n the
oi l fi l l er tube. An o-ri ng seal s the val ve to the fi l l er
tube.
(1) Return PCV val ve back to oi l fi l l er tube by
pl aci ng val ve l ocati ng tabs (Fi g. 23) i nto cam l ock.
Press PCV val ve i n and rotate val ve upward. A sl i ght
cl i ck wi l l be fel t when tabs have engaged cam l ock.
Val ve shoul d be poi nted towards rear of vehi cl e.
(2) Connect PCV l i ne/hose and rubber hose to PCV
val ve.
VACUUM LINES
DESCRIPTION
A vacuum schemati c for emi ssi on rel ated i tems can
be found on the VECI l abel . Refer to Vehi cl e Emi s-
si on Control I nformati on (VECI ) Label for l abel l oca-
ti on.
VAPOR CANISTER
DESCRIPTION
A mai ntenance free, EVAP cani ster i s used on al l
gasol i ne powered model s. The cani ster i s attached to
a two-pi ece support bracket l ocated behi nd the l eft-
rear wheel .
OPERATION
The EVAP cani ster i s fi l l ed wi th granul es of an
acti vated carbon mi xture. Fuel vapors enteri ng the
EVAP cani ster are absorbed by the charcoal granul es.
The cani ster serves two functi ons: as a temporary
fuel vapor storage poi nt whi l e refuel i ng the vehi cl e
for the ORVR system, as a temporary vapor storage
poi nt whi l e the engi ne i s runni ng.
Fuel tank pressure vents i nto the EVAP cani ster.
Fuel vapors are temporari l y hel d i n the cani ster unti l
they can be drawn i nto the i ntake mani fol d. The duty
cycl e EVAP cani ster purge sol enoi d al l ows the EVAP
cani ster to be purged at predetermi ned ti mes and at
certai n engi ne operati ng condi ti ons.
Refer to ORVR for addi ti onal i nformati on.
Fig. 23 PCV Valve/Oil Filler Tube Location
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - PCV VALVE
PCV VALVE (Continued)
REMOVAL
The EVAP cani ster i s l ocated behi nd the l eft-rear
wheel (Fi g. 24). I t i s attached to a two-pi ece support
bracket (Fi g. 25).
(1) Remove rear bumper faci a. Refer to Rear Faci a
Removal / I nstal l ati on i n Frame & Bumpers secti on.
(2) Remove 1 support bracket brace bol t (Fi g. 25).
nuts (Fi g. 26).
(4) Remove upper/rear support bracket mounti ng
bol t (Fi g. 27).
(5) Careful l y l ower support bracket assembl y to
gai n access to vapor /vacuum l i nes. To prevent dam-
age to l i nes, suspend bracket assembl y wi th rope or
stri ng.
(6) Di sconnect necessary vacuum / vapor l i nes at
EVAP cani ster.
(7) Remove EVAP cani ster mounti ng bol t (Fi g. 28).
(8) Li ft cani ster from support bracket (2 pi ns are
used to al i gn cani ster i nto support bracket)
INSTALLATION
The EVAP cani ster i s l ocated behi nd the l eft-rear
wheel (Fi g. 24). I t i s attached to a two-pi ece support
bracket (Fi g. 25).
(1) Posi ti on cani ster to support bracket. Gui de 2
al i gnment pi ns i nto support bracket.
(2) I nstal l EVAP cani ster mounti ng bol t (Fi g. 28).
Refer to Torque Speci fi cati ons.
(3) Careful l y i nstal l vapor /vacuum l i nes to cani s-
ter. The vapor/vacuum lines and hoses must be
firmly connected. Check the vapor/vacuum
lines at the LDP, LDP filter and EVAP canister
purge solenoid for damage or leaks. If a leak is
present, a Diagnostic Trouble Code (DTC) may
be set.
Fig. 24 LOCATION, LDP / EVAP CANISTER
1 - LEAK DETECTION PUMP
2 - EVAP CANISTER
VAPOR CANISTER (Continued)
(4) Careful l y rai se support bracket assembl y to
frame rai l . I nstal l 1 support bracket brace bol t (Fi g.
25) and 2 support bracket nuts (Fi g. 26).
(5) I nstal l upper/rear support bracket mounti ng
bol t (Fi g. 27). Refer to Torque Speci fi cati ons.
(6) I nstal l rear bumper faci a. Refer to Rear Faci a
Removal / I nstal l ati on i n Frame & Bumpers secti on.
Fig. 27 SUPPORT BRACKET BOLT
1 - EVAP CANISTER
2 - UPPER / REAR SUPPORT BRACKET BOLT
3 - SLOTTED HOLE
4 - ALIGNMENT PINS (2)
5 - TWO-PIECE SUPPORT BRACKET
Fig. 28 EVAP CANISTER REMOVE / INSTALL
1 - EVAP CANISTER MOUNTING BOLT
2 - SLOTTED HOLE
3 - EVAP CANISTER (LOWERED)
Fig. 26 SUPPORT BRACKET NUTS
VAPOR CANISTER (Continued)
SERVICE MANUAL COMMENTS
What features do you find most useful? ______________________________________________
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What errors have you found? Please include page number. ___________________________
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What topics are hard to locate, confusing, or not covered completely? ________________
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What comments or suggestions do you have? ________________________________________
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Your Name: _________________________ Dealership/Distributor: _________________________
Address: _____________________________________________________________________________
_____________________________________________________________________________
Vehicle Identification Number _________________________________________________________
Manual Name, Year, Language and Number: __________________________________________
All comments become property of DaimlerChrysler International and may be used without compensation.
DaimlerChrysler International Operations
Attn. Publications Dept.
CIMS 486-02-70
800 Chrysler Drive
Auburn Hills, MI 48326-2757

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