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Chrysler 1997 Stratus Convertible LHD, Service Manual, Page: 541 / 1196

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Chrysler 1997 Stratus Convertible LHD Service Manual Download Page 541

8W-42 AIR CONDITIONING-HEATER

INDEX

page

page

DESCRIPTION AND OPERATION

A/C EVAPORATOR TEMPERATURE SENSOR . . . 5
A/C OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 5
A/C PRESSURE TRANSDUCER . . . . . . . . . . . . . . 6
A/C-HEATER CONTROL . . . . . . . . . . . . . . . . . . . . 5

BLOWER MOTOR OPERATION . . . . . . . . . . . . . . 6
HELPFUL INFORMATION . . . . . . . . . . . . . . . . . . . 6
MODE DOOR ACTUATOR (MANUAL A/C) . . . . . . 5
RADIATOR FAN OPERATION . . . . . . . . . . . . . . . . 6

DESCRIPTION AND OPERATION

A/C-HEATER CONTROL

The air conditioning-heater system is controlled by

the Body Control Module (BCM). The BCM senses
voltage of the A/C-Heater control on circuit C58. The
control uses resistors to internal to the control. These
resistors are connected to the Z2 ground circuit.

When the operator requests a function in the sys-

tem the BCM measures the voltage, on circuit C58,
and activates the mode actuator door to the proper
position.

A separate A/C switch is used in the system. This

switch

works

the

same

as

the

mode

actuator

switches. When the operator presses the switch the
BCM measures the voltage on the C21 circuit and
activates the proper functions. Internal to the A/C-
Heater control the A/C switch is connected to the
blower motor switch. This allows the A/C system to
only operate when the blower switch in an ON posi-
tion.

Ground for the A/C switch is provided through the

blower motor switch to the Z1 circuit. This circuit
terminates at the instrument panel ground. A Light
Emitting Diode (LED) is connected in the C21 circuit
and illuminates when the A/C system is operating.

Illumination lamps and LED’s are internal to the

control. These are controlled by the BCM. The E2 cir-
cuit from the BCM provides the voltage to the control
for lamp and LED illumination. Ground for the
lamps and LED’s is provided on the Z1 circuit which
terminates at the instrument panel left side cowl.

MODE DOOR ACTUATOR (MANUAL A/C)

The mode door actuator is located on the lower left

side of the A/C- Heater housing. This actuator con-
trols the position of the panel/bi-level door and the
floor/defrost door.

Power for the mode door actuator is provided by

the Body Control Module (BCM) on the C26 circuit.
This is a 5 volt feed.

Circuit C35 is the mode drive circuit from the BCM

to the actuator.

The C37 circuit is the feedback from the actuator

to the BCM. The BCM uses this information to
adjust the door to the proper position.

Circuit C57 is the sensor return to the BCM. This

circuit is spliced with the blend air door actuator.

Circuit C34 is the common line that is spliced, and

connects, to the blend air door actuator and the recir-
culation door actuator.

A/C EVAPORATOR TEMPERATURE SENSOR

The A/C evaporator temperature sensor, located in

the A/C-Heater housing, provides the Body Control
Module (BCM) with the evaporator temperature to
prevent the evaporator from freezing. Power for the
sensor is provided from the BCM to the sensor on cir-
cuit C12. The ground for the sensor is on circuit C57
to the BCM.

Information on evaporator temperature is sent to

the Powertrain Control Module (PCM) across the
CCD Bus. The PCM uses this information to control
operation of the A/C compressor clutch.

A/C OPERATION

When the A/C switch is CLOSED or the Defrost

switch is moved to the ON position, and the evapora-
tor temperature is in the normal limits, the Body
Control Module (BCM) sends a signal to the Power-
train Control Module (PCM), over the CCD Bus,
requesting A/C operation.

After receiving this input, the PCM activates the

A/C compressor by grounding the C28 circuit, which
is attached to the coil side of the A/C clutch relay.
This relay is located in the Power Distribution Cen-
ter (PDC). Power for the coil side of the relay is sup-
plied on the F18 circuit. The F18 circuit is protected
by a 10 amp fuse located in cavity 9 of the Power
Distribution Center (PDC).

When the coil is energized contacts in the relay

CLOSE connecting circuits A16 and C3. Circuit A16
is protected by a 40 amp fuse located in cavity 17 of
the PDC and also supplies power for the radiator fan
relays. The C3 circuit connects from the relay to the
A/C compressor clutch.

JX

8W - 42 AIR CONDITIONING-HEATER

8W - 42 - 5

Summary of Contents for 1997 Stratus Convertible LHD

Page 1: ...Welcome to the 1997 Stratus Convertible RHD LHD Interactive Electronic Service Manual CLICK ON VEHICLE TO BEGIN tweddle litho dom parts cdrom demo 09 96 page 4 output 0828 ET 02 25 97 ...

Page 2: ...stem 8J Turn Signal and Flashers 8K Windshield Wipers and Washers 8L Lamps 8M Restraint System 8N Electrically Heated Systems 8P Power Door Locks 8Q Vehicle Theft Security System 8R Power Seats 8S Power Windows 8T Power Mirrors 8U Chime Warning Reminder System 8W Wiring Diagrams 9 Engine 11 Exhaust System and Intake Manifold 13 Bumpers and Frame 14 Fuel System 19 Steering 21 Transaxle 22 Tires and...

Page 3: ...anel near the left windshield pillar Fig 2 The VIN con sists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle Refer to VIN Code Breakdown table for decoding information VIN CHECK DIGIT To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden tific...

Page 4: ...OSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 3 Built in Mexico by Chrysler of Mexico 2 Make C Chrysler 3 Vehicle Type 3 Passenger Car 4 Other E Active Driver and Passenger Air Bag 5 Car LIne L Chrysler Sebring 6 Series 4 High line 5 Premium 7 Body Style 5 Convertible Open Body 8 Engines X 2 4L 4 Cyl 16 V Gasoline DOHC H 2 5 L 6 Cyl Gasoline SOHC S 2 4L 4 Cyl Gasoline DOHC Turbo sold...

Page 5: ... The last code shown on either plate will be fol lowed by END When two plates are reqired the last code space on the first plate will indicate CTD When a second plate is required the first four spaces of each line will not be used due to overlap of the plates STANDARD VEHICLE DIMENSIONS INTERIOR DIMENSIONS BODY HEADROOM LEG ROOM SHOULDER ROOM HIP ROOM FRONT REAR FRONT REAR FRONT REAR FRONT REAR CH...

Page 6: ...ponds to the number of line marks plus 2 The most commonly used metric bolt strength classes are 9 8 and 12 9 The metric strength class identification number is imprinted on the head of the bolt The higher the class number the greater the bolt strength Some metric nuts are imprinted with a single digit strength class on the nut face Refer to the Fastener Identification and Fastener Strength Charts...

Page 7: ...Bolt Head Markings Bolt Mark ings and Torque Val ues U S Customary SAE Grade Number Bolt Head Markings These are all SAE Grade 5 3 line Bolt Torque Grade 5 Bolt Bolt Torque Grade 8 Bolt FASTENER IDENTIFICATION JX INTRODUCTION 5 GENERAL INFORMATION Continued ...

Page 8: ...rk Hexagon flange bolt w washer hexagon bolt No mark Grooved Hexagon head bolt Two protruding lines Hexagon flange bolt w washer hexagon bolt Two protruding lines Welded bolt Hexagon head bolt Three protrud ing lines Hexagon head bolt Four protruding lines 6 INTRODUCTION JX GENERAL INFORMATION Continued ...

Page 9: ...RMULAS AND EQUIVALENT VALUES Multiply By To Get Multiply By To Get in lbs x 0 11298 Newton Meters N m N m x 8 851 in lbs ft lbs x 1 3558 Newton Meters N m N m x 0 7376 ft lbs Inches Hg 60 F 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 M x 1 09...

Page 10: ...388 11 8 104 4433 15 8 139 8478 24 212 4270 40 4 5193 80 9 0386 120 13 5580 160 18 0773 200 22 5966 4 35 4045 8 70 8090 12 106 2135 16 141 6180 25 221 2781 ft lbs to N m N m to ft lbs ft lb N m ft lb N m ft lb N m ft lb N m ft lb N m N m ft lb N m ft lb N m ft lb N m ft lb N m ft lb 1 1 3558 21 28 4722 41 55 5885 61 82 7049 81 109 8212 1 7376 21 15 9888 41 30 2400 61 44 9913 81 59 7425 2 2 7116 22...

Page 11: ...69 02717 89 03504 10 2 540 30 7 620 50 12 700 70 17 780 90 22 860 10 00394 30 01181 50 01969 70 02756 90 03543 11 2 794 31 7 874 51 12 954 71 18 034 91 23 114 11 00433 31 01220 51 02008 71 02795 91 03583 12 3 048 32 8 128 52 13 208 72 18 288 92 23 368 12 00472 32 01260 52 02047 72 02835 92 03622 13 3 302 33 8 382 53 13 462 73 18 542 93 23 622 13 00512 33 01299 53 02087 73 02874 93 03661 14 3 556 3...

Page 12: ... 25 59 600 43 65 670 48 14 1 5 91 930 67 100 1 050 76 16 1 5 140 1 400 101 6 1 8 80 69 in lbf 9 90 78 in lbf 8 1 25 19 195 14 21 210 15 6T 10 1 25 39 400 29 44 440 32 12 1 25 71 730 53 80 810 59 14 1 5 110 1 100 80 125 1 250 90 16 1 5 170 1 750 127 6 1 10 5 110 8 12 120 9 8 1 25 25 260 19 28 290 21 7T 10 1 25 52 530 38 58 590 43 12 1 25 95 970 70 105 1 050 76 14 1 5 145 1 500 108 165 1 700 123 16 ...

Page 13: ...vehi cles that are operated under the conditions listed at the beginning of the Maintenance Schedule section Use the schedule that best describes your driving conditions Where time and mileage are listed follow the interval that occurs first PARTS AND LUBRICANT RECOMMENDATIONS When service is required Chrysler Corporation recommends that only Mopart brand parts lubri cants and chemicals be used Mo...

Page 14: ... lubricants In addition API classification defines the lubricants usage LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI All approved products have the NLGI symbol Fig 3 on the label At the bottom NLGI symbol is the usage and quality identification letters Wheel bearing lubricant is identified by the letter G Chassis lubricant is identified by the latter L The l...

Page 15: ...ions such as dusty areas and very short trip driving UNSCHEDULED INSPECTION At Each Stop For Fuel Check engine oil level add as required Check windshield washer solvent and add if required Once A Month Check tire pressure and look for unusual wear or damage Check fluid levels of coolant reservoir power steering and automatic transmission and add as required Check all lights and all other electrica...

Page 16: ...iles 144 000 km or at 72 months Change engine oil Replace engine oil filter on all engines Check and replace if necessary the PCV valve Lubricate front and rear suspension ball joints Inspect front brake pads and rear brake linings Adjust drive belt tension Replace air cleaner air cleaner element Replace spark plugs on 2 4L engines 97 500 Miles 156 000 km or at 78 months Change engine oil Replace ...

Page 17: ... km Change engine oil Replace engine oil filter on all engines 60 000 Miles 96 000 km Change engine oil Replace engine oil filter on all engines Check and replace if necessary the PCV valve Lubricate front and rear suspension ball joints Replace drive belts Replace air cleaner element Replace spark plugs and ignition cables on 2 4L engines Change automatic transaxle fluid and filter Inspect front ...

Page 18: ...e oil Replace engine oil filter on 2 4 liter engines 102 000 Miles 163 000 km Change engine oil Replace engine oil filter on all engines 105 000 Miles 168 000 km Change engine oil Replace engine oil filter on 2 4 liter engines Replace the engine timing belt on 2 4 liter engines Police taxi or delivery service usage and trailer towing require the more frequent transaxle service indicated with a in ...

Page 19: ...ause of starting problem on dis abled vehicle is severe damage to booster vehicle charging system can result 2 When using another vehicle as a booster source park the booster vehicle within cable reach Turn off all accessories set the parking brake place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF 3 On disabled vehicle place gear selector in p...

Page 20: ...und clearance If minimum ground clearance cannot be reached use a towing dolly If a flat bed device is used the approach angle should not exceed 15 degrees GROUND CLEARANCE CAUTION If vehicle is towed with wheels removed install lug nuts to retain brake drums or rotors A towed vehicle should be raised until the lifted wheels are a minimum 100 mm 4 in from the ground Be sure there is at least 100 m...

Page 21: ...bles to suspension components or engine mounts damage to vehicle can result JX vehicles can be tied to a flat bed device using the reinforced loops located under the front and rear bumpers on the drivers side of the vehicle There are also four reinforced elongated holes for T or R hooks located on the bottom of the front frame rail torque boxes behind the front wheels and forward of the rear wheel...

Page 22: ......

Page 23: ... method of checking a vehicle s front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used Instruc tions furnished by the manufacturer of the equip ment being used should always be followed to ensure accuracy of the alignment except alignment specifi cations recommended by Chrysler Corporation MUST ALWAYS be used CAUTION Do not attempt to modify any...

Page 24: ...ns 5 Thrust Angle is defined as the average of the Toe settings on each rear wheel If this measurement is out of specification re adjust rear wheel Toe so that each wheel has 1 2 of the total Toe measure ment When re adjusting do not exceed the total Toe specification Fig 1 Alignment Camber Toe LOOSEN NUT TO ADJUST TOE ADJUST TOE NEGATIVE POSITIVE CAMBER TOE TOE OUT TOE IN FRONT 2 2 SUSPENSION JX ...

Page 25: ...e Wheel Lug Nuts 3 Verify Wheel Lug Nut Torque 4 Worn Or Broken C V Joint 4 Replace C V Joint 5 Worn Or Loose Ball Joint 5 Tighten Or Replace Ball Joint 6 Worn Or Loose Control Arm Bushing 6 Tighten To Specified Torque Or Replace Control Arm Bushing 7 Loose Crossmember Bolts 7 Tighten Crossmember Bolts To Specified Torque Road Wander 1 Incorrect Tire Pressure 1 Inflate Tires To Rcommended Pressure...

Page 26: ... on this vehicle is adjustable The rear camber on this vehicle is adjusted using the adjusting screw located in the forward and rear lat eral links of the vehicles rear suspension Fig 2 Rear Caster on this vehicle is not adjustable and is not shown as an alignment specification CAUTION Do not attempt to adjust the vehicles Caster or Camber by heating bending or any other modification of the suspen...

Page 27: ...e at their pre ferred specifications 6 While holding adjustment screws from turning use a crow foot and torque wrench and tighten all lateral link adjusting screw jam nuts to a torque of 65 N m 48 ft lbs This will securely hold adjusting screws from turning CAUTION Do not twist front inner tie rod to steer ing gear rubber boots during front wheel Toe adjustment 7 Loosen front inner to outer tie ro...

Page 28: ...3 4 in TOTAL TOE Specified In Degrees See Note TOE OUT When Backed On Alignment Rack Is TOE In When Driving 0 1 out to 0 3 in 0 1 in THRUST ANGLE or 0 15 0 0 Note Total Toe is the arithmetic sum of the left and right wheel Toe settings Positive is Toe in negative is Toe out Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting Toe Left and ...

Page 29: ...41 SPECIAL TOOLS FRONT SUSPENSION 42 GENERAL INFORMATION GENERAL INFORMATION CAUTION ONLY FRAME CONTACT HOISTING EQUIPMENT CAN BE USED ON THIS VEHICLE All vehicles have a fully independent rear suspension The vehicles can not be hoisted using equipment designed to lift a vehicle by the rear axle If this type of hoisting equipment is used damage to rear suspension components will occur CAUTION At n...

Page 30: ...between an upper seat located just below the top shock absorber mounting bracket and a lower spring seat located on the shock absorber The top of each shock absorber assembly is bolted to the cast aluminum upper control arm bracket which is then bolted to the shock tower of the vehicle using 4 mounting bolts The bottom of the shock absorber assembly attaches to the lower control arm of the vehicle...

Page 31: ...otter pin is used for positive retention of the castle nut The lower ball joint is lubricated for life at the time it is assembled in the lower control arm The ball joint does not require any type of addi tional lubrication for the life of the vehicle No attempt should be made to ever add any lubri cation to the lower ball joint UPPER CONTROL ARM BALL JOINT The ball joint is pressed into the upper...

Page 32: ...o be used for this vehicle 2 Install a dial indicator on the vehicle so it is contacting the top surface of the steering knuckle near the lower ball joint stud castle nut 3 Grab wheel and tire assembly and push it up and down firmly 4 Record the amount of up and down movement of the steering knuckle recorded on the dial indicator 5 Replace lower control arm if the movement in the lower control arm...

Page 33: ...r of the front wheel opening 8 Remove pinch bolt attaching shock absorber clevis to shock absorber Fig 6 9 Remove the nut and thru bolt Fig 7 attaching the shock absorber clevis to the lower control arm 10 Remove the clevis from the shock absorber by carefully tapping the clevis off the shock absorber using a soft brass drift 11 Remove the 4 bolts Fig 8 attaching the shock absorber upper control a...

Page 34: ...rol cable Fig 3 on the steering knuckle Install and securely tighten the routing bracket attaching bolt Fig 3 CAUTION When supporting lower control arm with jack stand do not position jack stand under the ball joint cap on the lower control arm Position in area of lower control arm shown in Fig 10 7 Lower vehicle to the ground with a jack stand positioned under the lower control arm Fig 10 Continu...

Page 35: ... Remove the nut and thru bolt Fig 15 attach ing the shock absorber clevis to the lower control arm Fig 10 Lower Control Arm Correctly Supported By Jack Stand SHOCK ABSORBER CLEVIS LOWER CONTROL ARM BALL JOINT CAP Fig 11 Wheel Speed Sensor Cable Routing Bracket SPEED SENSOR CABLE ROUTING BRACKET STEERING KNUCKLE ATTACHING BOLT BRAKE CALIPER FLEX HOSE WHEEL SPEED SEN SOR CABLE Fig 12 Ball Joint Atta...

Page 36: ... BRACKET WARNING WHEN COMPRESSING COIL SPRING FOR REMOVAL FROM SHOCK ABSORBER THE FIRST FULL TOP AND BOTTOM COIL OF THE COIL SPRING MUST BE CAPTURED BY THE JAWS OF THE COIL SPRING COMPRESSOR 12 Compress shock absorber coil spring using Professional Services Equipment Spring Compressor GP 2020 C3 5 fitted with the GP C42 top spring shoe and the GP A20 bottom spring shoe Fig 18 13 Hold the rod of th...

Page 37: ...from mounting bracket 18 Remove the 2 bolts Fig 24 attaching the upper control arm to the bushings in the upper con trol arm mounting bracket 19 Remove the upper control arm from the mounting bracket Fig 19 Shock Absorber Shaft Nut Removal SHOCK ABSORBER SOCKET SNAP ON A136 CROW FOOT Fig 20 Shock Absorber Rod Upper Washer SHOCK ABSORBER UPPER CONTROL ARM MOUNTING BRACKET ISOLATOR BUSHING WASHER Fi...

Page 38: ...sembly from the vise and remove the clevis from the shock absorber 10 Install shock absorber assembly with the cle vis bracket removed into the shock tower Align the 2 locating pins and the 4 mounting holes on the upper control arm shock absorber mount with the holes in shock tower Install the 4 upper control arm mount to shock tower mounting bolts Tighten the 4 bolts to a torque of 95 N m 70 ft l...

Page 39: ...ed to half specification Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs LOWER CONTROL ARM REMOVE 1 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the tire and wheel from the vehicle NOTE Remov...

Page 40: ...be taken not to hit lower control arm or ball joint grease seal CAUTION Pulling the steering knuckle outward from the vehicle after releasing it from the ball joint can separate inner C V joint See Driveshafts 7 Remove the shock absorber clevis to lower con trol arm bushing nut and thru bolt Separate the cle vis from lower control arm Fig 32 8 Remove nut attaching the stabilizer bar link to the lo...

Page 41: ... crossmember making it easier to remove control arm from cross member INSTALL 1 Position rear of lower control arm into front suspension crossmember first Then install front of lower control arm in front suspension crossmember Install bolts and nuts Fig 36 and Fig 35 attach ing the front and rear of lower control arm to front suspension crossmember Do not tighten front attaching bolt at this time ...

Page 42: ...le so the total weight of the vehicle is supported by the jack stand and lower con trol arm CAUTION When tightening the thru bolt do not turn the bolt in the clevis The serrations on the bolt and the hole in the clevis will be damaged 11 With the vehicle s suspension at curb height tighten the clevis to lower control arm bush ing thru bolt nut Fig 32 to a torque of 88 N m 65 ft lbs 12 Tighten fron...

Page 43: ...wing procedure hold tie rod end stud with a 11 32 socket while loosening and removing nut with wrench Fig 44 10 Remove the tie rod end from the steering knuckle using Remover Special Tool MB 991113 Fig 45 11 Remove the speed sensor cable routing bracket Fig 46 from the steering knuckle Fig 39 Cotter Pin Nut Lock HUB NUT NUT LOCK COTTER PIN SPRING WASHER Fig 40 Loosening Front Hub Nut FRONT HUB Fig...

Page 44: ...eel well as possible Using a hammer strike the boss on the steering knuckle Fig 48 until the steering knuckle separates from the stud of lower ball joint Fig 44 Tie Rod End Attaching Nut TIE ROD END HEAT SHIELD STEERING KNUCKLE TIE ROD END STUD NUT Fig 45 Tie Rod End Removal From Steering Knuckle SPECIAL TOOL MB 991113 TIE ROD END HEAT SHIELD STEERING KNUCKLE LOWER CONTROL ARM Fig 46 Speed Sensor ...

Page 45: ...installing steering knuckle on vehicle Refer to Hub And Bearing Ser vice in this section of the service manual for proper wheel bearing removal and installation procedure 2 Install the heat shield for the lower control arm ball joint grease seal before beginning the instal lation of the steering knuckle on the vehicle 3 Slide drive shaft back into front hub bearing assembly Then install steering k...

Page 46: ...hreads of the outer C V joint stub axle Install washer and hub nut Fig 54 onto stub axle and tighten nut 12 With vehicle brakes applied to keep braking disc from turning tighten hub nut to 203 N m 150 ft lbs of torque 13 Install the spring washer hub nut lock and new cotter pin Wrap cotter pin prongs tightly around the hub nut lock Fig 55 14 Install front wheel and tire assembly Install front whee...

Page 47: ...lower control arm retaining nuts Torque the stabi lizer bar attaching link nuts to 101 N m 75 ft lbs FRONT HUB BEARING ASSEMBLY The front hub bearing is serviced separately from the front steering knuckle Retention of the front hub bearing into the steering knuckle is by means of 3 bolts installed from the rear of the steering knuckle The bolts attach the hub bearing to the out board side of the s...

Page 48: ...kle Fig 64 Nut is to be removed from tie rod end using the following procedure hold tie rod end stud with a 11 32 socket while loosening and removing nut with wrench Fig 64 10 Remove the tie rod end from the steering knuckle arm using Remover Special Tool MB 991113 Fig 65 Fig 58 Cotter Pin Nut Lock HUB NUT NUT LOCK COTTER PIN SPRING WASHER Fig 59 Loosening Front Hub Nut FRONT HUB Fig 60 Front Disc...

Page 49: ...eering knuckle separates from stud of lower ball joint When striking steering knuckle care MUST be taken not to hit lower control arm or ball joint grease seal Fig 63 Removing Installing Front Braking Disc BRAKING DISC STEERING KNUCKLE DISC BRAKE CALIPER ASSEMBLY STORED Fig 64 Tie Rod End Attaching Nut Removal Installation TIE ROD END HEAT SHIELD STEERING KNUCKLE TIE ROD END STUD NUT Fig 65 Tie Ro...

Page 50: ...securely in a vise 20 Remove the 3 bolts Fig 72 attaching the hub bearing assembly to the steering knuckle 21 Remove the hub bearing assembly out from the front of the steering knuckle If bearing will not come out of steering knuckle it can be tapped out using a soft faced hammer 22 Thoroughly clean all hub bearing assembly mounting surfaces on steering knuckle 23 Install the replacement hub beari...

Page 51: ... crowfoot and 11 32 socket tighten the attaching nut to a torque of 61 N m 45 ft lbs Fig 73 9 Install rotor on hub and bearing 10 Install disc brake caliper assembly on steering knuckle Caliper is installed by first sliding top of caliper under top abutment on steering knuckle Then installing bottom of caliper against bottom abutment of steering knuckle Fig 74 11 Install disc brake caliper assembl...

Page 52: ...ove the front wheel and tire assembly from the vehicle 3 Remove front disc brake caliper to steering knuckle attaching bolts Fig 78 4 Remove disc brake caliper assembly from steer ing knuckle Caliper is removed by first lifting bot tom of caliper away from steering knuckle and then removing top of caliper out from under steering knuckle Fig 79 5 Support brake caliper adapter assembly using a wire ...

Page 53: ...ed by first sliding top of caliper under top abutment on steering knuckle Then installing bottom of caliper against bottom abutment of steering knuckle Fig 84 5 Install disc brake caliper assembly attaching bolts Fig 78 and torque to 31 N m 23 ft lbs Fig 79 Brake Caliper Removal ROTOR DISC BRAKE CALI PER ASSEMBLY OUTBOARD BRAKE SHOE STEERING KNUCKLE LIFT THIS END OF CALIPER AWAY FROM STEERING KNUC...

Page 54: ...coil spring and shock absorber assembly right or left according to which side of the vehicle the shock absorber was removed from and which shock absorber the coil spring was removed from WARNING DO NOT REMOVE THE SHOCK ABSORBER ROD NUT BEFORE SHOCK ABSORBER COIL SPRING IS COMPRESSED REMOVING SPRING TENSION FROM UPPER CON TROL ARM SHOCK ABSORBER MOUNTING BRACKET WARNING WHEN COMPRESSING COIL SPRING...

Page 55: ...bracket 9 Remove the lower isolator bushing from the shock absorber rod sleeve 10 Remove washer from top of dust shield Fig 92 11 Remove the dust shield Fig 93 from the shock absorber assembly Fig 87 Shock Absorber Shaft Nut Removal Installation SHOCK ABSORBER SOCKET SNAP ON A136 CROW FOOT Fig 88 Shock Absorber Rod Washer SHOCK ABSORBER UPPER CONTROL ARM MOUNTING BRACKET ISOLATOR BUSHING WASHER Fi...

Page 56: ...r assembly for the following Mount for cracks and distortion and locating pins for any sign of damage Severe deterioration of the upper or lower coil spring isolators Deterioration of the shock absorber rod to shock absorber mounting bracket bushings Inspect dust shield for rips and or deterioration Fig 92 Shock Absorber Rod Washer WASHER SHOCK ABSORBER ROD DUST SHIELD SPRING Fig 93 Shock Absorber...

Page 57: ... rod attention must be paid to their location so they are installed correctly Fig 98 7 Install the lower isolator bushing and sleeve Fig 91 in the shock absorber upper control arm mounting bracket Install coil spring upper isolator in mounting bracket Fig 91 8 Install the upper isolator bushing Fig 90 on the sleeve and the shock absorber upper control arm mounting bracket 9 Install the shock absor...

Page 58: ...ront bushing into lower control arm until bushing is sitting flush on the machined surface of the lower control arm This will correctly position front bushing in lower control arm 5 Install lower control arm assembly back on vehicle See Lower Control Arm Installation in this section of the service manual for the required instal lation procedure LOWER CONTROL ARM REAR ISOLATOR BUSHING To perform re...

Page 59: ...d Bushing Receiver Special Tool 6876 on Special Tool C 4212 F 3 Install lower control arm on Special Tools assembled for removal of the clevis isolator bushing Be sure Special Tool 6876 is square on lower control arm and Special Tool 6877 is positioned correctly on clevis bushing Fig 104 4 Tighten screw on Remover Installer Special Tool C 4212 F to press clevis bushing out of lower control arm ASS...

Page 60: ...joint used in the lower control arm of this vehicle is a lubricated for life ball joint This ball joint does not required any additional lubrication for the life of the vehicle Do not alter the lower control arm or ball joint in an attempt to lubricate the lower control arm ball joint If it is determined that the ball joint is lacking proper lubri cation the lower control arm will need to be repla...

Page 61: ...etaining ring on Installer Spe cial Tool 6875 1 Fig 109 Then place expandable collar from Installer Special Tool 6875 over tapered cone of the special tool Fig 109 6 Using the expandable collar of Installer Spe cial Tool 6875 Fig 110 push the seal boot retaining ring down the cone of Installer Special Tool 6875 Fig 106 Removing Ball Joint Seal Retaining Ring UPPER SEALING RING LOWER CONTROL ARM BA...

Page 62: ...all sealing boot as far as possible on ball joint assembly CAUTION Do not use an arbor press to install the sealing boot on the upper control arm ball joint assembly Damage to the sealing boot can occur do to excessive pressure applied to sealing boot when being installed 3 Position Receiving Cup Special Tool 6758 over sealing boot so it is aligned properly with bottom edge of sealing boot Fig 114...

Page 63: ...spension Crossmember Bolts 68 N m 50 ft lbs Tie Rod End Adjustment Jam Nuts 61 N m 45 ft lbs Lower Control Arm Ball Joint Stud Castle Nut 74 N m 55 ft lbs To Crossmember Pivot Bolt Front 183 N m 135 ft lbs To Crossmember Rear Bolt 95 N m 70 ft lbs Ball Joint Heat Shield Attaching Bolts 13 N m 10 ft lbs Upper Control Arm Ball Joint Stud Castle Nut 54 N m 40 ft lbs To Shock Bracket 88 N m 65 ft lbs ...

Page 64: ...Installer Ball Joint 6758 Press Ball Joint Remover Installer C 4212F Remover Ball Joint MB 990799 Remover Installer Control Arm Bushing 6602 5 In Tool Kit 6602 Installer Receiver Control Arm Bushing 6876 Installer Ball Joint 6758 2 42 SUSPENSION JX ...

Page 65: ...r Ball Joint 6756 Installer Bushing 6760 Remover Installer Control Arm Clevis Bushing 6877 Installer Ball Joint Seal Boot Retainer 6875 Remover Tie Rod End MB 991113 or MB 990635 Remover Lower Ball Joint C 4150A JX SUSPENSION 2 43 SPECIAL TOOLS Continued ...

Page 66: ...OTE If a rear suspension component becomes bent damaged or fails no attempt should be made to straighten or repair it Always replace with a new component DESCRIPTION AND OPERATION REAR SUSPENSION SYSTEM DESCRIPTION The rear suspension used on this vehicle is a fully independent short and long arm style suspension Fig 1 SHOCK ABSORBER ASSEMBLY The rear shock absorber assemblies support the weight o...

Page 67: ...Fig 1 Fully Independent Rear Suspension JX SUSPENSION 2 45 DESCRIPTION AND OPERATION Continued ...

Page 68: ...AND TRAILING LINKS The lateral movement of the rear knuckle is con trolled by the lateral arms going from the front and rear of the knuckle to the rear suspension crossmem ber Fore and aft movement of the knuckle is con trolled by a trailing link The lateral arms and trailing link have rubber iso lator bushings at each end to isolate suspension noise from the body of the vehicle The trailing link ...

Page 69: ...the trailing link is bent or damaged the trailing link will require replacement Do not ever attempt to repair or straighten a trailing link STABILIZER BAR AND BUSHINGS Inspect the stabilizer bar for damage or bending Inspect for broken or distorted stabilizer bar bush ings bushing retainers and worn or damaged stabi lizer bar to lateral arm attaching links If stabilizer bar to crossmember bushing ...

Page 70: ...5 Lower vehicle far enough to gain access to the passenger compartment of the vehicle 6 Install and tighten the 2 shock absorber mounting bracket attaching nuts Fig 3 to a torque of 54 N m 40 ft lbs 7 Install the sound matting over the top of the shock absorber attaching nuts 8 Install the plastic access panel Fig 2 in the convertible top storage well Refer to Group 23 Body in this service manual ...

Page 71: ...e exhaust pipe and the rear suspension crossmember STABILIZER BAR BUSHING INSPECTION Inspect for broken or distorted retainers and bush ings If bushing replacement is required bushings can be removed by opening slit in bushing and removing bushing from around stabilizer bar INSTALL 1 Install stabilizer bar back in vehicle with the bushings removed using the reverse sequence of removal 2 When stabi...

Page 72: ...ve the park brake cable from the park brake actuating lever Fig 10 Then remove the park brake cable from the rear brake support plate Fig 11 Park brake cable is removed from brake support plate using this procedure Position a 1 2 inch box end wrench over cable retainer Fig 11 to collapse retaining tabs Then pull bear brake cable from brake support plate 6 Remove the rear hub bearing assembly retai...

Page 73: ...age 11 Remove the nut and washer attaching the trailing link to the rear knuckle Use a wrench on the flat of the trailing link to keep it from turning when removing nut Fig 17 12 Remove the shock absorber clevis bracket to knuckle attaching nut and bolt Fig 18 13 Remove the knuckle assembly from the vehi cle Fig 13 Rear Brake Support Plate Mounting Bolts REAR BRAKE SUP PORT PLATE REARKNUCKLE BRAKE...

Page 74: ...sor head mounting bolt to 7 N m 60 in lbs 7 Attach routing bracket for speed sensor cable to brake flex hose bracket and securely tighten attaching bolt Fig 9 8 Install park brake cable into brake support plate Ensure cable retainer is securely holding cable to support plate Then connect park brake cable to park brake lever on brake shoe 9 Install rear hub and bearing assembly on knuckle and insta...

Page 75: ...move the rear exhaust pipe hanger bracket from the rear suspension crossmember Fig 23 Let exhaust system drop down as far as possible 6 On only the side of the vehicle requiring con trol arm removal separate the control arm ball joint from the rear knuckle using following procedure Remove cotter pin and castle nut attaching upper control arm ball joint to knuckle Remove ball joint stud from knuckl...

Page 76: ...hers and the upper con trol arm from the rear suspension crossmember 13 Transfer any required components to the replacement control arm INSTALL NOTE One flat washer is used at each upper con trol arm pivot bar attaching bolt The flat washer is located between the pivot bar and the rear suspen sion crossmember Be sure 1 flat washer is used at each bolt attaching the pivot bar to the rear suspen sio...

Page 77: ... ball joints are replaceable ONLY as an assem bly do not attempt any type of repair on the ball joint assembly The replacement procedure for the ball joint assembly is detailed in this section of the service manual The ball joint housing is a pressed fit into the con trol arm with the joint stud retained in the knuckle by a castle nut The castle nut is retained on the ball joint stud by a cotter p...

Page 78: ...d properly with bottom edge of sealing boot Fig 33 Apply pressure BY HAND to special tool 6758 until sealing boot is pressed squarely against surface of control arm REAR SUSPENSION CROSSMEMBER REMOVE 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this v...

Page 79: ...wer the rear suspension crossmember enough to access the upper control arm pivot bar to crossmember attaching bolts Fig 40 Fig 35 Muffler Support Bracket REAR FASCIA MUFFLER SUPPORT BRACKET ATTACHING BOLTS MUFFLER Fig 36 Exhaust Pipe Hanger At Rear Suspension Crossmember BOLT REAR SUSPENSION CROSSMEMBER HANGER BRACKET EXHAUST PIPE Fig 37 Lowering And Supporting Rear Suspension Crossmember WOODEN B...

Page 80: ...spen sion crossmember 3 Align the upper control arm pivot bars with the mounting holes in the rear suspension crossmember Install the pivot bar attaching bolts and washers Tighten the 4 pivot bar to crossmember attaching bolts Fig 40 to a torque of 107 N m 80 ft lbs 4 Using transmission jack raise rear suspension crossmember up to the rear frame rails and loosely install the 4 attaching bolts 5 Po...

Page 81: ...n crossmember Fig 44 6 Remove the forward lateral link from the vehi cle INSTALL 1 Install the lateral link and the attaching nut and bolt at rear suspension crossmember Fig 44 The forward lateral link is to be installed with the cup in cast portion facing down and toward rear knuckle Fig 43 2 Install the lateral link and attaching nut bolt and washer at rear knuckle Fig 43 3 Torque both lateral l...

Page 82: ...ll nuts are torqued to half specifica tion Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 5 Lower vehicle to the ground 6 Check and reset rear wheel Camber and Toe to specifications if required Refer to Front And Rear Alignment Setting Procedure in the Wheel Alignment Check And Adjustment section in this group of the service manual for the required alignment...

Page 83: ...of trailing link assembly in rear knuckle CAUTION It is important that the following proce dure be done when installing the trailing arm hanger bracket to the body of the vehicle This pro cedure will ensure that the hanger bracket is installed in the correct position on the vehicle 3 Install trailing link hanger bracket on vehicle and loosely install the 4 attaching bolts Fig 51 Then install 2 dri...

Page 84: ...ring ser vice from the vehicle Refer to Shock Assembly Removal in Servicing Rear Shock Absorbers in this section of the service manual 2 Position shock absorber assembly in a vise Shock absorber is to be clamped only by the clevis bracket on the bottom of the shock absorber Fig 52 3 Mark the coil spring and the shock absorber right or left according to which side of the vehicle it was removed from...

Page 85: ...coil spring and the spring com pressor as an assembly Fig 60 from the shock absorber Mark left and right springs for instal lation back on correct side of vehicle NOTE The collar Fig 61 can not be removed from the shock absorber rod When removing the jounce bumper it will have to be carefully pulled over the collar Fig 54 Shock Absorber Shaft Nut SHOCK ABSORBER SOCKET SNAP ON A136 CROW FOOT Fig 55...

Page 86: ... absorber 16 Remove the upper bushing and sleeve from the shock absorber mount Fig 63 17 Remove the lower bushing from the rear shock absorber mount Fig 64 18 Inspect the rear shock absorber mount upper and lower bushings and upper and lower spring iso lators for the following Mount for cracks and distortion and locating studs for any sign of damage Severe deterioration of the upper or lower coil ...

Page 87: ...shock absorber 7 Install the washer on rod of shock absorber assembly and on top of dust shield Fig 58 8 Install the isolator on the top of the coil spring Isolator must be installed with the two half circle for mations in the isolator facing up Fig 57 9 Install the shock absorber mounting bracket and isolators as an assembly on the rod of the shock absorber assembly Fig 56 10 Install the top wash...

Page 88: ... Stabilizer Bar Isolator Bushing Retainer Bolt 28 N m 20 ft lbs To Lateral Link Attaching Link Nut 35 N m 26 ft lbs Bracket To Crossmember Bolts 28 N m 20 ft lbs Trailing Link Shaft Nuts Front And Rear 99 N m 73 ft lbs Bracket To Body Mounting Bolts 34 N m 25 ft lbs Lateral Links To Knuckle Nuts 108 N m 80 ft lbs Jam Nuts 65 N m 48 ft lbs To Suspension Crossmember Nuts 108 N m 80 ft lbs Hub And Be...

Page 89: ...oints are true constant velocity C V joint assemblies The inner tripod joint allows for the changes in driveshaft length through the jounce and rebound travel of the front suspen sion On vehicles equipped with ABS brakes the outer C V joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation The inner tripod joint of both driveshafts is splined into the transaxle ...

Page 90: ...to prevent foreign contaminants from entering the C V joint Mishandling such as allowing the assemblies to dangle unsupported or pulling or pushing the ends can cut boots or dam age C V joints During removal and installation pro cedures always support both ends of the driveshaft to prevent damage DIAGNOSIS AND TESTING DRIVESHAFT DIAGNOSIS VEHICLE INSPECTION 1 Check for grease in the vicinity of th...

Page 91: ...icle is to be supported or moved on its wheels with a driveshaft removed install a PROPER SIZED BOLT AND NUT through front hub Tighten bolt and nut to 244 N m 180 ft lbs This will ensure that the hub bearing cannot loosen 1 Remove cotter pin nut lock and spring washer from the end of the outer C V joint stub axle Fig 2 2 Loosen but do not remove stub axle to hub bearing retaining nut Loosen hub nu...

Page 92: ...BRAKE SHOE STEERING KNUCKLE LIFT THIS END OF CALIPER AWAY FROM STEERING KNUCKLE FIRST Fig 6 Correctly Supported Brake Caliper ABS SPEED SEN SOR CABLE STEERING KNUCKLE ROTOR UPPER CONTROL ARM DISC BRAKE CALI PER ASSEMBLY WIRE HANGER Fig 7 Removing Tie Rod End Attaching Nut TIE ROD END HEAT SHIELD STEERING KNUCKLE TIE ROD END STUD NUT Fig 8 Tie Rod End Removal from Steering Knuckle Fig 9 Wheel Speed...

Page 93: ...haft must be supported 14 Pull steering knuckle assembly out and away from outer C V joint of the driveshaft assembly Fig 12 CAUTION When inserting pry bar between inner tripod joint and transaxle case care must be used to ensure no damage occurs to oil seal in transaxle case 15 Support the outer end of the driveshaft assembly Insert a pry bar between inner tripod joint and transaxle case Fig 13 P...

Page 94: ...de gear tripod joint will not be removable by hand 4 Clean all debris and moisture out of steering knuckle in the area were outer C V joint will be installed into steering knuckle 5 Ensure that front of outer C V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C V joint into hub and bearing assembly Fig 15 6 Slide driveshaft back into...

Page 95: ...UTING BRACKET STEERING KNUCKLE ATTACHINGBOLT BRAKE CALIPER FLEX HOSE Fig 19 Installing Tie Rod End Nut TIE ROD END HEAT SHIELD STEERING KNUCKLE TIE ROD END STUD NUT Fig 20 Torquing Tie Rod End Nut HEAT SHIELD TIE ROD END STEERING KNUCKLE TORQUE WRENCH 11 32 SOCKET CROWFOOT Fig 21 Disc Brake Caliper Assembly Installation ROTOR DISC BRAKE CALI PER ASSEMBLY OUTBOARD BRAKE SHOE STEERING KNUCKLE LIFT T...

Page 96: ... uses a new design for retaining the cross to the interconnecting shaft These driveshafts incorpo rate a slight twist helical in the spline on the inter connecting shaft where the cross is installed This twist causes a interference fit between the intercon necting shaft and the cross when the outer C V joint is installed on the interconnecting shaft This design eliminates the clearance between the...

Page 97: ...mp which retains inner tripod joint sealing boot to tripod joint housing and discard Remove small clamp which retains inner tri pod joint sealing boot to interconnecting shaft and discard Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft CAUTION When removing the tripod joint housing from the spider assembly hold the bearings in place on the spider trunion...

Page 98: ...ng the spider body with a brass drift Fig 32 Do not hit the outer tripod bear ings in an attempt to install spider assembly on interconnecting shaft 3 Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of inter connecting shaft Fig 33 Be sure the snap ring is fully seated into groove on interconnecting shaft 4 Distribute 1 2 the amount of grease provided in...

Page 99: ...ipod joint assembly Fig 37 When inserting trim stick between tri pod housing and sealing boot ensure trim stick is held flat and firmly against the tripod hous ing If this is not done damage to the sealing boot can occur If inner tripod joint has a Hytrel hard plastic sealing boot be sure trim stick is inserted between soft rubber insert and tripod hous ing not the hard plastic sealing boot and so...

Page 100: ...amp locking tool Snap On YA3050 or an equiva lent Place prongs of clamp locking tool in the holes of the clamp Fig 40 Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp Fig 41 1 Install the driveshaft back on the vehicle See Servicing Driveshaft for the required driveshaft installation procedure OUTER C V JOINT SEALING BOOT SERVICE CAUTION The outer...

Page 101: ...ft assemblies must be removed from the vehicle See Servicing Driveshaft for the required driveshaft removal and replacement proce dure BEARING SHIELD REMOVAL FROM OUTER C V JOINT 1 Clamp driveshaft in a vise by the interconnect ing shaft 2 Using a drift Fig 42 tap around the entire edge of the bearing shield until it is removed from the outer C V Joint BEARING SHIELD INSTALLATION ON OUTER C V JOIN...

Page 102: ...tud Nut 95 N m 70 ft lbs Tie Rod End To Knuckle 61 N m 45 ft lbs SPECIAL TOOLS DRIVESHAFT SPECIAL TOOLS Fig 44 Correctly Installed Bearing Shield HAMMER SPECIAL TOOL C 4698 2 BEARING SHIELD BEARING SEAL MUST BE FLUSH WITH FRONT OF OUTER C V JOINT SPECIAL TOOL C 4698 1 Tie Rod Remover MB 990635 Bearing Shield Installer C 4698 Boot Clamp Installer C 4975A 3 14 DIFFERENTIAL AND DRIVELINE JX ...

Page 103: ...signated ABX 4 and is sup plied by Bendix This system shares the base brake hardware as vehicles not equipped with ABS The ABS system does however use a different master cyl inder and chassis brake tube assembly Also included in the ABS system is a hydraulic control unit HCU four wheel speed sensors and an electronic controller CAB These components will be described in detail in the Bendix ABX 4 b...

Page 104: ...LUID RESERVOIR 52 FRONT AND REAR DISC BRAKE CALIPER 53 WHEEL CYLINDER REAR DRUM BRAKE 58 CLEANING AND INSPECTION CHASSIS TUBES AND HOSES 59 FRONT DISC BRAKE COMPONENT INSPECTION 58 REAR DRUM BRAKE WHEEL CYLINDER 59 REAR DRUM BRAKES 59 REAR WHEEL HUB AND BEARING ASSEMBLY 60 ADJUSTMENTS PARKING BRAKES 61 REAR DRUM BRAKE SHOE ADJUSTMENT 60 STOP LAMP SWITCH 60 SPECIFICATIONS BRAKE ACTUATING SYSTEM 61 ...

Page 105: ...groove in the piston Fig 4 This prevents contamination in the bore area Fig 2 Front Disc Brake Caliper Exploded View CALIPER GUIDE PIN BOLT SLEEVE BUSHING CALIPER PISTON SEAL DUST SEAL PISTON OUTBOARD BRAKE SHOE WEAR INDICATOR INBOARD BRAKE SHOE BUSHING SLEEVE CALIPER GUIDE PIN BOLT CAP BLEEDER SCREW Fig 1 Front Disc Brake Components BRAKE PADS AND LININGS BRAKE ROTOR DRIVING HUB CALIPER ASSEMBLY ...

Page 106: ...h is connected to a flexible steel cable There is an individual park brake cable for each rear wheel which are joined using a park cable equalizer before terminating at the floor mounted hand operated park brake lever PROPORTIONING VALVES This vehicle uses in line proportioning valves The proportioning valves are located in the rear brake tubes on vehicles not equipped with Antilock Brakes Fig 7 o...

Page 107: ...ipped with ABS brakes the master cylinder is a two outlet design On vehicles not equipped with ABS brakes the master cylinder is a 4 outlet design All vehicles are equipped with a mas ter cylinder having a bore diameter of 22 2 mm The master cylinder assembly Fig 11 consists of the following components The body of the master cylinder is an anodized aluminum casting It has a machined bore to accept...

Page 108: ...gm Engine vacuum is always present on the other side This difference in pressure forces the out put rod of the vacuum booster Fig 15 out against the primary piston of the master cylinder As the pis tons in the master cylinder move forward this creates the hydraulic pressure in the brake system Different systems and engine combinations require different vacuum hose routings The vacuum booster assem...

Page 109: ...m should be checked for evidence of a leak STOP LAMP SWITCH The stop lamp switch controls operation of the vehicles stop lamps Also if the vehicle is equipped with speed control the stop lamp switch will deacti vate speed control when the brake pedal is depressed The stop lamp switch controls operation of the right and left tail stop and turn signal lamp and CHMSL lamp by supplying battery current...

Page 110: ...p Light On Without Brakes 3 All Brakes Drag 5 Rear Brakes Drag 2 NO NO Grabby Brakes O X Spongy Brake Pedal X NO Premature Rear Brake Lockup 4 NO NO O Excessive Pedal Effort 1 O Rough Engine Idle NO O Brake Chatter Rough NO NO X Surge During Braking NO NO X Noise During Braking NO NO X Rattle Or Clunking Noise NO NO X Pedal Pulsates During Braking NO NO X Pull To Right Or Left NO NO X No Not A Pos...

Page 111: ...ND RELEASE TURN FRONT WHEEL BY HAND OPEN BLEEDER SCREW AND TURN WHEEL AGAIN IF WHEEL TURNS HYDRAULIC PRESSURE WAS TRAPPED IN SYSTEM YES NO LOW ENGINE VACUUM SEE 6 CONTAMINATED FLUID SEALS SWOLLEN BINDING CALIPER PINS OR BUSHINGS REPLACE BUSH INGS BLOCKED OR PINCHED LINE OR HOSE OR BOOSTER VACUUM HOSE LINING TRANSFER ON FRONT ROTOR GLAZED LINING SAND ROTOR REPLACE LINING MASTER CYLINDER NOT RELEASI...

Page 112: ... FLUID LEVEL SWITCH AND MASTER CYLINDER FLOAT FOR PROPER OPERATION FLUID LEVEL LOW CHECK ENTIRE SYSTEM FOR LEAKS REPAIR OR REPLACE AS REQUIRED LIGHT OFF CHECK WARNING LIGHT CIRCUIT APPLY PARKING BRAKE IGNITION IN RUN POSITION WARNING LIGHT ON OK PARKING BRAKE RELEASED LIGHT OFF CHECK WIRE CONNECTED TO WARNING SWITCH IN ENGINE COMPARTMENT WARNING LIGHT OFF NOT OK CHECK AND REPAIR ELEC TRICAL CIRCUI...

Page 113: ...THAN 1 0 INCH Hg IN ONE MINUTE YES NO LEAK TEST BRAKES APPLIED BOOSTER IS DEFECTIVE AND SHOULD BE REPLACED NO YES APPLY LIGHT EFFORT APPROXIMATELY 15 POUNDS OF PEDAL FORCE TO THE BRAKE PEDAL AND HOLD STEADY IN THIS POSITION DO NOT MOVE THE PEDAL FROM THIS POSITION AS IT WILL AFFECT THE LEAKAGE READING IF VACUUM SUPPLY IS BELOW 12 INCHES REPLACE OR REPAIR VACUUM HOSE AND VACUUM FITTINGS ALSO TUNE O...

Page 114: ...ES PADS PINCHED LINES LEAKING SEALS PLUGGED BANJO BOLT REFER TO GROUP 2 SUS PENSION EXCESSIVE PEDAL TRAVEL DEFECTIVE AUTOMATIC ADJUSTER CHECK AIR IN BRAKE HYDRAULIC SYSTEM BLEED BRAKE HYDRAULIC SYSTEM LEAK IN BRAKE HYDRAULIC SYSTEM LOOK FOR WET AREAS AND REPAIR MASTER CYLINDER INTERNAL LEAK REPLACE MASTER CYLINDER EXCESSIVE PEDAL EFFORT INSPECT FRONT AND REAR BRAKES FOR FROZEN PIS TONS CONTAMINATE...

Page 115: ...kes are applied Excessive wear and scoring of the rotor can cause temporary improper lining contact if ridges are not removed before installation of new brake pad assem blies Some discoloration or wear of the rotor surface is normal and does not require resurfacing when lin ings are replaced Excessive runout or wobble in a rotor can increase pedal travel due to piston knock back This will increase...

Page 116: ...e as possible from each side of rotor Remove equal amounts from each side of rotor Do not reduce thick ness below minimum thickness cast into the un ma chined surface of the rotor Thickness variation measurements of rotor should be made in conjunction with runout Measure thick ness of rotor at 12 equal points with a micrometer at a radius approximately 25 mm 1 inch from edge of rotor Fig 23 If thi...

Page 117: ...essure Fittings Special Tool 6805 Fig 24 which are to be used for testing the proportioning valves These same pressure fittings are used if the proportioning valves are either mounted in the HCU on an antilock equipped vehi cle or in line on the brake tube on non antilock equipped vehicles The pressure gauges used with the pressure test fittings for testing the in line proportioning valves on both...

Page 118: ...ressure reading on the pro portioning valve outlet gauge If proportioning valve outlet pressure does not agree with value shown on the following chart when inlet pressure shown on chart is obtained replace the proportioning valve If proportioning valve is within pressure specifications do not replace proportioning valve 10 Check rear wheel brake shoe linings for con tamination or for replacement b...

Page 119: ...e following chart Then check the pressure reading on the pro portioning valve outlet gauge If proportioning valve outlet pressure does not agree with value shown on the following chart when inlet pressure shown on chart is obtained replace the proportioning valve If proportioning valve is within pressure specifications do not replace proportioning valve 10 Check rear wheel brake shoe linings for c...

Page 120: ...ULL AND MIN indicating proper range of the master cylinder fluid level Fig 28 CAUTION Use only MoparT brake fluid or an equivalent from a tightly sealed container Brake fluid must conform to DOT 3 specifications Do not use petroleum based fluid because seal damage in the brake system will result If necessary add specified brake fluid bringing level to the FULL mark on the side of the master cylind...

Page 121: ...h a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose Fig 30 2 Pump the brake pedal three or four times and hold it down before the bleeder screw is opened 3 Open the bleeder screw at least 1 full turn When the bleeder screw opens the brake pedal will drop 4 Close the bleed...

Page 122: ...booster BRAKE ROTOR MACHINING DISC BRAKE ROTOR TURNING PROCEDURES Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action BRAKE ROTOR REFINISHING INFORMATION If the rotor surface is deeply scored or warped or there is a complaint of brake roughness or pulsation the rotor should be resurfaced or refaced Fig 35 or Fig 36 Fig 3...

Page 123: ...eration of rotor turning equipment is required The use of a double straddle cutter Fig 35 that machines both sides of the rotor at the same time is highly recommended RESURFACNG BRAKE ROTOR This operation can be used when rotor surface is rusty has lining deposits or excessive lateral runout or thickness variation is evident A sanding rotor attachment will remove surface contamination without remo...

Page 124: ...42 Open handles of Flaring Tool Special Tool C 4047 or equivalent Then rotate jaws of tool until the mating jaws of tubing size are centered between vertical posts on tool Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place Place gauge Form A on edge over end of brake tubing Push tubing through jaws until end of tubing conta...

Page 125: ... several times to insure the vehicle has a firm brake pedal REMOVE 1 Raise vehicle on jackstands or centered on a hoist See Hoisting in the Lubrication and Mainte nance section of this manual 2 Remove front wheel and tire assemblies from vehicle 3 Remove the 2 caliper to steering knuckle guide pin bolts Fig 44 4 Remove brake caliper from steering knuckle by first rotating bottom end of caliper awa...

Page 126: ...ops to wear off any foreign material on the brakes and to seat the brake pads FRONT BRAKE SHOES WARNING ALTHOUGH FACTORY INSTALLED BRAKELININGS ARE MADE FROM ASBESTOS FREE MATERIALS SOME AFTER MARKET BRAKE LINING MAY CONTAIN ASBESTOS THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE S BRAKE SYSTEM WHEN AFTER MAR KET BRAKELININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE ALWAYS WEAR A RESPIRA...

Page 127: ... pushing the brake shoe inward until retaining pins on brake shoe can be removed from holes in caliper Fig 51 Then slide the brake shoe off the caliper 9 Pull inboard brake shoe away from piston until retaining clip is free from cavity in piston Fig 52 CALIPER INSPECTION Check caliper for piston seal leaks brake fluid in and around boot area and inboard lining and for any ruptures of the piston du...

Page 128: ...ar sensor Fig 53 and the hold down clip must be on the upper end of the caliper when the caliper and brake shoes are installed on the steering knuckle 5 Install the new inboard brake shoe assembly into the caliper piston by firmly pressing into piston bore Fig 54 Be sure inboard brake shoe assembly is positioned squarely against face of caliper piston 6 Slide the new outboard brake shoe assembly o...

Page 129: ...e a ridge worn in them by the brake shoes This ridge causes the brake drum to interfere with the brake shoes thus not allowing the brake drum to be removed Further clearance can be obtained by backing off the brakes automatic self adjuster mech anism using the following procedure 1 Remove the rubber plug Fig 56 from the brake support plate 2 Insert a screwdriver through the automatic adjuster acce...

Page 130: ...d on a hoist See Hoisting in the Lubrication and Mainte nance section of this manual 2 Remove the rear wheel and tire assemblies from the vehicle 3 Remove rear brake drum to hub retaining clips if equipped Then remove rear brake drum from hub and bearing assembly Fig 59 4 Remove the automatic adjuster lever actuating spring from the leading brake shoe Fig 60 Then remove the automatic adjuster actu...

Page 131: ...of brake shoes Check to see if shoes are bent Brake shoe lining should show contact across its entire width and from the heel to the toe of the lin ing otherwise replace Fig 63 Hold Down Spring And Pin BRAKE SUPPORT PLATE LEADING BRAKE SHOE ATTACHING PIN HOLD DOWN SPRING Fig 64 Automatic Adjuster AUTOMATIC ADJUSTER BRAKE SUPPORT PLATE PARK BRAKE ACTUATING LEVER TRAILING BRAKE SHOE Fig 65 Park Brak...

Page 132: ... 71 6 Install the automatic adjuster on the trailing brake shoe and park brake actuating lever Fig 64 7 Install the leading brake shoe on the brake support plate Then install the attaching pin and hold down spring for the leading brake shoe Fig 63 8 Install the brake shoe lower return spring Fig 62 9 Install the upper return spring on the brake shoes Fig 61 10 Install the automatic adjuster actuat...

Page 133: ...ocedure 6 Disconnect rear brake flex hose tube from wheel cylinder and remove the brake flex hose bracket from the brake support plate Fig 74 7 Position a 1 2 wrench over the retainer fingers on the end of the parking brake cable Fig 75 Com press cable housing retaining fingers and start cable housing out of support plate Fig 75 Remove wrench when retainer is free from the park brake cable mountin...

Page 134: ...u ally check the boots for cuts tears or heat cracks If any of these conditions exist the wheel cylinders should be completely cleaned inspected and new parts installed 1 In case of a leak remove brake shoes replace if soaked with grease or brake fluid 2 Disconnect rear brake flex hose tube from wheel cylinder and remove the flex hose routing bracket from the brake support plate Fig 76 3 Remove re...

Page 135: ...ining nut to a torque of 250 N m 185 ft lbs 2 Install hub bearing assembly dust cap Fig 79 using a soft faced hammer 3 Install the rear brake drum Fig 78 on the hub bearing assembly 4 Install rear wheel and tire assembly on vehicle Tighten all wheel stud nuts in criss cross pattern to one half the specified torque Then repeat pattern fully tightening the stud nuts to a torque of 129 N m 95 ft lbs ...

Page 136: ...2 Fill brake fluid reservoir with brake fluid con forming to DOT 3 specifications such as Mopar or an Equivalent 3 Insert an appropriate size wooden dowel in the end of the master cylinder piston Fig 87 Using the dowel slowly depress the piston to the full extent of its travel and then allow the piston to return to its released position Continue to repeat this step until bubbles no longer appear i...

Page 137: ... Install the 2 master cylinder to power brake vacuum booster mounting nuts Fig 84 Tighten both nuts to a torque of 28 N m 250 in lbs 4 Connect brake tubes to master cylinder pri mary and secondary ports Fig 82 Then tighten the tube nuts to a torque of 17 N m 145 in lbs 5 Install the connector from the vehicle wiring harness on the fluid level sensor in the master cylin der fluid reservoir Fig 81 V...

Page 138: ...y and vacuum hoses Fig 94 from the EGR valve Valve removal is necessary for required clearance to remove power brake vacuum booster from vehi cle and not damage transducer during removal Fig 90 Speed Control Servo Attachment MOUNTING BRACKET ATTACHING NUTS LEFT STRUT TOWER SPEED CONTROL SERVO MASTER CYLINDER ASSEMBLY Fig 91 Purge Control Solenoid MASTER CYLIN DER LEFT STRUT TOWER PURGE SOLE NOID E...

Page 139: ... of brake pedal pin Then pull retaining clip off brake pedal pin Discard retaining clip Replace only with a new retaining clip when assembled 13 Remove the 4 nuts attaching the vacuum booster to the dash panel Nuts are accessible from under dash panel in area of the steering column and pedal bracket assembly Fig 99 14 Slide vacuum booster forward until mounting studs clear dash panel and then tilt...

Page 140: ...nt frame rail Tighten the purge control solenoid mounting bolt 10 Install the EGR transducer assembly on the EGR valve Fig 94 Install the vehicle wiring harness connector Fig 94 on the EGR transducer ensuring the retaining clip is fully engaged with transducer 11 Connect all previously removed vacuum hoses onto the power brake vacuum booster check valve Fig 93 12 If equipped install speed control ...

Page 141: ...ition Sensor Fig 104 on the throttle body Then remove the 4 bolts Fig 104 attaching the throttle body to the intake manifold and remove it from intake manifold 5 Without removing cables from bracket remove the throttle and speed control cable mounting bracket Fig 104 from the intake manifold 6 Remove the EGR tube Fig 105 from the intake manifold and EGR valve Fig 102 Correctly Isolated Remote Grou...

Page 142: ...removing the routing clip and brake tubes from the mounting stud do not bend or kink the chassis brake line tubes Fig 106 Speed Control Servo Attachment To Strut Tower STRUT TOWER AIR CLEANER SPEED CONTROL SERVO MOUNTING NUTS Fig 107 Master Cylinder Brake Fluid Level Sensor LEFT SHOCK TOWER MASTER CYLINDER FLUID LEVEL SENSOR BRAKE TUBES MASTER CYLINDER ASSEMBLY Fig 108 Primary And Secondary Brake ...

Page 143: ... ter tang on the power brake booster input rod to brake pedal pin retaining clip Fig 113 Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin Then pull retaining clip off brake pedal pin Discard retain ing clip Replace only with a new retaining clip when assembled 18 Remove the 4 nuts attaching the vacuum booster to the dash panel Nuts are accessible fr...

Page 144: ...r cylinder Tighten the tube nuts to a torque of 17 N m 145 in lbs 12 Install the vehicle s wiring harness connector on the master cylinder brake fluid level sensor Fig 107 13 If equipped install speed control servo on the mounting studs in the left strut tower Fig 106 Install the 2 speed control servo bracket mounting nuts Fig 106 Tighten the 2 mounting nuts to a torque of 6 N m 55 in lbs Install ...

Page 145: ...al pin Fig 119 Then pull retaining clip off brake pedal pin 5 Remove the nut from the brake pedal pivot pin 6 Remove bake pedal pivot pin from the brake pedal and pedal mounting bracket 7 Remove brake pedal from mounting bracket INSTALL 1 Lubricate the brake pedal pivot pin and brake pedal bushings using Mopar Lubriplate or an equiv alent 2 Install the brake pedal in the pedal bracket Align the pi...

Page 146: ...Banjo Bolts and tighten all fittings to their specified torques The flexible front hydraulic brake hose should always be installed on the vehicle by first attaching the Banjo connector to the disc brake caliper After routing the flex hose around the strut hand start the chassis brake tube nut into the end of the flex hose Following this procedure will prevent twisting of the flex hose when the fle...

Page 147: ...CHANISM BEFORE REMOVING PARK BRAKE CABLES FROM EQUALIZER COULD RESULT IN SERIOUS INJURY 9 Reload the adjuster mechanism on the park brake lever using the following procedure Ensure the park brake lever is in the full down position when attempting to pull on park brake lever output cable Fig 125 Grasp the park brake lever output cable Fig 125 by hand and pull upward Continue to pull upward on cable...

Page 148: ...down on the end of the clutch spring where shown Fig 126 While the end of the clutch spring is held down pull outward on park brake mechanism output cable If output cable can not be pulled out of park brake mechanism by pulling directly on output cable use a screwdriver inserted in tension equal izer Fig 126 to assist in pulling on cable 11 Disconnect the wiring harness from the ground switch on t...

Page 149: ...ig 125 Remove the drill bit from the adjuster mecha nism of the park brake lever Fig 125 Slowly release the park brake lever output cable until all slack is removed from the cable 4 Clip the wiring harness to the park brake lever bracket 5 Install the wiring harness connector on the ground switch of the park brake lever Fig 128 6 Cycle the park brake lever once from the released position to the fu...

Page 150: ...ise the rear of the center console high enough to access the center console wiring harness connector Fig 134 Disconnect the center console wiring harness connector from the vehicle wiring harness 10 way connector Fig 134 7 Remove the center console from the vehicle 8 Lower the park brake lever to its fully released position WARNING THE AUTO ADJUSTING FEATURE OF THIS PARK BRAKE LEVER CONTAINS A CLO...

Page 151: ...hown Fig 136 While end of clutch spring is held down pull out ward on park brake mechanism output cable If output cable can not be pulled out of park brake mechanism by pulling directly on output cable use a screwdriver inserted in tension equal izer Fig 136 to assist in pulling on cable 10 Remove both rear wheel park brake cables from the park brake cable tension equalizer Fig 137 Fig 134 Console...

Page 152: ...e the 2 clips attaching the carpeting to the cross car beam 16 Fold rear carpeting forward to expose park brake cables 17 Remove the routing clip Fig 138 attaching the rear park brake cables to the floor pan 18 Install the box end of a 1 2 in wrench over the park brake cable retainer as indicated in Fig 139 This will compress tabs on park brake cable retainer allowing cable to be removed from cons...

Page 153: ... 27 Raise vehicle 28 Remove the 2 routing brackets Fig 145 attaching the park brake cable to the vehicle frame rail Fig 141 Rear Hub Bearing Dust Cap HUB BEARING ASSEMBLY DUST CAP Fig 142 Hub Bearing Retaining Nut RETAINING NUT SPINDLE HUB BEARING ASSEMBLY Fig 143 Rear Park Brake Cable At Actuating Lever PARK BRAKE ACTUATING LEVER TRAILING BRAKE SHOE PARK BRAKE CABLE BRAKE SUPPORT PLATE Fig 144 Pa...

Page 154: ...ed into the floor pan 12 Route park brake cable under carpeting and up to park brake cable hole in console bracket on floor pan Then install park brake cable into console bracket Fig 147 Be sure tabs Fig 147 on park brake cable retainer have expanded out to hold park brake cable in console bracket 13 Install the routing bracket holding park brake cables to the floor pan of the vehicle Fig 138 WARN...

Page 155: ...nting bracket 3 Disconnect wiring harness connector from stop lamp switch INSTALL NOTE Prior to installing stop lamp switch into bracket the plunger must be moved to its fully extended position using procedure in Step 1 1 Hold stop lamp switch firmly in one hand Then using other hand pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position 2 Con...

Page 156: ...s connector from brake fluid reservoir level sensor Fig 150 2 Compress the retaining tabs Fig 151 on the end of the brake fluid level sensor 3 While compressing retaining tabs grasp oppo site end of brake fluid level sensor and pull it out of master cylinder fluid reservoir Fig 152 FRONT AND REAR DISC BRAKE CALIPER CLEANING AND INSPECTION Check for brake fluid leaks in and around dust boot area an...

Page 157: ... PIN BUSHINGS 1 Remove caliper from brake rotor See Brake Shoe Removal Hang caliper assembly on a wire hook away from the brake rotor 2 Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown in Fig 153 3 Using your fingers collapse one side of the bushing Then pull on the opposite side to remove the bushing from the brake caliper housing Fig 154 INSTALLI...

Page 158: ...eeve and into the seal grove on sleeve Fig 159 Be sure other end of bushing did not come out of seal grove in sleeve 8 When the sleeve is seated properly into the bushing the sealed for life sleeve bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove CALIPER DISASSEMBLY WARNING UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE US...

Page 159: ...scard Fig 160 8 Using a soft tool such as a plastic trim stick work piston seal out of its groove in caliper piston bore Fig 161 Discard old seal Do not use a screw driver or other metal tool for this opera tion because of the possibility of scratching piston bore or burring edges of seal groove 9 Clean all parts using alcohol or a suitable sol vent and wipe dry using only a lint free cloth No lin...

Page 160: ...R ASSEMBLY CAUTION Excessive vise pressure will cause bore distortion and binding of piston 1 Clamp caliper in a vise with protective caps installed on jaws of vise 2 Dip new piston seal in clean brake fluid and install in the groove of the caliper bore Seal should be positioned at one area in groove and gently worked around the groove Fig 163 using only your fingers until properly seated NEVER US...

Page 161: ...as lint from the rag will stick to bore sur faces 4 Wheel cylinder bores and pistons that are badly scored or pitted should be replaced Cylinder walls that have light scratches or show signs of cor rosion can usually be cleaned with crocus cloth using a circular motion Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder ASSEMBLE Before assembling ...

Page 162: ...shoes Check to see if shoes are bent Lining should show contact across entire width and from heel to toe otherwise replace Shoes with lack of contact at toe or heel may be improperly ground Clean and inspect the brake support plate and the automatic self adjusting mechanism Visually examine the adjuster assembly to ensure it is functioning correctly by checking for the follow ing operation Be sure...

Page 163: ...If the rear wheel bear ings exhibit these conditions during inspection the hub and bearing assembly should be replaced Damaged bearing seals and resulting excessive grease loss may also require bearing replacement Moderate grease loss from bearing is considered nor mal and should not require replacement of the hub and bearing assembly ADJUSTMENTS STOP LAMP SWITCH 1 Remove stop lamp switch from its...

Page 164: ...ed This will correctly adjust the tension of the park brake cables 8 Install the rubber plugs into the adjuster access holes in the brake support plates Fig 169 PARKING BRAKES Due to the automatic adjustment feature of the parking brake system used on this vehicle manual adjustment of the parking brakes is not required Proper adjustment of the parking brakes on this vehicle relies on the proper ad...

Page 165: ...o 3 32 BRAKE FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE BRAKE TUBES Tube Nuts To Fittings And Components 20 N m 180 in lbs BRAKE HOSE Front Caliper Banjo Bolt 48 N m 35 ft lbs Rear Intermediate Bracket 11 N m 100 in lbs Front And Rear Brackets To Frame Rails 10 N m 95 in lbs MASTER CYLINDER To Vacuum Booster Mounting Nut 28 N m 250 in lbs BRAKE BOOSTER To Dash Panel Mounting Nuts 37 N m 27 ...

Page 166: ...CIAL TOOLS BASE BRAKE SYSTEM Adapters Brake Pressure Test 6805 Gauge Set C 4007 A Handle Universal C 4171 Installer Dust Boot C 4689 Dial Indicator C 3339 Tubes Master Cylinder Bleeding 6802 5 64 BRAKES JX ...

Page 167: ...EEL SPEED SENSOR 80 GENERAL SERVICE CAUTIONS 74 HYDRAULIC CONTROL UNIT RELAY BOX 78 HYDRAULIC SYSTEM PROPORTIONING VALVES 78 MASTER CYLINDER AND POWER BRAKE BOOSTER 78 REAR WHEEL SPEED SENSORS 82 SPECIFICATIONS BRAKE FASTENER TORQUE SPECIFICATIONS 83 SPEED SENSOR TONE WHEEL RUNOUT 83 WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE 83 DESCRIPTION AND OPERATION ANTILOCK BRAKES OPERATION DESCRIPTION The p...

Page 168: ...when the tires ride on a film of water This results in the vehicles tires leaving the road surface rendering the vehicle virtually uncontrollable In addition extreme steering maneuvers at high speed or high speed cor nering beyond the limits of tire adhesion to the road surface may cause vehicle skidding independent of vehicle braking For this reason the ABS system is termed Antilock instead of An...

Page 169: ...hen the pressure equal izes the spring loaded Shuttle Orifice valves will return to the unrestricted position HYDRAULIC CONTROL UNIT FLUID SUMPS There are two fluid sumps in the hydraulic control unit HCU one each for the primary and secondary hydraulic circuits The fluid sumps temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle This fluid is then delivered to t...

Page 170: ...ning valve being replaced WHEEL SPEED SENSORS One Wheel Speed Sensor WSS is located at each wheel Fig 4 and Fig 5 and sends a small AC sig nal to the control module CAB This signal is gener ated by magnetic induction created when a toothed sensor ring tone wheel Fig 4 and Fig 5 passes the stationary magnetic wheel speed sensor The CAB converts the AC signal generated at each wheel into a digital s...

Page 171: ...Warning Lamp and disable the ABS braking system The normal Non ABS braking system will remain operational The CAB contains a self diagnostic program which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected Faults are then stored in a diagnostic program memory There are multiple fault messages which may be stored in the CAB and displayed through the DRB scan tool These faul...

Page 172: ...is service manual This includes brake noise brake pulsation lack of power assist parking brake Red Brake Warning Lamp lighting or vehicle vibration during normal braking Many conditions that generate customer com plaints may be normal operating conditions but are judged to be a problem due to not being familiar with the ABS system These conditions can be recognized without performing extensive dia...

Page 173: ...nnector halves or terminals not fully seated in the connector body 2 Improperly formed or damaged terminals All connector terminals in a suspect circuit should be carefully reformed to increase contact tension 3 Poor terminal to wire connection This requires removing the terminal from the connector body to inspect 4 Pin presence in the connector assembly 5 Proper ground connections Check all groun...

Page 174: ...ve caliper seals wheel cylinder seals Antilock Brakes hydraulic unit and all hydraulic fluid hoses VEHICLE TEST DRIVE INFORMATION AND PROCEDURE Most ABS complaints will require a test drive as a part of the diagnostic procedure The purpose of the test drive is to duplicate the condition NOTE Remember conditions that result in the turning on of the Red BRAKE Warning Lamp may indicate reduced brakin...

Page 175: ...ke bleeding only the base brake system needs to be bled It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal During bleeding operations be sure that the brake fluid level remains close to the FULL level in the res ervoir Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required The Allied Signal ...

Page 176: ...ended to be serviced individually Attempting to remove or disconnect certain system components may result in improper system opera tion Only those components with approved removal and installation procedures in this manual should be serviced CAUTION Brake fluid will damage painted sur faces If brake fluid is spilled on any painted sur faces wash off with water immediately The following are general...

Page 177: ...3 Remove all exhaust system support isolators from the vehicle s exhaust system Fig 14 Remove support isolators from brackets on exhaust system components and leave attached to body of vehicle Lower exhaust system as a complete assembly away from the underbody of the vehicle Fig 14 Exhaust System Support Isolator Locations REAR MUFFLER SUPPORT ISOLATORS FRONT MUFFLER SUPPORT ISOLATOR RESONATOR SUP...

Page 178: ... the pro portioning valves and the right front brake tube from the outlet port of the HCU Fig 19 Fig 15 Right Side Splash Shield SPLASH SHIELD Fig 16 HCU Heat Shield EXHAUST PIPE ATTACHING BOLT HCU HEAT SHIELD STEERING GEAR FRONT SUSPENSION CROSSMEMBER HCU MOUNTING BRACKET DRIVESHAFT Fig 17 Electrical Connections At HCU And Relay Box BRAKE TUBE RELAY BOX 6 WAY PUMP MO TOR CONNECTOR 10 WAY RELAY BO...

Page 179: ... tube nuts to a torque of 20 N m 180 in lbs Install the brake tube routing clip Fig 18 on the HCU mount ing bracket and securely tighten attaching bolt 7 Install the 6 way connector on the HCU wiring harness and the 10 way connector on the relay box of the HCU Fig 17 8 Install the HCU heat shield Fig 16 on the HCU mounting bracket Install and securely tighten attaching bolt 9 Install exhaust syste...

Page 180: ... the HCU requires removal from the vehicle This is to allow visual access of the relay box to HCU electrical con nection Visual access to this connection is necessary to be sure connection is correctly made when install ing the relay box on the HCU REMOVE 1 Disconnect negative ground cable from the battery and isolate the cable 2 Remove the HCU from the vehicle See Hydraulic Control Unit in the Re...

Page 181: ...r bleeding procedure 8 Road test vehicle to ensure proper operation of the base and ABS systems CONTROLLER ANTILOCK BRAKES CAB The CAB is located in the right front corner of the engine compartment Fig 28 It is mounted to the vehicle using an integral mounting bracket which is attached by 2 bolts to the inner fender and the front crossmember REMOVE 1 Turn vehicle ignition off 2 Disconnect the wiri...

Page 182: ... the vehicle 3 Remove the speed sensor cable routing bracket Fig 31 from the steering knuckle Remove the wir ing harness sealing grommet retainer and speed sen sor routing bracket from the inner fender 4 Remove speed sensor sealing grommet from the inner fender Fig 32 Then unplug the speed sensor cable from the vehicle wiring harness Fig 32 5 Remove bolt Fig 33 attaching the speed sen sor head to ...

Page 183: ...ly grom met into the front inner fender Fig 31 Install speed sensor cable grommet retainer routing bracket on the inner fender of the vehicle and install and securely tighten attaching bolt Fig 31 CAUTION When installing the wheel speed sensor cable routing bracket on the steering knuckle Fig 31 the speed sensor cable must be looped toward the shock absorber as shown in Fig 35 If speed sensor cabl...

Page 184: ... 40 INSTALL CAUTION Proper installation of wheel speed sen sor cables is critical to continued system operation Be sure that cables are installed in retainers Fail ure to install cables in retainers as shown in this section may result in contact with moving parts and or over extension of cables resulting in an open circuit 1 Install speed sensor head into brake support plate Fig 40 Fig 37 Rear Spe...

Page 185: ...r is 0 15 mm 006 in WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE FRONT WHEEL Minimum Clearance 35mm 014 in Maxamum Clearance 1 2 mm 047 in REAR WHEEL Minimum Clearance 40mm 016 in Maxamum Clearance 1 2 mm 047 in BRAKE FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE BRAKE TUBES Tube Nuts To Fittings And Components 20 N m 180 in lbs BRAKE HOSE Front Caliper Banjo Bolt 48 N m 35 ft lbs Rear Intermedi...

Page 186: ......

Page 187: ...RESSURE RELIEF CHECK 16 PRESSURE TESTING COOLING SYSTEM PRESSURE CAP 17 RADIATOR FAN CONTROL 15 TEMPERATURE GAUGE INDICATION 17 TESTING SYSTEM FOR LEAKS 16 WATER PUMP DIAGNOSIS 15 SERVICE PROCEDURES ADDING ADDITIONAL COOLANT 18 DRAINING COOLING SYSTEM 18 REFILLING COOLING SYSTEM 19 ROUTINE COOLANT LEVEL CHECK 18 SERVICING COOLANT LEVEL 18 REMOVAL AND INSTALLATION ACCESSORY DRIVE BELT 2 5L ENGINE 2...

Page 188: ...mance and emission levels under all expected driving conditions It also provides hot water cool ant for heater performance and cooling for automatic transmission oil It does this by transferring heat from engine metal to coolant moving this heated coolant to the radiator and then transferring this heat to the ambient air Coolant flow circuits for 2 4L engine equipped vehi cles are shown in Fig 1 T...

Page 189: ...COOLDOWN Fig 3 Engine Inlet Coolant Pipes 2 5L Engine O RING INLET PIPE GASKETS O RINGS HEATER TUBES COOLANT OUTLET COOLANT INLET ELBOW THERMO STAT GASKET THERMO STAT HOUS ING O RING Fig 4 Drive Belts All Engines POWER STEERING PUMP GENERATOR IDLER AIR CONDITIONING COMPRESSOR CRANKSHAFT DAMPER JX COOLING SYSTEM 7 3 GENERAL INFORMATION Continued ...

Page 190: ...There is a relief in the cylinder head for locating the air bleed The 2 5L engine thermostat is located in a thermo stat housing located below the throttle body This thermostat has an air bleed valve located in the thermostat flange Fig 7 WATER PUMP The water pump body is made of aluminum with a steel impeller The water pump is bolted to the front of the block and driven by the timing belt The wat...

Page 191: ...ent valve Fig 9 to ensure proper sealing when boiling point is reached There is a gasket in the cap that seals to the top of the filler neck so that vacuum is maintained to draw coolant back into the system from the coolant reserve system tank RADIATOR The radiators are cross flow types horizontal tubes with design features that provide greater strength as well as sufficient heat transfer capabili...

Page 192: ...tion and will freeze at 22 C 8 F 50 50 Ethylene Glycol and Distilled Water 82 btu is the recommended combination that provides a freeze point of 37 C 35 F The radiator water pump engine water jacket radiator pressure cap thermostat temperature gauge coolant sensor and heater are all designed for 50 50 ethylene glycol Where required a 56 percent glycol and 44 percent water mixture will provide a fr...

Page 193: ...f replacement is necessary replace with the original Mopar equipment spring type clamp ENGINE BLOCK HEATER The heater operated by ordinary house current 110 Volt A C through a power cord and connector behind the radiator grille provides easier engine starting and faster warm up when vehicle is operated in areas having extremely low temperatures The heater is mounted in a core hole in place of a co...

Page 194: ...ing system Fig 14 Engine Block Heater BLOCK HEATER LEFT REAR SIDE VIEW FWD 2 04L ENGINE 2 04L ENGINE RIGHT REAR SIDE VIEW BLOCK HEATER FWD 2 5L ENGINE LEFT REAR SIDE VIEW FWD Fig 15 Water Pump CYLINDER BLOCK PUMP BODY Fig 16 Water Pump and Inlet Tube WATER PUMP O RING INLET PIPE O RING GASKET 7 8 COOLING SYSTEM JX DESCRIPTION AND OPERATION Continued ...

Page 195: ...imbed vehicle being operated in slow moving traffic or engine idling during high ambient outside temperatures with air conditioning on High altitudes Could aggravate these conditions 1 This may be a temporary condition and repair is not necessary Turn off the air conditioning and drive the vehicle without any of the previous conditions Observe the temperature gauge the gauge should return to the n...

Page 196: ... at filler neck with some coolant removed engine warm and thermostat open Coolant should be observed flowing through filler neck If flow is not observed determine reason for lack of flow and repair as necessary 10 Radiator or A C condenser fins are dirty or clogged 10 Clean insects or debris 11 Radiator core is plugged or corroded 11 Replace or re core radiator 12 Fuel or ignition system problems ...

Page 197: ...ter a few minutes of engine operation 6 Coolant level low in radiator air will build up in the cooling system causing the thremostat to open late 6 Check and correct coolant leaks Refer to Testing Cooling System For Leaks in this group 7 Cylinder head gasket leaking allowing exhaust gas to enter cooling system causing thermostat to open late 7 a Check for cylinder head gasket leaks with a commerci...

Page 198: ...lly blocked or plugged Check for blockage and repair as necessary ELECTRIC RADIATOR FAN RUNS ALL THE TIME 1 Fan relay powertrain control module PCM or engine coolant temperature sensor defective 1 Refer to appropriate Powertrain Diagnostic Procedures manual for operation of the DRB scan tool Repair as necessary 2 Check for low coolant level 2 Repair as necessary ELECTRIC RADIATOR FAN WILL NOT RUN ...

Page 199: ... On Board Diagnostic in Group 25 and replace thermostat if necessary 2 Coolant level low 2 Refer to testing cooling system for leaks in this section Repair as necessary 3 Obstructions in heater hose fittings at engine 3 Remove heater hoses at both ends and check for obstructions Repair as necessary 4 Heater hose kinked 4 Locate kinked area and repair as necessary 5 Water pump is not pumping coolan...

Page 200: ...e thermostat using the DRB scan tool Replace thermostat if necessary STEAM IS COMING FROM FRONT OF VEHICLE NEAR 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 rad...

Page 201: ...ulating WARNING DO NOT REMOVE THE COOLING SYS TEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR 2 Remove pressure cap when engine is cold remove small amount of coolant Idle engine until thermostat opens you should observe coolant flow while looking down the filler neck Once flow is detected install the pressure cap RADIATOR FAN CONTROL The radiat...

Page 202: ...te a faulty head gasket cracked engine block or cylinder head There may be internal leaks which can be deter mined by removing the oil dip stick If water globules appear intermixed with the oil it will indicate a internal leak in the engine If there is an internal leak the engine must be disassembled for repair PRESSURE CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK The pressure cap upper gasket se...

Page 203: ... is faulty If the pressure cap tests properly while posi tioned the on radiator pressure tester but will not hold pressure or vacuum when positioned on the filler neck inspect the filler neck and cap top gas ket for irregularities that may prevent the cap from sealing properly LOW COOLANT LEVEL AERATION Low coolant level in a cross flow radiator will equalize in both tanks with engine off With eng...

Page 204: ... tank should drop slightly Then remove the radi ator cap The radiator should be full to the top If not and the coolant level in the CRS tank is at the ADD mark there is a air leak in the CRS system Check hose or hose connections to the CRS tank radiator filler neck or the pressure cap seal to the radiator filler neck for leaks DRAINING COOLING SYSTEM NOTE Drain flush and fill the cooling system at...

Page 205: ... reserve tank to maintain cool ant level between the FULL HOT and ADD mark after three or four warm up cool down cycles and trapped air has been removed REMOVAL AND INSTALLATION WATER PUMP 2 4L ENGINE REMOVAL 1 Raise vehicle on a hoist Remove right inner splash shield 2 Remove accessory drive belts and power steer ing pump Refer to Accessory Drive Belt service of this section 3 Drain cooling syste...

Page 206: ...er pipe press assembly to cause water pipe insertion into pump housing 4 Install pump to block mounting bolts and tighten to 27 N m 20 ft lbs 5 See Group 9 Engine and install timing belt Reassemble engine 6 Fill cooling system See Refilling Cooling Sys tem 7 Install accessory drive belts Refer to Accessory Drive Belts in this Group for procedure WATER PUMP INLET TUBE 2 4L REMOVAL 1 Drain cooling s...

Page 207: ...efill the cooling system to the proper level Refer to Refilling Cooling System outlined in this sec tion for procedure THERMOSTAT 2 5L REMOVAL 1 Drain cooling system to the thermostat level or below 2 Remove inlet hose and bolts from coolant elbow Remove elbow Fig 30 3 Remove thermostat assembly and clean sealing surfaces INSTALLATION 1 Install thermostat into the recess in the ther mostat housing...

Page 208: ...or can now be lifted free from engine compartment Care should be taken not to dam age radiator cooling fins or water tubes during removal INSTALLATION 1 Slide radiator and fan module down into posi tion seat the radiator assembly lower rubber isola tors in the mount holes provided 2 Attach air conditioning condenser to radiator if equipped Tighten mounting screws to 5 N m 45 in lbs 3 Connect engin...

Page 209: ...trength performance and safety 1 To remove fan from motor shaft bench support the motor and motor shaft while removing the fan retaining clip so that the shaft and motor will not be damaged by excessive force Surface burr removal may be required to remove fan from motor shaft Fig 34 Do not permit the fan blades to touch the bench 2 To install fan on motor shaft slide the fan over shaft Support mot...

Page 210: ...roper level vent air and inspect for leaks Pressurize sys tem with Radiator Pressure Tool before looking for leaks The power cord must be secured in its retainer clips and not positioned so it could contact linkages or exhaust manifolds and become damaged GENERATOR POWER STEERING PUMP AND AIR CONDITIONING COMPRESSOR DRIVE BELT 2 4L ENGINE AIR CONDITIONING COMPRESSOR AND GENERATOR BELT Fig 35 Engin...

Page 211: ...4 N m 40 ft lbs ACCESSORY DRIVE BELT 2 5L ENGINE AIR CONDITIONING BELT AND GENERATOR BELT To remove and install the air conditioning compres sor and generator drive belt first loosen the idler pulley lock bolt then turn the adjusting screw to increase or decrease the idler pulley tension Fig 38 To adjust the air conditioning and generator drive belt loosen the idler pulley bolt Fig 38 and adjust b...

Page 212: ...the shaft seal is leaking evi dent by traces of coolant leaks from vent hole A in Fig 41 Impeller rubs inside of pump Excessively loose or rough turning bearing ACCESSORY DRIVE BELT INSPECTION Belt replacement under any or all of the following conditions is required excessive wear frayed cords or severe glazing Poly V Belt system with back drive pulley may develop minor cracks across the ribbed si...

Page 213: ...eal is part of thermostat Install suit able flushing gun to thermostat housing hose Turn on water and when engine is filled turn on air but no higher than 138 kPa 20 psi in short blasts Allow engine to fill between blasts of air Continue this pro cedure until water runs clean Install thermostat and fill cooling system Refer to Refilling Cooling Sys tem for procedure REVERSE FLUSHING Reverse flushi...

Page 214: ...m 123 in lbs Fan Module to Radiator Fasteners 7 N m 65 in lbs Fan Motor to Shroud Fasteners 5 N m 45 in lbs Transmission Oil Cooler Hose Clamps 2 N m 18 in lbs SPECIAL TOOLS COOLING ACCESSORY DRIVE BELT GAUGE 2 0 2 4L ENGINE AIR CONDITIONING COMPRESSOR GENERATOR NEW 150 LB USED 80 LB POWER STEERING PUMP NEW 130 LB USED 80 LB 2 5L ENGINE AIR CONDITIONING COMPRESSOR GENERATOR NEW 150 LB USED 80 LB P...

Page 215: ...e OE battery is sealed and water cannot be added The battery is vented to release gases that are cre ated when the battery is being charged and dis charged The battery top posts and terminals should be cleaned when other under hood maintenance is performed When the electrolyte level is below the top of the plates the battery must be replaced The battery must be completely charged and the battery s...

Page 216: ...ged battery requires more charging time than a partially charged battery Elec trolyte is nearly pure water in a completely dis charged battery At first the charging current amperage will be low As water is converted back to sulfuric acid inside the battery the current amp rate will rise Also the specific gravity of the electrolyte will rise Refer to Battery Charging procedures DIAGNOSIS AND TESTIN...

Page 217: ...ective battery BATTERY IGNITION OFF DRAW TESTS High battery current draw with the ignition switch in the OFF position will discharge a battery After a dead battery is serviced the vehicle Ignition Off Draw IOD should be checked To determine if a high cur rent draw condition exists then check the vehicle with a multi meter on the Milliampere Scale 1 Verify all electrical accessories are OFF Remove ...

Page 218: ...Daytime Running Lamps DRL 20 Amp Optional Audio Power Amplifier 20 Amp Interior lamps 10 Amp Instrument Cluster 20 Amp CAUTION Always disconnect the milliampere meter before opening a door 1 Remove all seven fuses By removing these fuses all ignition off draw from the vehicle electronics will be disconnected There should be no reading on the milliampere meter If no reading go to Step 2 If a readin...

Page 219: ...g there is no Ignition Off Draw If there is a reading go to Step 14 14 Disconnect the Hazard Flasher a If meter has no reading replace the Hazard Flasher b If meter has a reading there is a short cir cuit in the A15 circuit Refer to Group 8W Wiring Diagrams BATTERY LOAD TEST A fully charged battery must have cranking capac ity To provide the starter motor and ignition system enough power to start ...

Page 220: ...ge of a battery and whether it is ready for a load test at 50 percent of the battery s cold crank rating Refer to Battery Load Test If a battery has open circuit voltage reading of 12 4 volts or greater and will not pass the load test replace the battery because it is defective To test open circuit voltage perform the following operation 1 Remove both battery cables negative cable first Connect a ...

Page 221: ...erate Refer to operating instructions provided with battery charger being used CAUTION Do not overcharge Battery refer to Charging Rate Chart After the battery has been charged to 12 4 volts or greater perform a load test to determine cranking capacity Refer to Battery Load Test in this Group If the battery will endure a load test return the bat tery to use If battery will not endure a load test i...

Page 222: ...t battery tray for damage caused by acid from battery If acid damage is present it will be nec essary to clean area with Baking soda solution Wire brush Scraper 4 Clean battery terminals with baking soda and suitable cleaning tool 5 Inspect cables for damage and broken termi nals Replace damaged frayed cables and broken ter minal 6 Inspect battery for proper or damaged hold down ledge REMOVAL AND ...

Page 223: ...LD CRANK RATING The current battery can deliver for 30 seconds and maintain a terminal voltage of 7 2 volts or greater at 18 C 0 F RESERVE CAPACITY RATING The length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of 10 5 volts at 27 C 80 F TORQUE DESCRIPTION TORQUE Battery Hold Down Bolt Clamp Bolt 14 N m 160 in lbs Fig 16 Battery Tray Removal BATTERY STRAP RETAINER ...

Page 224: ......

Page 225: ...d a control circuit that operates on less than 20 amps DESCRIPTION AND OPERATION BOSCH AND MELCO STARTERS The Bosch and Melco are permanent magnet starter motors A planetary gear train transmits power between starter motor and pinion shaft The fields have six permanent magnets The Bosch is used on 2 0L engines and Melco is used on 2 5L engines NIPPONDENSO STARTER The Nippondenso is a reduction gea...

Page 226: ...Particu larly at starter terminals c Repeat test If engine still fails to crank prop erly trouble is within starter or starter mounted solenoid and replace starter STARTER RELAY WARNING CHECK TO ENSURE THAT THE TRANS MISSION IS IN THE PARK POSITION NEUTRAL WITH THE PARKING BRAKE APPLIED RELAY TEST The starter relay is located in the Power Distribu tion Center PDC in the engine compartment Refer to...

Page 227: ...er to Group 21 Transaxle IGNITION SWITCH After testing starter solenoid and relay test igni tion switch and wiring Refer to Group 8D Ignition Systems or Group 8W Wiring Diagrams Check all wiring for opens or shorts and all connectors for being loose or corroded BATTERY Refer to Group 8A Battery for proper procedures ALL RELATED WIRING AND CONNECTORS Refer to Group 8W Wiring Diagrams FEED CIRCUIT R...

Page 228: ...UTION Do not overheat the starter motor or draw the battery voltage below 9 6 volts during cranking operations 5 After the starting system problems have been corrected verify the battery state of charge and charge battery if necessary Disconnect all testing equipment and connect ASD relay Start the vehicle several times to assure the problem has been cor rected STARTING SYSTEM TEST For circuit des...

Page 229: ...Position Switch Visually inspect the park neutral position switch for indica tions of physical damage and loose or corroded wire harness connections Starter Relay Visually inspect the starter relay for indications of physical damage and loose or corroded wire harness connections Starter Visually inspect the starter for indi cations of physical damage and loose or corroded wire harness connections ...

Page 230: ...e starter assembly STARTER ENGAGES FAILS TO TURN ENGINE 1 Battery discharged or faulty 2 Starting circuit wiring faulty 3 Starter assembly faulty 4 Engine seized 1 Refer to Group 8A Battery Charge or replace battery as necessary 2 Refer to the Feed Circuit Resistance Test and the Feed Circuit Test in this section Repair as necessary 3 If all other starting system components and circuits check OK r...

Page 231: ...shock tower Fig 6 2 Remove air cleaner resonator refer to Group 14 Fuel 3 Remove the battery positive cable nut from starter Remove battery positive cable and generator output wire from starter Fig 7 4 Disconnect push on solenoid connector 5 Remove two bolts attaching starter to trans mission housing and remove starter from vehicle INSTALLATION For installation reverse the above procedures Clean c...

Page 232: ...id 7 Connect battery positive cable to solenoid post Fig 8 8 Connect the push on solenoid connector 9 Lower vehicle 10 Tighten top starter bolt to 54 N m 40 ft lbs torque 11 Install TCM and the mounting screws 12 Install air cleaner resonator refer to Group 14 Fuel 13 Connect battery remote cable to the remote terminal 2 5L ENGINE REMOVAL 1 Disconnect battery negative cable from remote negative te...

Page 233: ...rter Mounting Bolts 54 N m 40 ft lbs Starter Solenoid Battery Nut 10 N m 90 in lbs Manufacturer BOSCH MELCO NIPPONDENSO Engine 2 0L 2 5L 2 4L Application Power rating 0 95 Kw 1 2 Kw 1 4 Kw Voltage 12 VOLTS 12 VOLTS 12 VOLTS Brushes 4 4 4 Drive Planetary Planetary Offset Gear Gear Train Gear Train Reduced JX STARTING 8B 9 SPECIFICATIONS Continued ...

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Page 235: ... tester and 12 volt test lamp may be required All OBD sensed systems are monitored by the PCM Each monitored circuit is assigned a Diagnos tic Trouble Code DTC The PCM will store a DTC in electronic memory for any failure it detects See the On Board Diagnostics Test in Group 8C Charging System for more information DESCRIPTION AND OPERATION CHARGING SYSTEM OPERATION The charging system consists of ...

Page 236: ...e refer to Battery Temperature Sen sor for more information It then compensates and regulates generator current output accordingly Also see Charging System Operation for additional infor mation DIAGNOSIS AND TESTING CHARGING SYSTEM When the ignition switch is turned to the ON posi tion battery potential will register on the voltmeter During engine cranking a lower voltage will appear on the meter ...

Page 237: ...Charging System Schematic Typical JX CHARGING SYSTEM 8C 3 DIAGNOSIS AND TESTING Continued ...

Page 238: ...OLTS YES CLEAN MOUNTING SUR FACES TIGHTEN FASTENERS TO SPECIFIED TORQUE NO CHECK ON BOARD DIAG NOSTIC TROUBLE CODES DTC PERFORM OUTPUT VOLT AGE TEST YES LOW OR NO CHARGING VOLTAGE OR DTC 41 OR 47 NO REFER TO VOLTAGE DROP TEST NO CHARGING SYSTEM AND GENERATOR IS OK CHARGING VOLTAGE ABOVE MAXIMUM OR DTC 41 OR 46 REFER TO LOAD TEST VOLTAGE YES REFER TO OVERCHARGE TEST 8C 4 CHARGING SYSTEM JX DIAGNOSI...

Page 239: ...UT VOLTAGE TEST DISCONNECT FIELD TERMINAL MEASURE RESISTANCE FROM K20 CIRCUIT ON WIRING HAR NESS TO ENGINE GROUND YES IS RESISTANCE LESS THAN 1000 OHMS NO REPAIR SHORT TO GROUND MEASURE RESISTANCE FROM K20 TERMINAL ON GENERATOR TO ENGINE GROUND REPLACE GENERATOR YES IS RESISTANCE LESS THAN 1000 OHMS NO REPEAT OUTPUT VOLTAGE TEST JX CHARGING SYSTEM 8C 5 DIAGNOSIS AND TESTING Continued ...

Page 240: ...rmation 2 Check condition of battery cables at battery Clean if necessary 3 Start the engine and allow it to reach normal operating temperature 4 Shut engine off 5 Connect an engine tachometer 6 Fully engage the parking brake TEST 1 Start engine 2 Place heater blower in high position 3 Turn on headlamps and place in high beam position 4 Turn vehicle interior lamps on 5 Bring engine speed up to 240...

Page 241: ...ight generator battery electrical connections 5 Be sure the generator drive belt is properly tensioned Refer to Group 7 Cooling System for information 6 A volt amp tester equipped with both a battery load control carbon pile rheostat and an inductive type pickup clamp ammeter probe will be used for this test Refer to operating instructions supplied with tester When using a tester equipped with an ...

Page 242: ... NO NO CHECK FOR BLOWN FUSE LINK IF LESS THAN 5 OHMS IF GREATER THAN 5 OHMS MEASURE VOLTAGE AT K 20 TERMI NAL ON THE GENERATOR YES YES REPAIR WIRE DISCONNECT FIELD CONNECTOR REPLACE PCM REPLACE GENERATOR YES VOLTAGE AT K 20 LESS THAN 10 VOLTS REPEAT OUTPUT VOLTAGE TEST CHECK SHORT CIRCUIT IN WIRE REPAIR FUSE LINK AND WIRE SHORT REFER TO GROUP 8W WIRING DIA GRAMS YES NO SHORT CIR CUIT IN FEED WIRE ...

Page 243: ...ptom not as the cause for the problem In some cases because of the design of the diagnostic test procedure a DTC can be the reason for another DTC to be set Therefore it is important that the test pro cedures be followed in sequence to understand what caused a DTC to be set See the Generator Diagnostic Trouble Code chart Fig 7 for DTC s which apply to the charging sys tem Refer to the Powertrain D...

Page 244: ...ting bolt to allow removal of the gen erator drive belt Refer to Group 7 Cooling System 8 Remove adjusting T bolt 9 Remove pivot bolt 10 Remove ABS braking unit by removing the two lower plate mounting bolts Refer to Group 5 Brakes 11 Remove Coolant Overflow bottle Refer to Group 7 Cooling System 12 Remove by sliding alternator under the air conditioning lines towards passenger side of vehicle 13 ...

Page 245: ...l connector from sensor INSTALLATION 1 Connect electrical connector to sensor 2 Install screw and tighten 3 Lower vehicle SPECIFICATIONS GENERATOR RATINGS TORQUE SPECIFICATIONS DESCRIPTION TORQUE Battery Terminal Nut 10 N m 90 in lbs Battery Hold Down Clamp Bolt 10 N m 90 in lbs Battery Negative Cable Nut at Shock Tower 10 N m 90 in lbs Generator B Terminal 9 N m 75 in lbs Generator Mounting Bolt ...

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Page 247: ...IMING PROCEDURE 12 INTAKE AIR TEMPERATURE SENSOR 12 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR TEST 12 SPARK PLUG CONDITION 13 TESTING FOR SPARK AT COIL 2 4L 9 TESTING FOR SPARK AT COIL 2 5L 10 THROTTLE POSITION SENSOR 12 REMOVAL AND INSTALLATION AUTOMATIC SHUTDOWN RELAY 18 CAMSHAFT POSITION SENSOR DOHC 19 CRANKSHAFT POSITION SENSOR 2 4 L 19 CRANKSHAFT POSITION SENSOR 2 5L 20 DISTRIBUTOR CAP 2 5L 21 DI...

Page 248: ...puts to the PCM The PCM deter mines crankshaft position from these sensors The PCM calculates injector sequence and ignition timing from crankshaft position For a description of both sensors refer to Camshaft Position Sensor and Crankshaft Position Sensor in this section POWERTRAIN CONTROL MODULE PCM The PCM regulates the ignition system Fig 1 The PCM supplies battery voltage to the ignition coil ...

Page 249: ...amic insulator damage during plug removal and installation CAUTION Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs This would damage the platinum pads which would shorten spark plug life Apply a very small amount of anti seize compound to the threads when reinstalling the vehicle s original spark plugs that have been determined good Do not apply anti seize comp...

Page 250: ...battery voltage to the ignition coil The PCM provides a ground contact circuit for energizing the coil When the PCM breaks the contact the energy in the coil primary transfers to the secondary causing the spark The PCM will de energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs Refer to Auto Shut down ASD Relay PCM Output in this section...

Page 251: ...ding a 60 degree signature notch Fig 7 From the crankshaft position sensor input the PCM determines engine speed and crank shaft angle position The notches generate pulses from high to low in the crankshaft position sensor output voltage When a metal portion of the counterweight aligns with the crankshaft position sensor the sensor output voltage goes low less than 0 5 volts When a notch aligns wi...

Page 252: ...slots for a total of 12 slots Fig 10 Basic timing is set by the position of the last slot in each group Once the Pow ertrain Control Module PCM senses the last slot it determines crankshaft position which piston will next be at TDC from the camshaft position sensor input The 4 pulses generated by the crankshaft posi tion sensor represent the 69 49 29 and 9 BTDC marks It may take the PCM one engine...

Page 253: ...haft and indexes to the correct posi tion The target magnet has four different poles arranged in an asymmetrical pattern As the target magnet rotates the camshaft position sensor senses the change in polarity Fig 14 The sensor input switches from high 5 volts to low 0 30 volts as the target mag net rotates When the north pole of the target magnet passes under the sensor the output switches high Th...

Page 254: ...nking for the PCM to determine the position of piston number 6 ENGINE COOLANT TEMPERATURE SENSOR The Engine Coolant Temperature ECT sensor has one element The sensor provides an input voltage to the PCM The sensor is a variable resistance ther mistor with a range of 40 F to 265 F As coolant temperature varies the sensors resistance changes resulting in a different input voltage to the PCM The PCM ...

Page 255: ...PS The TPS output voltage input signal to the powertrain control module represents throttle blade position The TPS output voltage to the PCM varies from approximately 0 38 volts to 1 2 volts at mini mum throttle opening idle to a maximum of 3 1 volts to 4 4 volts at wide open throttle Along with inputs from other sensors the PCM uses the TPS input to determine current engine oper ating conditions ...

Page 256: ... FROM CONTACT WITH THIS SYSTEM CAUTION Spark plug wire damage may occur if the spark plug is moved more than 1 4 inch away from the engine ground CAUTION Do not leave any one spark plug cable disconnected any longer than necessary during test or possible heat damage to catalytic converter will occur Total test time must not exceed 1 minute Use a new spark plug and spark plug cable for the followin...

Page 257: ...ned and left in the On position the PCM automatically energizes the Auto Shutdown ASD relay However the controller de en ergizes the relay within one second because it has not received a camshaft position sensor signal indi cating engine rotation During cranking the ASD relay will not energize until the PCM receives a camshaft position sensor signal Secondly the ASD relay remains energized only if...

Page 258: ... adjustable CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR The output voltage of a properly operating cam shaft position sensor or crankshaft position sensor switches from high 5 0 volts to low 0 3 volts By connecting an Moper Diagonostic System MDS and engine analyzer to the vehicle technicians can view the square wave pattern DISTRIBUTOR CAP RESISTANCE TEST 2 5L There is a resistor buil...

Page 259: ...may be caused by sticking valves or misfire conditions Cold carbon fouling of the entire set may be caused by a clogged air cleaner Cold fouling is normal after short operating peri ods The spark plugs do not reach a high enough operating temperature during short operating peri ods Replace carbon fouled plugs with new spark plugs FUEL FOULING A spark plug that is coated with excessive wet fuel is ...

Page 260: ... can be consid ered normal in condition cleaned and reused CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap Under certain conditions severe detonation also can separate the insulator from the center electrode Fig 28 Spark plugs with chipped electrode insulators must be replaced PREIGNITION DAMAG...

Page 261: ...jumper ter minal SPARK PLUG CABLES 2 4L Clean high tension cables with a cloth moistened with a non flammable solvent Wipe the cables dry Check for brittle or cracked insulation Resistance cables are identified by the words Elec tronic Suppression REMOVAL Disconnect the cable from the ignition coil first The cables insulate the spark plugs and cover the top of the spark plug tubes Fig 3 To remove ...

Page 262: ...he threads when reinstalling the vehicle s original spark plugs that have been determined good Do not apply anti seize compound to new spark plugs NOTE Anti seize compound is electrically conduc tive and can cause engine misfires if not applied correctly It is extremely important that the anti seize compound doesn t make contact with the spark plug electrodes or ceramic insulator SPARK PLUG REMOVA...

Page 263: ...d the spark plug hole and the area around the spark plug 16 Remove the spark plug using a quality socket with a rubber or foam insert 17 Inspect the spark plug condition Refer to Spark Plug Condition in this section SPARK PLUG INSTALLATION 1 To avoid cross threading start the spark plug into the cylinder head by hand 2 Tighten spark plugs to 28 N m 20 ft lbs torque 3 Install ignition cables over s...

Page 264: ... new coil pack The coil pack towers are numbered with the cylinder identification Be sure the ignition cables snap onto the towers IGNITION COIL 2 5L The ignition coil is located in the distributor hous ing Fig 40 If ignition coil is defective replace distributor assembly Refer to Distributor Service AUTOMATIC SHUTDOWN RELAY The relay is located in the Power Distribution Cen ter PDC Fig 41 The PDC...

Page 265: ...crews to 9 N m 80 in lbs torque 3 Carefully attach electrical connector to cam shaft position sensor Installation at an angle may damage the sensor pins 4 Install filtered air tube Tighten clamps to 3 N m 61 25 in lbs 65 torque CRANKSHAFT POSITION SENSOR 2 4 L The crankshaft position sensor mounts to the engine block behind the generator just above the oil filter Fig 45 REMOVAL 1 Disconnect electr...

Page 266: ...until contact is made with the drive plate While holding the sensor in this position install and tighten the retaining bolt to 12 N m 105 in lbs torque 2 Connect crankshaft position sensor electrical connector to the wiring harness connector 3 Attach connector to heater tube bracket 4 Install speed control servo Tighten nuts to 9 N m 80 in lbs torque DISTRIBUTOR 2 5L REMOVAL 1 Remove bolt holding ...

Page 267: ...or cap 8 Install spark plug cables onto distributor cap The cap is numbered as well as the cables Ensure sure all high tension wires are firmly in the cap tow ers 9 Install transmission dispstick tube 10 Install EGR tube to intake manifold Tighten bolts to 11 N m 95 in lbs torque DISTRIBUTOR CAP 2 5L REMOVAL 1 Remove bolt holding air inlet resonator to intake manifold 2 Loosen clamps holding air c...

Page 268: ...erature ECT sensor is located next to the thermostat housing Fig 50 REMOVAL 1 With the engine cold drain the cooling system until coolant level drops below sensor Refer to Group 7 Cooling System 2 Disconnect ECT sensor electrical connector 3 Remove ECT sensor INSTALLATION 2 5L 1 Install ECT sensor Tighten sensor to 7 N m 60 in lbs torque 2 Attach electrical connector to sensor 3 Fill cooling syste...

Page 269: ...he ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder Fig 53 For ignition switch terminal and circuit identifi cation refer to Group 8W Wiring Diagrams REMOVAL 1 Disconnect negative cable from auxillary jumper terminal on driver s side strut tower 2 Remove fuse panel cover from left end of instrument panel Remove screw holding end of instrument panel top co...

Page 270: ...r down and slide lower shroud forward to remove it from column Fig 60 10 Tilt wheel to full down position and remove upper steering column shroud Fig 56 Instrument Panel Top Cover Center TOP COVER SCREWS Fig 57 Knee Bolster Attaching Points KNEE BOLSTER SCREW LOCATIONS UNDER TOP COVER LOWER SCREW LOCATIONS Fig 58 Lower Steering Column Shroud Screw Locations LOWER STEERING COLUMN SHROUD SCREW LOCA ...

Page 271: ...rxt tamper proof bit 15 Depress retaining tabs Fig 53 and pull igni tion switch from steering column Fig 61 Multi Function Switch Removal Installation MULTI FUNCTION SWITCH ATTACHING SCREWS Fig 62 Lock Cylinder Removal IGNITION SWITCH SCREW DRIVER LOCK CYLINDER RETAINING TAB Fig 63 Ignition Switch ATTACHING GROUNDING SCREW LOCK HOUSING IGNITION SWITCH MULTI FUNCTION SWITCH Fig 64 Ignition Switch C...

Page 272: ...nstall key in lock cylinder Turn key to run position retaining tab on lock cylinder can be depressed 2 The shaft at the end of the lock cylinder aligns with the socket in the end of the housing To align the socket with the lock cylinder ensure the socket is in the Run position Fig 67 3 Align the lock cylinder with the grooves in the housing Slide the lock cylinder into the housing until the tab st...

Page 273: ...sor 2 5L 27 N m 20 ft lbs Crankshaft Position Sensor Screw 12 N m 105 in lbs Coolant Temp Sensor 18 6 N m 165 in lbs Distributor Holddown Nut 2 5L 13 N m 9 ft lbs EGR Tube to Intake 11 N m 95 in lbs Ignition Coil to Cyl Head 2 4L 12 N m 105 in lbs IAT Sensor 2 4 2 5L 11 5 N m 100 in lbs Knock Sensor 10 N m 90 in lbs MAP IAT Sensor Plastic Manifold 2 N m 20 in lbs MAP IAT Sensor Aluminum Manifold 3...

Page 274: ...Plug Gap Thread Size 2 4L RC12YC5 0 048 TO 0 053 14mm 3 4 in reach 2 5L RC10PYP4 0 038 TO 0 043 14mm 3 4 in reach Engines Coil Manufacture Primary Resistance at 21 C 27 C 70 F 80 F Secondary Resis tance at 21 C 27 C 70 F 80 F 2 0 2 4L Toyodenso Diamond 0 51 TO 0 61 Ohms 11 500 to 13 500 Ohms 2 5L Melco 0 6 TO 0 8 Ohms 12 500 to 18 000 Ohms Coil Polarity DIAMOND BRASS TOWERS Coil Polarity WEASTEC S...

Page 275: ... PANEL 9 JUNCTION BLOCK BODY CONTROL MODULE 11 LEFT UNDER INSTRUMENT PANEL SILENCER DUCT 11 MASK LENS 11 ODOMETER TRANSMISSION RANGE INDICATOR 12 POWER OUTLET 12 RADIO 12 RIGHT UNDER INSTRUMENT PANEL SILENCER DUCT 12 SPEEDOMETER TACHOMETER AND ODOMETER TRANSMISSION RANGE INDICATOR 12 VEHICLE THEFT SECURITY SYSTEM LED 12 GENERAL INFORMATION ELECTRO MECHANICAL INSTRUMENT CLUSTER The mechanical instr...

Page 276: ...rmation is accom plished by actuating the Step and US M buttons simultaneously The CMTC is active only when the ignition switch is in the ON position When the ignition switch is turned ON the CMTC will turn on all of the seg ments in the display for one second then return to the last function screen that was displayed prior to the ignition being turned OFF The functions that are available via acti...

Page 277: ...onic display odometer and transmission range indicator and all warning lamps except Cruise Fog lamps High beam Low fuel Turn signal will illuminate for a brief period If the cluster is not receiving CCD bus messages the cluster will appear nonfunctional except for the continuously illuminated airbag indicator and NO BUS message displayed If the cluster is not receiving CCD bus messages refer to th...

Page 278: ...isplayed replace the module If CCd is displayed check the CCD and Body Con trol Module BCM for proper operation refer to the appropriate diagnostic test procedures manual If the CCD and the BCM are OK replace the CMTC mod ule For additional diagnostic information on the CMTC and for identifying CMTC problems refer to the proper Body Diagnostic Procedures manual CHEC 2 WARNING LAMP DISPLAY SERVICE ...

Page 279: ...brated point the vehicle in each of the following four directions N S E and W DIRECT METHOD Turn the vehicle to head in either a North or South direction The vehicle must be within 45 degrees of the North or South position or the SETTING the VARIANCE will be ignored The vehicle may be sta tionary or driving at any speed for this operation Depress the STEP button until the Compass Temper ature scre...

Page 280: ...of the hood down on the instrument panel while sliding the hood forward to engage the retaining clips CLUSTER LAMP Refer to Fig 8 for appropriate lamp locations Replace fog lamp indicator lamp and security LED socket assembly only if equipped CLUSTER PRINTED CIRCUIT BOARD REMOVAL 1 Remove six cluster back cover retaining screws and remove the cover 2 Disconnect odometer transmission range indi cat...

Page 281: ...llation reverse the above procedures The cubby bin must engage the console at its forward edge prior to installing the mounting screws Fig 8 Lamp Location VEHICLE THEFT SECURITY SYSTEM LED LOW FUEL HIGH BEAM CHARGING SYSTEM AIR BAG SEAT BELT FOG LAMP BRAKE ABS OIL PRESSURE MIL CHECK ENGINE NOT USED LEFT TURN RIGHT TURN CRUISE NOT USED ILLUMINATION LAMP HI TEMP Fig 9 Printed Circuit Board RETAINING...

Page 282: ...N For installation reverse the above procedures HVAC CONTROL REMOVAL 1 Remove center bezel by pulling rearward to disengage four clips and remove attaching screws from cubby bin Fig 6 2 Remove the HVAC control attaching screws Pull the control out to disconnect two electrical con nectors and two control cables Remove HVAC con trol INSTALLATION For installation reverse the above procedures The forw...

Page 283: ...ESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS REMOVAL When removing a passenger airbag module refer to Group 8M Restraint Systems for Passenger Air Bag Module Removal 1 Disconnect and isolate the battery negative remote cable 2 Open both vehicle front doors Remove left end cover by pulling ...

Page 284: ...at steering column plenum One at glove box hinge to cowl Two at center support to the floor pan bracket 21 Remove attaching screw at the rear of HVAC to the center support bracket 22 Lift up instrument panel and move rearward to remove INSTALLATION For installation reverse the above procedures DO NOT CONNECT battery negative remote cable Refer to Group 8M Restraint Systems for Air Bag System test ...

Page 285: ...onnectors are in good condition and connectors are properly installed BODY CONTROL MODULE REMOVAL 1 The Junction Block BCM removed from the vehicle separate the BCM from the Junction Block 2 Remove the two BCM attaching screws and release the two BCM locking latches from the Junc tion Block 3 Disconnect BCM from the Junction Block INSTALLATION For installation reverse the above procedures LEFT UND...

Page 286: ... right end of instrument panel 2 Maneuver part off center floor distribution duct to remove INSTALLATION For installation reverse the above procedures SPEEDOMETER TACHOMETER AND ODOMETER TRANSMISSION RANGE INDICATOR REMOVAL 1 Remove mask lens retaining screws and remove mask lens Fig 11 2 Disconnect odometer transmission range indi cator connector from the printed circuit board Fig 12 3 Remove scr...

Page 287: ...uarter panel speakers While driving the amplifier provides unique sound equalizations when the convertible top is in the up position or in the down position The amplifier remembers which mode it is in as long as the battery voltage B is supplied to the amplifier If the bat tery voltage is removed for only a few minutes by Disconnecting the battery Dead battery Fuse Removal Amplifier disconnected T...

Page 288: ...tem is ON and all or some speakers are not operating or have a noise distortion refer to the diagnostic tests Refer to Group 8W Wir ing Diagrams for Pin numbers and location REMOTE CD CHANGER The remote CD changer is located in the center console and is capable of holding up to six disc in a magazine The magazine can be ejected at anytime that the ignition switch is in the ON position After the ig...

Page 289: ...NNEC TOR PINS 6 7 FOR BATTERY VOLTAGE YES EXCHANGE RADIO REPAIR CIR CUIT AS NEC ESSARY TRY KNOWN GOOD RADIO OK EXCHANGE SPEAKER NOT OK EXCHANGE RADIO ARE ALL SPEAKERS DIS TORTED OR INOP ERA TIVE NO ONLY ONE SPEAKER ONE CHANNEL LEFT OR RIGHT FRONT OR REAR CHECK FOR SHORT OR OPEN CIRCUIT IN SPEAKERS IN THE BAD CHANNEL NOISE STATIC RUN STATIC NOISE CHECK YES AM ONLY INOP ERATIVE RUN ANTENNA SYS TEM C...

Page 290: ... REFER TO GROUP 8W WIR ING DIAGRAMS FOR SPEAKER PLUS AND MINUS TERMINALS PLACE ONE LEAD OF THE OHMMETER TO GROUND AND THE OTHER TO THE PLUS TERMINAL SWITCH THE LEAD FROM THE PLUS TERMINAL TO THE MINUS TERMINAL DOES ANY CIR CUIT SHOW RESISTANCE TO GROUND YES REPAIR AS NECES SARY NO TEST RESISTANCE BETWEEN THE SPEAKER PLUS AND MINUS TERMINALS FOR A READING OF 3 TO 8 OHMS AT RADIO CONNECTOR CONDITION...

Page 291: ...STATIC NOISE YES USING A KNOWN GOOD AMPLIFIER OK CHECK ENGINE GROUND STRAPS CHECK ANY OTHER ELECTRICAL COM PONENTS OR MOTORS THAT MAY CAUSE NOISE EXCHANGE RADIO NO CONDITION OK YES REPLACE AMPLIFIER REPAIR AS NECES SARY CHECK ANTENNA COAXIAL CABLE CONNECTIONS REAR OF RADIO CONNECT FROM BODY HARNESS TO I P HARNESS ANTENNA BODY REPAIR AS NEC ESSARY NO CONDITION OK YES USING A TEST ANTENNA CHECK RECE...

Page 292: ...S EXCHANGE UNIT ADVISE OWNER OF WORN OR DEFECTIVE TAPE POOR PERFOR MANCE TRY A KNOWN GOOD TAPE NO PLAYS OK YES CLEAN WITH WET HEAD CLEANER ADVISE OWNER OF WORN OR DEFECTIVE TAPE IF NOT OK EXCHANGE UNIT NO EJECT Do Not Force Removal of Jammed Cassette EXCHANGE UNIT CHECK TAPES FOR CRACKED OR WARPED CASE LOOSE LABEL ON CASE TAPE PAD MISSING TAPE SPOOL S JAMMING CASE PAD LABEL SPOOL S 8F 6 AUDIO SYST...

Page 293: ...AY CONNEC TOR PINS 6 7 FOR BATTERY VOLTAGE YES EXCHANGE RADIO REPAIR CIR CUIT AS NEC ESSARY TRY KNOWN GOOD RADIO OK EXCHANGE SPEAKER NOT OK EXCHANGE RADIO ARE ALL SPEAKERS DIS TORTED OR INOP ERA TIVE NO ONLY ONE SPEAKER ONE CHANNEL LEFT OR RIGHT FRONT OR REAR CHECK FOR SHORT OR OPEN CIRCUIT IN SPEAKERS IN THE BAD CHANNEL NOISE STATIC RUN STATIC NOISE CHECK YES AM ONLY INOP ERATIVE RUN ANTENNA SYS ...

Page 294: ... OF THE 2 WAY CONNECTOR FOR A MINIMUM OF 11 VOLTS REFER TO GROUP 8W WIRING DIAGRAMS CHECK FOR BATTERY VOLT AGE AT V TERMINALS AND ON OFF TERMINALS NO VOLTAGE CONDITION OF VOLTAGE NO IS VOLTAGE OK YES REPAIR AS NECESSARY NO IS VOLTAGE OK YES CHECK FROM AMPLIFIER TO FUSE FOR HIGH RESIS TANCE AND REPAIR AS NECESSARY LOW VOLTAGE SUBSTITUTE WITH A KNOWN GOOD AMPLIFIER CHECK AMPLIFIER FOR GOOD GROUND EX...

Page 295: ...N 3 8 OHMS YES SUBSTITUTE WITH A KNOWN GOOD AMPLI FIER REPAIR AS NECESSARY NO CONDITION OK YES SUBSTITUTE WITH A KNOWN GOOD SPEAK ER S REPLACE AMPLIFIER YES CONDITION OK NO CHECK RADIO AND AMPLIFIER CONNECTORS FOR A LOOSE CONNECTIONS B BROKEN WIRES C CORROSION CHECK WIR ING HARNESS NO CONDITION OK YES REPLACE SPEAKER REPAIR AS NECESSARY NO CONDITION OK YES USING AN OHMMETER WITH BOTH RADIO AND AMP...

Page 296: ...ERE STATIC NOISE YES USING A KNOWN GOOD AMPLIFIER OK CHECK ENGINE GROUND STRAPS CHECK ANY OTHER ELECTRICAL COM PONENTS OR MOTORS THAT MAY CAUSE NOISE EXCHANGE RADIO NO CONDITION OK YES REPLACE AMPLIFIER REPAIR AS NECES SARY CHECK ANTENNA COAXIAL CABLE CONNECTIONS REAR OF RADIO CONNECT FROM BODY HARNESS TO I P HARNESS ANTENNA BODY REPAIR AS NEC ESSARY NO CONDITION OK YES USING A TEST ANTENNA CHECK ...

Page 297: ...OK YES EXCHANGE UNIT ADVISE OWNER OF WORN OR DEFECTIVE TAPE POOR PERFOR MANCE TRY A KNOWN GOOD TAPE NO PLAYS OK YES CLEAN WITH WET HEAD CLEANER ADVISE OWNER OF WORN OR DEFECTIVE TAPE IF NOT OK EXCHANGE UNIT NO EJECT Do Not Force Removal of Jammed Cassette EXCHANGE UNIT CHECK TAPES FOR CRACKED OR WARPED CASE LOOSE LABEL ON CASE TAPE PAD MISSING TAPE SPOOL S JAMMING CASE PAD LABEL SPOOL S JX AUDIO S...

Page 298: ...VE DISC IF APPLI CABLE IS CD SCRATCHED YES REPLACE DAM AGED CD NO BATTERY VOLT AGE 11 VOLTS OR MORE NO REPAIR AS NECES SARY NO IS CD DIRTY OR CONTAMINATED YES GENTLY CLEAN WITH A SOFT CLOTH FROM CEN TER TO EDGE DO NOT SPRAY WITH ANY SOL VENTS OR CLEANERS USE CAUTION YES EXCHANGE UNIT NO CD WILL SKIP AS A RESULT OF EXTREME BUMPS OR EXCESSIVE VIBRATION NOTE THE CD PLAYER WILL ONLY OPERATE BETWEEN AP...

Page 299: ...ms resistance to the non operative speaker Refer to Group 8W Wiring Diagrams for the appropriate pin numbers If resistance is less than two ohms test speaker for resistance If OK refer to Audio Diagnostic Test Procedures If not OK replace speaker ALL SPEAKERS NON OPERATIVE Check radio for being ON are the display lights on Radio not ON refer to Radio Diagnosis Check fuses amplifier connectors and ...

Page 300: ...t Check for broken teeth on the mast drive rod or bent mast 8 If the mast checks good the antenna assembly should be replaced REMOTE CD CHANGER TEST CD changer inoperative 1 The CD changer receivers its power and ground through the radio via the DIN connector Ver ify that the radio powers up and functions before pro ceeding 2 With the radio turned ON check the radio dis play when pushing the MODE ...

Page 301: ...im stick along rear edge d While lifting rear edge slide top cover rear ward to disengage front clips and remove the top cover 2 To remove right or left speaker remove two retaining screws Lift up speaker and disconnect wire connector Fig 5 ERROR MESSAGES DIS PLAY EXPLANATION WHAT TO DO nocd No disc or discs in magazine Load discs in magazine No magazine in player Load magazine in player Err HOT P...

Page 302: ... antenna body down through the hole in the quarter panel INSTALLATION For installation reverse the above procedures Tighten antenna cap to 7 N m 65 in lbs torque POWER ANTENNA MAST REMOVAL 1 Remove cap nut 2 Turn ignition key to ACCESSORY position and turn on radio 3 While the mast is moving up pull upward to remove mast contact spring and drive rod from the mast tube INSTALLATION 1 Insert new dri...

Page 303: ...ocedure REAR QUARTER PANEL SPEAKER CAUTION Do not operate the radio with speaker leads detached Damage to the output devices may result REMOVAL 1 Remove rear quarter panel trim grille 2 Remove four retaining screws Fig 10 3 Disconnect wire connector and remove speaker INSTALLATION For installation reverse the above procedure Be sure that the wire connectors are facing rearward in vehicle Fig 8 Cen...

Page 304: ...the OFF position 2 Remove the instrument cluster hood Refer to Group 8E Instrument Panel and Systems for removal procedures 3 Remove the two CD changer attaching screws located under the HVAC control 4 Slide the CD changer power outlet assembly rearward in the vehicle 5 Disconnect CD cable power outlet and the light socket assembly wire connectors 6 Remove the CD changer INSTALLATION For installat...

Page 305: ...ltage refer to Horn Does Not Sound If voltage is OK go to Step 5 5 Using ohmmeter test ground wire for continu ity to ground 6 If no ground repair as necessary 7 If wires test OK and horn does not sound replace horn HORN SWITCH The horn switch is mounted between the outer and inner covers of the Driver Airbag Module When the driver airbag module is pressed the horn switch makes contact to ground T...

Page 306: ...lay from the Junction Block If the amperage draw drops to 0 amps the horn switch or circuit is shorted Refer to group 8W Wiring Diagrams for circuit information If amperage does not drop go to Step 5 5 Disconnect both horns If amperage does not drop with both horns disconnected and the horn switch depressed go to Step 7 If the amperage draw drops go to Step 6 6 Disconnect the wire connector from o...

Page 307: ...nched horn switch wire under Driver Airbag Module 4 Defective horn switch 1 Refer to horn relay test 2 Check horn relay terminal 8 in the Junction Block for continuity to ground indicates a Wiring harness shorted to ground b Find the short and repair as necessary 3 Remove Driver Airbag Module and check for rubbing shorted or loose wire connector and repair as necessary 4 Replace Driver Airbag Modu...

Page 308: ... attaching bolt from the front frame rail Do not remove horn from mounting bracket Fig 4 5 Remove horn from vehicle INSTALLATION For installation reverse the above procedures HORN SWITCH The Horn Switch is part of the Driver Airbag Mod ule Refer to Group 8M Restraint System Driver Air bag Module Removal and Installation procedures HORN RELAY REMOVAL 1 Open driver s door and remove instrument panel...

Page 309: ...ICLE SPEED SENSOR 11 GENERAL INFORMATION INTRODUCTION The speed control system is electronically con trolled and vacuum operated The electronic control is integrated into the powertrain control module located on the left side of the engine compartment next to the air cleaner The controls are located on the steering wheel and consist of five switches The ON and OFF buttons are located on the left s...

Page 310: ...ransmission is in Park or Neutral The speed control can be disengaged manually by Stepping on the brake pedal Depressing the OFF switch Depressing the CANCEL switch The speed control can be disengaged also by any of the following conditions An indication of Park or Neutral The VSS signal increases at a rate of 10 mph per second indicates that the co efficient of friction between the road surface a...

Page 311: ...is delayed until the set speed is achieved to reduce cycling and provide better response STOP LAMP SWITCH Vehicles equipped with the speed control option use a dual function stop lamp switch The switch is mounted in the same location as the conventional stop lamp switch on the brake pedal mounting bracket under the instrument panel The PCM mon itors the state of the dual function stop lamp switch ...

Page 312: ...s of three flashes in rapid succession a slight pause then four flashes in rapid succession would indicate diagnostic code 34 3 A speed control malfunction may occur without either diagnostic code being indicated If no diagnos tic code appears or diagnostic code 15 or 34 is observed refer to the appropriate flow chart Refer to Group 25 for further information and use age of the DRB scan tool and a...

Page 313: ...tion is needed concerning wiring refer to Group 8W Wiring Diagrams Fig 4 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 When electrical connections are removed corrosion should be removed from electrical terminals and a light...

Page 314: ...SIGNAL RESUME ACCEL SET COAST CANCEL ON OFF VACUUM LINE VACUUM RESERVOIR VACUUM SOURCE S C CABLE T C CAM THROTTLE BODY K29 BRAKE SWITCH SIGNAL V36 SPEED CNT VAC SPEED CONTROL VACUUM SOLENOID V35 SPEED CNT VENT BRAKE LAMP SWITCH CCD BUSS BAR CRUISE LIGHT INST CLUSTER 8H 6 VEHICLE SPEED CONTROL SYSTEM JX DIAGNOSIS AND TESTING Continued ...

Page 315: ...m 6 If servo pulls cables replace servo 7 Ground Pin 1 on servo 8 Check that the throttle cable pulls in and holds as long as the vacuum pump is connected After one minute check if cable is still holding If cable does not hold replace the servo 9 Disconnect jumper from pin 3 Cable should return to rest position If not replace servo 10 Connect 4 way electrical connector and vac uum harness to servo...

Page 316: ...ues do not fall within these specification replace the switch STOP LAMP SWITCH TEST 1 Remove the stop lamp switch refer to Stop Switch Removal Installation in this section Discon nect connector from stop lamp switch Fig 7 Using an ohmmeter switch continuity may be checked as follows 2 With switch plunger released there should be continuity between Pin 5 and Pin 6 3 With switch plunger depressed th...

Page 317: ...inuity perform the following test a Check for continuity between pin 62 and pin 3 of the stop lamp switch connector If no continu ity repair as necessary b If continuity perform Stop Lamp Switch Test 9 If the Stop Lamp Switch Test is OK check for continuity between pin 6 of the stop lamp switch and ground When the pedal is depressed the meter should show open circuit If no continuity repair as nec...

Page 318: ...et ing sound will be heard during this procedure Connect the wiring harness to the switch Mount the switch into the bracket by holding the switch with the plunger facing forward in car There is an index key on the switch that mates with the bracket slot at the top of the square hole Align key and push switch into square hole in bracket while depressing the brake pedal Once the switch is seated in ...

Page 319: ...and Intake Manifold 2 Disconnect vacuum hoses from reservoir 3 Pull vacuum reservoir from dash panel INSTALLATION 1 Push reservoir onto dash panel 2 Connect hoses to reservoir 3 2 5L ONLY Install intake manifold refer to Group 11 Exhaust System and Intake Manifold VEHICLE SPEED SENSOR For Removal Installation refer to Vehicle Speed Sensor in Group 21 Transaxle Fig 12 Disconnecting Throttle Cable T...

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Page 321: ...hich comes in contact with the cancel actuator on the multi func tion switch The canceling cam lobe pushes on the cancel actuator and returns the switch to the off posi tion If only momentary signaling such as indication of a lane change is desired the switch is actuated to a left or right intermediate detent position In this position the signal lamps flash as described above but the switch return...

Page 322: ...n top of the button Push and release the button to turn the hazard function ON or OFF The button will move out from the steering column in the ON position and will remain in toward the column in the OFF position DIAGNOSIS AND TESTING COMBINATION FLASHER For test combination flasher refer to Fig 2 for Combination Flasher Diagnosis MULTI FUNCTION SWITCH 1 Remove multi function switch refer to remova...

Page 323: ...S AT DOUBLE NORMAL RATE EXTERNAL LAMP DOES NOT LIGHT 1 Open circuit in wire to external lamp 1 Replace wiring harness 2 Burned out lamp 2 Replace lamp SYSTEM DOES NOT FLASH ON EITHER SIDE 1 Faulty fuse 1 Replace fuse 2 Faulty flasher unit 2 Replace flasher 3 Loose bulkhead connector 3 Tighten connector 4 Loose or faulty rear wiring Harness or terminals 4 Replace wiring harness 5 Open circuit to fl...

Page 324: ...Fig 3 Multi Function Switch Continuity Test COMBO FLASHER A 7 WAY CONNECTOR B 10 WAY CONNECTOR C 8J 4 TURN SIGNAL AND FLASHERS JX DIAGNOSIS AND TESTING Continued ...

Page 325: ...connect wire connectors Lift the switch straight up to remove INSTALLATION For installation reverse the above procedures 1 Tighten multi function switch to column retain ing screws to 2 3 N m 20 in lbs torque 2 Tighten steering column cover retaining screws to 2 N m 17 in lbs torque STEERING COLUMN COVER REMOVAL 1 Remove three lower cover attaching screws 2 Remove five knee bolster mounting screws...

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Page 327: ...l Module BCM The lever has a selection of delay intervals and by turn ing lever the wiper will cycle every half second to 36 seconds depending ON the vehicle s speed The wiper has two cycle two speeds The windshield wipers will only operate when the ignition switch is in the ACCESSORY or IGNITION position Fuse 15 located in the Junction Block fuses 8 and 14 in the Power Distribution Center block p...

Page 328: ...servoir to the motor The fluid is forced by the pump through rubber hoses to the hood mounted nozzles which direct the fluid streams to the wind shield The hose assembly has two one way flow check valves located just before each hood nozzle The purpose of the check valves is to improve fluid flow response time and to prevent excessive washer fluid staining the surface of the hood The hood mounted ...

Page 329: ...ck motor operation in all switch positions c If motor is still inoperative and the fuse does not blow go to Step 2 d If replacement fuse blows go to Step 11 2 Disconnect motor wire harness connector 3 Check the wiper motor low speed Using two jumper wires connect one jumper wire between the battery positive jump start terminal and Pin B on the wiper motor connector Fig 6 Connect the other jumper w...

Page 330: ...ion switch to the ON position Slowly move the wiper switch from OFF position through each position to HIGH a If voltage increases from zero to approxi mately 10 volts in the HIGH position replace BCM If no voltage go to Step 2 b Using an ohmmeter check for continuity from terminal 2 of wiper switch connector to termi nal 10 of the BCM J3 22 way connector If no con tinuity repair circuit If OK go t...

Page 331: ...y HI LO wiper relay WIPERS RUN AT HIGH SPEED WITH SWITCH IN LOW SPEED POSITION WIPERS OPERATE IN INTERMITTENT MODE BUT EACH WIPE IS AT HIGH SPEED 1 Disconnect motor connector 2 Using two jumper wires connect one between the battery positive jump start terminal and Pin B on the wiper motor connector Connect the second lead between ground and Pin C on the wiper motor connector Fig 6 If motor runs at...

Page 332: ...motor and the BCM Repair as necessary b If the battery voltage ensure that the 14 way connector is disconnected and check Pin 10 if it has 12 volts If no voltage replace the BCM If battery voltage test for a wiring short refer to Group 8W Wiring Diagrams WIPERS OPERATE IN INTERMITTENT SETTINGS BUT DOES NOT HAVE SIX DIFFERENT SPEEDS To test the multi function windshield wiper switch refer to Group ...

Page 333: ...Fig 9 Wiper Motor Test JX WINDSHIELD WIPERS AND WASHERS 8K 7 DIAGNOSIS AND TESTING Continued ...

Page 334: ...unction switch to column retain ing screws to 2 3 N m 20 in lbs torque 2 Tighten steering column cover retaining screws to 2 N m 17 in lbs torque WASHER NOZZLE REMOVAL To replace nozzle disconnect washer fluid hose Using a needle nose pliers squeeze together the lock ing tabs on the nozzle INSTALLATION For installing make sure that both locking tabs are securely snapped into position Connect washe...

Page 335: ... turn ignition OFF 2 Unsnap arm cover By hand rock gently side to side and slide away from arm pivot To remove the left side raise hood for clearance 3 Loosen retention nut 4 Remove the arm from the pivot by using a uni versal claw puller or by hand rock gently side to side and slide Raise blade and arm off glass and rock side to side while applying pressure with the puller till loose Ensure that ...

Page 336: ...nd of the rubber element Fig 16 WIPER ARM LINKAGE OR CAP REMOVAL 1 Remove wiper arms and blades 2 Remove the cowl screen 3 Remove wiper motor assembly 4 Disconnect wiper arm linkage by using an ball joint tie rod separator separate the right and left ball cap from the ball Fig 17 5 Disconnect drive link from the motor crank Using an ball joint tie rod separator and separate the ball cap from the b...

Page 337: ...lat facing up 2 The left outboard grommet has a small eyelet 3 The right inboard grommet threaded eyelet 4 The two center grommets have a large eyelets CLEANING AND INSPECTION WIPER BLADES Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road grime The wip...

Page 338: ... blade should be 18 to 42 mm 75 to 1 60 ins 7 If not OK check for worn parts 8 In the event the blade tip strikes the cowl screen or molding remove arm Remove metal key way from the pivot shaft by cutting or breaking it off File the surface smooth Position arm on windshield and tighten to 37 to 43 N m 27 to 32 ft lbs torque Fig 19 Fig 19 Arm Adjustment 8K 12 WINDSHIELD WIPERS AND WASHERS JX ADJUST...

Page 339: ...sulator Female terminals should not be sprung open or disengaged from the insulator Bent and sprung terminals can be repaired using needle nose pliers and pick tool Corroded terminals appear chalky or green Corroded terminals should be replaced to avoid recurrence of the problem symp toms Wire connector terminals should be coated with Mopart Multi purpose Grease or equivalent to avoid corrosion Be...

Page 340: ... replace fuse 3 Loose or corroded terminals or splices in circuit 3 Inspect and repair all connectors and splices refer to Group 8W HEADLAMPS ARE DIM WITH ENGINE RUNNING 1 Charging system output too low 1 Test and repair charging system refer to Group 8A ABOVE IDLE 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations refer to Group 8W 3 High resistance in headlamp c...

Page 341: ...up 8W FOG LAMPS ARE DIM WITH ENGINE RUNNING 1 Charging system output too low 1 Test and repair charging system refer to Group 8A ABOVE IDLE 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations refer to Group 8W 3 High resistance in fog lamp circuit 3 Test amperage draw of fog lamp circuit 4 Both fog lamp bulbs defective 4 Replace both fog lamp bulbs FOG LAMPS FLASH ...

Page 342: ...ank for each estimated gallon of missing fuel ADJUSTMENTS HEADLAMP ADJUSTMENT USING ALIGNMENT SCREEN ALIGNMENT SCREEN PREPARATION 1 Position vehicle on a level surface perpendicu lar to a flat wall 7 62 meters 25 ft away from front of headlamp lens Fig 3 2 If necessary tape a line on the floor 7 62 meters 25 ft away from and parallel to the wall 3 From the ground up 1 27 meters 5 ft tape a line on...

Page 343: ...am pattern should be correct when the low beams are aligned properly NOTE The bubble level and gauge wheel is cali brated before the headlamp is installed in the vehi cle The bubble level cannot be calibrated without damaging the headlamp module If bubble level is faulty replace headlamp module To adjust headlamp alignment rotate alignment screws to achieve the specified low beam hot spot pattern ...

Page 344: ...on the alignment screen 100 mm 4 in below the fog lamp centerline and straight ahead To adjust fog lamp alignment rotate alignment screw to achieve the specified hot spot pattern Fig 6 Fig 5 Fog Lamp Alignment CENTER OF FOGLAMP TOP OF BEAM PATTERN 49 FRONT OF FOGLAMP 7 62 METERS 25 FT Fig 6 Fog Lamp Adjuster UP DOWN ADJUSTER FOGLAMP 8L 6 LAMPS JX ADJUSTMENTS Continued ...

Page 345: ...for the headlamp switch can be found in Group 8E Instrument Panel and Gauges More information can be found in Group 8W Wiring Diagrams HEADLAMP DIMMER SWITCH The headlamp dimmer switch is incorporated into the turn signal switch Proper procedures can be found in Group 8J Turn Signal and Flashers More information can be found in Group 8W Wiring Dia grams JX LAMPS 8L 7 ...

Page 346: ... quarter turn 6 Separate retaining ring from headlamp module 7 Pull bulb from headlamp module Fig 1 INSTALLATION 1 Insert bulb into headlamp module 2 Position retaining ring to headlamp module 3 Rotate retaining ring clockwise one quarter turn 4 Engage wire connector from back of headlamp bulb 5 Position headlamp module to radiator closure panel 6 Install screws holding headlamp module to radiator...

Page 347: ...in lamp bezel release tab holding lamp to cubby bin 2 Pull bezel and lamp assembly from cubby bin 3 Pull lamp socket from assembly 4 Pull bulb from socket INSTALLATION 1 Push bulb into lamp socket 2 Push lamp socket into assembly 3 Push bezel and lamp assembly into cubby bin to engage tabs FLOOR CONSOLE COURTESY LAMP BULB REMOVAL 1 Using a small flat bladed tool inserted into top edge of courtesy ...

Page 348: ...rter turn 6 Pull socket from back of lamp Fig 7 7 Pull bulb from socket INSTALLATION 1 Push bulb into socket 2 Push socket into back of lamp 3 Rotate socket clockwise one quarter turn 4 Position lamp to opening in quarter panel 5 Install plastic nuts holding tail lamp to rear closure panel 6 Install trunk lining BACK UP LAMP BULB REMOVAL 1 Release trunk latch and open trunk lid 2 Remove trunk lini...

Page 349: ...ULB The center high mounted stop lamp CHMSL has no serviceable bulb If the lamp does not function properly the CHMSL assembly must be replaced LICENSE PLATE LAMP BULB REMOVAL 1 Remove screws holding license plate lamp to rear bumper fascia 2 Separate license plate lamp from rear fascia 3 Rotate socket counterclockwise one quarter turn 4 Pull socket from back of lamp Fig 8 5 Pull bulb from socket I...

Page 350: ...TION 1 Position fog lamp in front fascia 2 Install nuts holding fog lamp to front fascia 3 Engage wire connector to fog lamp bulb HEADLAMP MODULE The headlamp module contains the park and turn signal lamps and is serviced as an assembly REMOVAL 1 Release hood latch and open hood 2 Remove screws holding headlamp module to radiator closure panel and headlamp adapter Fig 2 3 Separate headlamp module ...

Page 351: ... latch and open glove box 2 Reach inside glove box to rear side of glove box lamp and release tabs holding lamp to instrument panel 3 Pull lamp from glove box 4 Disengage wire connector from lamp 5 Separate lamp from vehicle INSTALLATION 1 Position lamp to vehicle 2 Engage wire connector from lamp 3 Push lamp into opening in glove box ASH RECEIVER CUP HOLDER LAMP REMOVAL 1 Using a small flat blade...

Page 352: ...3 Engage inverter for lighted PRNDL letter bezel to shifter cover 4 Engage wire harness connector on bottom side of floor console 5 Install floor console Refer to Group 23 Body for proper procedure DOOR COURTESY LAMP REMOVAL 1 Using a small flat bladed tool inserted into rear edge of door courtesy lamp lens remove lens Fig 7 Fig 4 Tail Stop Turn Signal Backup and Side Marker Lamp TAIL STOP TURN SI...

Page 353: ...onnector and reposition trunk trim panel 3 Install screws holding CHMSL assembly to upper deck molding 4 Install upper deck molding Refer to Group 23 Body for proper procedure LICENSE PLATE LAMP REMOVAL 1 Remove screws holding license plate lamp to rear bumper fascia 2 Separate license plate lamp from rear fascia Fig 10 3 Rotate socket counterclockwise one quarter turn 4 Pull socket from back of l...

Page 354: ...SPECIAL TOOLS LAMP SERVICE Fig 10 License Plate Lamp REAR BUMPER FASCIA LICENSE PLATE LAMP Trim Stick C 4755 8L 16 LAMPS JX SPECIAL TOOLS Continued ...

Page 355: ...wner s Manual for more information ILLUMINATED ENTRY The Illuminated Entry System is available on vehi cles equipped with the Remote Keyless Entry system The Illuminated Entry System turns ON the courtesy lamps when the remote keyless entry system is acti vated The Remote Keyless Entry Module and the Body Controller are used to control the system Cour tesy lamps will turn on for 30 seconds 6 1 sec...

Page 356: ...em is operating properly before testing illuminated entry circuits The body controller uses input from the remote keyless entry system to switch ON the courtesy lamps Refer to Group 8W Wiring Diagrams for compo nent location and circuit information Refer to Body Systems Diagnostic Procedures Manual for more information 8L 18 LAMPS JX DIAGNOSIS AND TESTING Continued ...

Page 357: ...omponent is removed from the vehicle Contact local dealer for location of nearest ASC A C Heater Control 37 A C Heater ISO Symbols LED Ash Receiver 37 Instrument Cluster PC194 Radio ASC INDICATOR LAMPS Service procedures for most of the lamps in the instrument panel instrument cluster and switches are located in Group 8E Instrument Panel and Gauges A C Compressor LED Air Bag PC194 Anti lock Brake ...

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Page 359: ...RIM SIDE OF THE AIRBAG SHOULD BE POINTING AWAY FROM THE BODY TO MINIMIZE POSSIBILITY OF INJURY IF ACCIDENTAL DEPLOYMENT OCCURS REPLACE AIRBAG SYSTEM COMPONENTS WITH MOPART REPLACEMENT PARTS SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE BUT INTERNAL DIFFERENCES MAY RESULT IN INFE RIOR OCCUPANT PROTECTION WEAR SAFETY GLASSES RUBBER GLOVES AND LONG SLEEVED CLOTHING WHEN CLEANING POWDER RESIDUE FROM VEH...

Page 360: ...e center of the steering wheel The Driver Airbag Module is mounted directly to the steering wheel WARNING NEVER DISASSEMBLE THE PASSEN GER AIRBAG MODULE THERE ARE NO SERVICE ABLE PARTS WITHIN THE MODULE The Passenger Airbag Module is located beneath the decorative cover of the instrument panel facing the passenger seat Fig 1 The passenger inflator assembly is within the mod ule housing The module ...

Page 361: ...roblem If the airbag warning lamp either fails to light or goes on and stays on there is a system malfunction Refer to the proper Passive Restraint Diagnostic Test Manual to diag nose the problem To test the airbag warning lamp operation in the cluster only refer to Group 8E Instrument Panel and Systems for procedures STRUCTURAL SEAT BELT SYSTEM CONDITIONS Refer to Group 8W wiring Diagrams for cir...

Page 362: ...OK replace Seat Belt Control Timer Module If not OK check for open or shorted circuit and repair as necessary or replace the seat belt solenoid Passenger seat belt locked driver seat belt unlock Using a ohmmeter check the seat belt solenoid from Pin 8 of the Seat Belt Control Timer Module to ground for a reading of 50 to 60 ohms If OK replace Seat Belt Control Timer Module If not OK check for open...

Page 363: ...e Codes is not required REMOVAL AND INSTALLATION AIRBAG CONTROL MODULE ACM WARNING REPLACE AIRBAG SYSTEM COMPO NENTS WITH CHRYSLER MOPART SPECIFIED REPLACEMENT PARTS SUBSTITUTE PARTS MAY VISUALLY APPEAR INTERCHANGEABLE BUT INTERNAL DIFFERENCES MAY RESULT IN INFE RIOR OCCUPANT PROTECTION THE ACM CONTAINS AN IMPACT SENSOR THAT ENABLES THE SYSTEM TO DEPLOY THE AIR BAGS TO AVOID ACCIDENTAL DEPLOYMENT ...

Page 364: ...ring is centered by using the yellow indicator in the centering window Refer to Clockspring Centering Procedure 3 Locate the clockspring on the lock housing and gently push into place Connect the natural 3 way and the yellow 2 way connectors to the back side of the clockspring 4 Install the multi function switch and tighten to 1 5 to 2 5 N m 14 to 22 in lbs torque 5 Install the steering column shr...

Page 365: ...nector The connector should be fully seated Feel for positive snap to ensure a posi tive connection 2 Connect the horn wire 3 Install two bolts and tighten to 10 to 11 N m 90 to 100 in lbs torque 4 Install covers to the steering wheel back shroud or connect the wire connectors to the speed control switches and install switches Tighten fas tener to 2 N m 20 in lbs torque 5 Do not connect the batter...

Page 366: ...lose the glove box door 16 Remove five screws attaching panel retainer to plenum 17 Remove the steering column attaching bolts 18 Disconnect the engine and body wire harness from Junction Block BCM 19 Remove the fasteners Four at the left end and three at the right end of the cross car beam Two at the steering column plenum One at the glove box hinge to cowl Two at the center support to the floor ...

Page 367: ...Refer to Diagnosis and Testing for Air bag System Test procedures SEAT BELT CONTROL TIMER MODULE REMOVAL 1 Raise parking brake lever as high as possible 2 Loosen set screw on front of shifter knob and remove shift lever knob 3 Remove plastic plunger rod from shifter lever 4 Remove cap covering screw head near shifter lever 5 Remove lighted PRNDL bezel 6 Remove screws next to floor shifter and in c...

Page 368: ... 2 Install the steering wheel ensuring the flats on hub align with the clockspring Pull the horn lead airbag and speed control leads through the larger slot Ensure leads do not get pinched under the steer ing wheel 3 Install the steering wheel retaining nut and tighten it to 61 N m 45 ft lbs torque 4 Install the airbag module Refer to Driver Air bag Module Removal and Installation for proper pro c...

Page 369: ...ck When the button is depress to the ON position current is directed to the rear defogger grid lines A yellow indicator within the center of the button will illuminate while the defogger is ON The heated grid lines will heat the rear glass and clear the window surface of fog or frost CAUTION Grid lines can be damaged or scraped off with sharp instruments care should be taken in cleaning glass or r...

Page 370: ...on 10 If the system operation has been verified but indicator bulb does not light check fuse 6 in the junction block If not OK replace as necessary If OK test the HVAC control module 11 For detailed wiring information refer to group 8W Wiring Diagrams GRID LINES The horizontal grid lines and vertical bus bar lines printed and fired on inside surface of rear window glass Fig 3 comprise an electrica...

Page 371: ...R KIT MAY CAUSE SKIN OR EYE IRRITATION THE KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER AND HARMFUL DO NOT TAKE INTERNALLY IF SWALLOWED INDUCE VOMITING AND CALL A PHYSICIAN IMME DIATELY IF CONTACTED WITH SKIN WASH AFFECTED AREAS WITH SOAP AND WATER IF CONTACTED WITH EYES FLUSH WITH PLENTY OF WATER USE WITH ADEQUATE VENTILATION DO NOT USE NEAR FIRE OR OPEN FLAME THE CONTENTS CONTAIN FLAMMABLE S...

Page 372: ... 15 minutes Hold gun approximately 254 mm 10 inches from repaired area 10 After conductive epoxy is properly cured remove wedge from terminal and check out operation of rear window defogger Do not attach connectors until curing is complete REMOVAL AND INSTALLATION HVAC CONTROL Refer to Group 8E Instrument Panel and Systems for proper Removal and Installation procedures REAR WINDOW DEFOGGER RELAY 1...

Page 373: ...y use of the door lock switches only When this system is enabled the automatic door locks will operate automatically The Body Control Module controls the power locks when the door lock switch is activated If the door lock switch is pressed for longer than eight consecu tive seconds the BCM will de energize the door lock relay Also the BCM will automatically lock all doors when all of the condition...

Page 374: ...lem maybe caused by a short or a bad switch Disconnecting the defec tive latch will allow the others to work To test an individual door latch disconnect the electrical connector from the latch To lock the door connect a 12 volt power source to the positive pin of the latch and a ground wire to the other pin Fig 1 To unlock the door reverse the wire connections at the latch pin terminals If these r...

Page 375: ...e door trim panel refer to Group 23 Body for removal procedures 2 Disconnect motor latch wire connector Fig 1 3 Disconnect linkage from Outside door handle Inside door handle Locking knobs Key cylinder 4 Remove motor latch assembly attaching screws and remove assembly INSTALLATION For installation reverse the above procedures DOOR LOCK SWITCH REMOVAL 1 Start at the rear center of the bezel Using y...

Page 376: ...ng code will go out of synchronization In this case the rolling code has to be synchronized again for complete oper ation Refer to Synchronization of Rolling Code The Deck Lid Release switch is located in the cen ter console and is disabled whenever the Vehicle Theft Security System VTSS is activated OPERATION The key fob transmitter has four buttons for oper ation Fig 1 They are LOCK UNLOCK DECK ...

Page 377: ... terminals 30 and 87 and no continuity between terminals 87A and 30 If OK refer to Relay Circuit Test procedure If not OK replace the faulty relay RELAY CIRCUIT TEST 1 The relay common feed terminal cavity 30 is connected to battery voltage and should be hot at all times If OK go to Step 2 If not OK repair the open circuit to the circuit breaker as required 2 The relay normally open terminal 87 is...

Page 378: ... the BCM 20 Pin connector for a voltage pulse Fig 3 Depress the lock button the voltmeter should read battery volt age for approximately 1 second 2 If no voltage pulse is measured replace the BCM If voltage is measured repair harness from BCM to the driver door latch Driver door will unlock with the key fob transmitter but passenger door will not lock 1 Using a voltmeter check Pin 1 2 and 3 of the...

Page 379: ...that the code has been syn chronized This may take as long as six minutes This is for a key fob transmitter that has been pre viously programed to this vehicle only REMOVAL AND INSTALLATION DECK LID RELEASE RELAY REMOVAL 1 The relay is located above the brake pedal to the right side Fig 2 2 Grasp the relay and pull downward to discon nect the relay INSTALLATION Align the relay pins with the connec...

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Page 381: ...using The Remote Keyless Entry The Central Lock Feature If the LED lamp does not illuminate at all upon door closing it indicates that the system is not arm ing or the LED lamp is not operation Refer to the System Self Tests Passive disarming occurs upon normal vehicle entry by unlocking either door with the ignition key remote transmitter This disarming will also halt the alarm once it has been a...

Page 382: ...n close each door one at a time Rotate the ignition key in each of the door lock cylinders to the lock and unlock positions Cycle the ignition switch key to the ON position as the last step A single horn pulse will indicate proper operation of the ignition switch This will also take the system out of the stand alone diagnostic mode The self diagnostic mode may also be exited by using the scan tool...

Page 383: ...lectri cal tests CIRCUIT BREAKER Find correct circuit breaker on fuse block Pull out slightly but be sure that circuit breaker terminals still contact terminals in fuse block Connect ground wire of voltmeter to a good ground With probe of voltmeter positive wire check both terminals of cir cuit breaker for battery voltage If only one terminal checks at battery voltage circuit breaker is defective ...

Page 384: ...at operation SEAT SWITCH REMOVAL 1 Remove left cushion side shield Fig 2 2 Disconnect wiring from switch 3 Remove the seat and recliner switch knobs 4 Remove attaching screws and switch from bezel INSTALLATION For installation reverse the above procedure SEAT TRACK REMOVAL 1 Seat removed from vehicle Using a clean area to place seat 2 Remove two seat back mounting screws and also remove two seat b...

Page 385: ...N For installation reverse the above procedure Fig 4 Seat Track Removal TRACK TO SEAT CUSHION SCREWS FRONT SEAT BACK RECLINER SCREWS VIEWED FROM TOP OF TRACK JX POWER SEATS 8R 3 REMOVAL AND INSTALLATION Continued ...

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Page 387: ...or battery voltage If OK go to Win dow Switch Test below If not OK check 20 amp circuit breaker in the Junction Block if the circuit breaker is OK repair wire as necessary For wiring specific connector type and location refer to Group 8W Wiring Diagrams WINDOW DROP RELAY ASSEMBLY CONDITIONS When testing for a voltage signal use a digital voltmeter because the signal will last only 280 to 380 milli...

Page 388: ...nnect the regulator from the glass lift plate Remove the two attaching screws and slide the window up and down by hand WINDOW SWITCH For switch testing remove the switch from its mounting refer to Switch Removal Using an ohm meter refer to Window Switch Continuity Charts to determine if continuity is correct Fig 2 and Fig 3 If the results are not obtained replace the switch The master window switc...

Page 389: ...regulator when the motor is removed 5 Remove three mounting screws that hold motor gearbox to regulator Fig 4 6 Remove motor from regulator INSTALLATION 1 Install new motor on regulator by positioning motor gearbox so that it engages regulator sector teeth 2 A slight rotational or rocking movement may be necessary to bring three motor gearbox screw holes into proper position 3 Install three gearbo...

Page 390: ... Use care not to mar the door trim 2 With the rear of the bezel raised pull the for ward end up to release the third clip 3 Disconnect the power window switches and door lock switch wire connectors 4 Remove attaching screws and remove window switch INSTALLATION For installation reverse the above procedures Fig 5 Window Switch Bezel 8S 4 POWER WINDOWS JX REMOVAL AND INSTALLATION Continued ...

Page 391: ... rear window defogger is on The mirror should become warm to the touch DIAGNOSIS AND TESTING HEATED MIRROR 1 Using a ohmmeter check Pin 1 of the mirror motor harness connector for continuity to ground If OK go to Step 2 If not OK repair as necessary Refer to Group 8W Wiring Diagrams 2 Activate the rear window defogger switch use a voltmeter and check Pin 2 for battery voltage a If OK go to Step 3 ...

Page 392: ...emoval refer to Group 23 Body 2 Disconnect mirror 3 Remove attaching nuts 4 Test operation of mirror before installing door trim panel INSTALLATION For installation reverse the above procedures MIRROR SWITCH REMOVAL 1 Place a small flat blade tool into the slot above the L R selector end of the switch Pushing against the switch and pulling upward will release the mounting clip located directly bel...

Page 393: ...he key was left in ignition DESCRIPTION AND OPERATION DOOR AJAR CHIME An audible chime will sound when the vehicle begins to move and the transmission range indicator display will indicate DOOR EXTERIOR LAMPS LEFT ON To test the headlamps left on function turn igni tion off turn exterior lamps on with driver s door open Chime should sound until headlamps are turned off or drivers door is closed FA...

Page 394: ...spect Body Control Module connectors and wires for proper connection NO TONE OR DOOR INDICATED IN PLACE OF ODOMETER WHEN A DOOR IS AJAR AND VEHICLE BEGINS MOVING The vehicle must be moving for the chime to occur However the door indicator will come ON regardless of the vehicle movement The CCD bus Transmission Control Module TCM and Powertrain Control Mod ule PCM must be operational 1 Check all do...

Page 395: ...MPS ARE TURNED OFF AND OR KEY IS REMOVED FROM IGNITION 1 Use scan tool to perform CCD diagnostics on Body Control Module for headlamp or key in ignition inputs 2 Check wiring for a grounded condition between key in switch and Body Control Module Check head lamp switch to Body Control Module wiring for short to battery 3 Inspect Body Control Module connectors and wires for proper connection REMOVAL...

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Page 397: ...OUTLET 8W 41 1 8W 42 AIR CONDITIONING HEATER 8W 42 1 8W 43 AIRBAG SYSTEM 8W 43 1 8W 44 INTERIOR LIGHTING 8W 44 1 8W 45 BODY CONTROL MODULE 8W 45 1 8W 46 TRAVELER 8W 46 1 8W 47 AUDIO SYSTEM 8W 47 1 8W 48 REAR WINDOW DEFOGGER 8W 48 1 8W 50 FRONT LIGHTING 8W 50 1 8W 51 REAR LIGHTING 8W 51 1 8W 52 TURN SIGNALS 8W 52 1 8W 53 WIPERS 8W 53 1 8W 60 POWER WINDOWS 8W 60 1 8W 61 POWER DOOR LOCKS 8W 61 1 8W 6...

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Page 399: ...nt is part of several different circuits it is shown in the diagram for each For example the headlamp switch is the main part of the exterior lighting but it also affects the interior lighting and the chime warning system It is important to real ize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle For example a short piece of wire is treated ...

Page 400: ...ARNING 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 ...

Page 401: ...identification wire colors and functions All connectors are viewed from the terminal end unless otherwise specified To find the connector loca tion in the vehicle refer to section 8W 90 This sec tion uses the connector identification number from the wiring diagrams to provide a figure number ref erence TAKE OUTS The abbreviation T O is used in the component location section to indicate a point in ...

Page 402: ...Fig 5 Symbol Identification 8W 01 4 8W 01 GENERAL INFORMATION JX DESCRIPTION AND OPERATION Continued ...

Page 403: ...rrosion failure of the spring If a plastic clip is missing or is lost or broken during servicing a vehicle replace only with the equivalent part listed in the parts catalog DIAGNOSIS AND TESTING TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below Jumper Wire This is a test wire used to con nect...

Page 404: ...nning any tests on a vehicles electrical system use the Wiring Diagrams and study the cir cuit Also refer to the Troubleshooting Wiring Prob lems section in this section TESTING FOR VOLTAGE 1 Connect the ground lead of a voltmeter to a known good ground Fig 9 2 Connect the other lead of the voltmeter to the selected test point The vehicle ignition may need to be turned ON to check voltage Refer to...

Page 405: ...he problem area 5 Repair the problem 6 Verify proper operation For this step check for proper operation of all items on the repaired circuit Refer to the wiring diagrams SERVICE PROCEDURES WIRING REPAIR When replacing or repairing a wire it is important that the correct gauge be used as shown in the wir ing diagrams The wires must also be held securely in place to prevent damage to the insulation ...

Page 406: ...equired Fig 15 4 Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680 Pull on the wire to remove the terminal from the connector Fig 16 Fig 17 5 Reset the terminal locking tang if it has one 6 Insert the removed wire in the same cavity on the repair connector 7 Repeat steps four through six for each wire in the connector being sure that all ...

Page 407: ...he connection together using rosin core type solder only Do not use acid core solder 13 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 14 Repeat steps 8 through 13 for each wire 15 Re tape the wire harness starting 1 1 2 inches behind the connector and 2 inches past the repair...

Page 408: ... remove 1 inch of insulation 9 Place a piece of heat shrink tubing over one side of the wire Make sure the tubing will be long enough to cover and seal the entire repair area 1 10 Spread the strands of the wire apart on each part of the exposed wires 11 Push the two ends of wire together until the strands of wire are close to the insulation 12 Twist the wires together 13 Solder the connection toge...

Page 409: ...he harness and remove the protective covering 3 Remove the diode from the harness pay atten tion to the current flow direction Fig 24 4 Remove the insulation from the wires in the harness Only remove enough insulation to solder in the new diode 5 Install the new diode in the harness making sure current flow is correct If necessary refer to the appropriate wiring diagram for current flow 6 Solder t...

Page 410: ...SPECIAL TOOLS WIRING TERMINAL Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 8W 01 12 8W 01 GENERAL INFORMATION JX ...

Page 411: ...h 8W 45 61 Decklid Solenoid 8W 61 Distributor 8W 30 Door Ajar Switches 8W 39 45 67 Door Arm Disarm Switches 8W 39 Door Courtesy Lamps 8W 44 Door Speakers 8W 47 Door Window Motor Relays 8W 60 Component Page Driver Seat Belt Solenoid 8W 67 Driver Side Airbag 8W 43 Duty Cycle Evap Purge Solenoid 8W 30 Electronic EGR Transducer Solenoid 8W 30 Engine Coolant Temperature Sensor 8W 30 Engine Starter Moto...

Page 412: ...or Assembly 8W 42 Radio 8W 47 Rear Floor Courtesy Lamp 8W 44 Rear Fog Lamp Switch 8W 51 Component Page Rear Window Defogger 8W 47 Rear Window Defogger Relay 8W 47 Remote Keyless Entry Antenna 8W 45 61 Seat Belt Control Module 8W 67 Seat Belt Switch 8W 40 45 Side Repeaters 8W 52 Speakers 8W 47 Speedometer 8W 40 Splice Details 8W 70 Stop Lamp Switch 8W 33 Tachometer 8W 40 Tail Stop Lamps 8W 51 Throt...

Page 413: ...ORMATION INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W For information on system operation refer to the appropriate section of the wiring diagrams JX 8W 02 COMPONENT INDEX 8W 02 3 ...

Page 414: ......

Page 415: ...10 7 9 11 Fuse 11 8W 10 3 7 9 Fuse 12 8W 10 3 10 11 Fuse 13 8W 10 3 10 11 Fuse 14 8W 10 3 7 10 Fuse 15 8W 10 3 7 11 Fuse 16 8W 10 3 12 13 Component Page Fuse 17 8W 10 3 7 12 Fuse 18 8W 10 3 13 Fuse 19 8W 10 3 14 G301 8W 10 6 Headlamp 8W 10 11 Headlamp Switch 8W 10 11 High Speed Radiator Fan Relay 8W 10 8 12 Ignition Switch 8W 10 6 7 13 Immobilizer 8W 10 5 8 Instrument Cluster 8W 10 6 8 Intermitten...

Page 416: ...UEL TRANSMISSION CONTROL RELAY NOT USED NOT USED RELAY WIPER INTERMITTENT A C COMPRESSOR CLUTCH RELAY RELAY STARTER MOTOR ENGINE FAN RELAY RADIATOR LOW SPEED NOT USED POWER DISTRIBUTION CENTER PDC PIN OUT INFORMATION SEE PAGE 8W 10 15 FOR 8W 10 2 8W 10 POWER DISTRIBUTION JX 978W 14 JXI00129 ...

Page 417: ...E 14 JUNCTION BLOCK TO PK WT 12 A13 40A FUSE 15 A3 12 RD WT JUNCTION TO BLOCK 40A FUSE 16 A2 12 PK BK IGNITION SWITCH TO 40A FUSE 17 TO RELAY WIPER INTERMITTENT RD GY 12 A5 S103 TO RD LG 12 A16 CENTER DISTRIBUTION POWER BATTERY 65 55 42 52 56 66 53 43 67 57 54 44 77 69 64 63 73 74 49 50 61 62 72 71 60 59 48 47 46 45 11 FUSE 40A C121 A25 12 DB TO A45 18 BR C121 TO 75 76 19 FUSE 40A 18 FUSE 40A USED...

Page 418: ...YSTEM ABS PK YL 16 A24 TRANSMISSION RELAY IN PDC 34 56 TRANSMISSION CONTROL MODULE CENTER DISTRIBUTION POWER 4 ASSEMBLY SWITCH PRESSURE SOLENOID AND TRANSMISSION T16 16 RD BR RD BR 16 T16 RD BR 16 T16 RD BR 16 T16 16 17 26 RD BR 16 T16 5 C104 S100 8W 10 5 8W 10 3 8W 30 10 8W 35 2 8W 31 2 8W 31 2 8W 10 3 8W 31 6 8W 31 7 8W 10 4 8W 10 POWER DISTRIBUTION JX 978W 14 JXI00131 ...

Page 419: ...TRAIN CONTROL MODULE S104 IN PDC A14 16 RD TN RD TN 18 A14 A14 16 RD TN 4 PK 16 A15 COMBINATION FLASHER A15 18 PK 9 C126 C1 FUSED B B FUSED 1 PK 18 A15 89 A142 18 DG OR POWER DISTRIBUTION CENTER 41 51 DG OR 18 A142 TO S118 6 C111 A142 18 DG OR 10A FUSE 1 C1 IMMOBILIZER 8W 10 3 8W 30 4 8W 33 3 8W 10 3 8W 12 2 8W 12 3 8W 12 6 8W 30 2 8W 52 3 8W 10 3 8W 70 5 8W 10 4 8W 61 5 JX 8W 10 POWER DISTRIBUTIO...

Page 420: ...AY IN PDC IN PDC RELAY MOTOR STARTER ENGINE MOTOR STARTER ENGINE BR 14 T40 T40 14 BR DG WT 14 A141 A141 14 DG WT FUEL PUMP MODULE 1 S102 IN PDC 87 79 35 27 5 C113 5 C121 BLOCK JUNCTION GY DB 22 G9 2 C2 Z1 20 BK C5 7 C4 5 G9 22 GY DB 6 C2 BRAKE WARNING LAMP INSTRUMENT CLUSTER 6 C4 3 C9 JUNCTION BLOCK BK 14 Z1 G301 RUN ACC A31 ST A41 ST RUN A21 ST RUN OFF A81 8W 10 3 8W 10 3 8W 10 13 8W 10 13 8W 30 ...

Page 421: ...FUSED IGN ST BATT A1 4 ACC 3 LOCK 0 OFF 2 RUN 1 START SWITCH IGNITION 4 1 2 0 3 3 0 2 1 4 3 0 2 1 4 3 0 2 1 4 3 0 2 1 4 4 1 2 0 3 JUNCTION BLOCK 11 FUSE 10A A41 16 YL 8 DG RD 18 A81 2 C7 2 C1 10 C2 9 C2 8 C2 BATT A1 CONTROL BODY MODULE 11 2 1 SWITCH LOCK INTER CLUTCH YL 16 A41 MTX ATX YL 16 A41 A41 16 YL RD 8W 12 12 8W 12 2 8W 31 5 8W 12 11 8W 12 11 8W 10 9 8W 10 3 8W 10 8 8W 21 2 8W 10 6 8W 12 2 ...

Page 422: ...ELAY IN PDC IN PDC RELAY FAN RADIATOR SPEED LOW HIGH SPEED RADIATOR FAN RELAY IN PDC F18 20 LG BK F18 20 LG BK F18 20 LG BK F18 20 LG BK S106 IN PDC SOLENOID PURGE EVAP CYCLE DUTY OIL PRESSURE LAMP LAMP WARNING ABS 2 F18 20 LG BK IMMOBILIZER 8W 10 3 8W 10 7 8W 40 6 8W 42 3 8W 42 4 8W 42 4 8W 30 16 8W 61 5 8W 10 8 8W 10 POWER DISTRIBUTION JX 978W 14 JXI00135 ...

Page 423: ...78 FUSED IGN ST RUN ST RUN A21 7 DB WT 18 F12 CONTROLLER ANTI LOCK BRAKE 20 C2 DB WT 18 F12 60 DB WT 18 F12 S105 IN PDC BATT A0 ST RUN IGN FUSED 46 45 11 FUSE 40A 9 C121 A25 12 DB DB 12 A25 C RELAYS DOWN UP TOP POWER 8W 30 3 8W 30 2 8W 10 3 8W 10 7 8W 35 2 8W 10 3 8W 66 2 JX 8W 10 POWER DISTRIBUTION 8W 10 9 JXI00136 978W 14 ...

Page 424: ...ITTENT WIPER RELAY IN PDC 36 28 11 BLOCK JUNCTION PK WT 12 A13 2 C3 40A FUSE 12 60 59 20A FUSE 7 8 FUSE 20A 71 72 13 FUSE 20A A45 18 BR 5 B FUSED BR 18 A45 C121 8 MODULE CONTROL BELT SEAT IN PDC RELAY LOW HIGH WIPER 8W 53 3 8W 10 3 8W 10 3 8W 53 3 8W 12 2 8W 12 8 8W 12 9 8W 67 2 8W 53 3 8W 10 10 8W 10 POWER DISTRIBUTION JX 978W 14 JXI00137 ...

Page 425: ... FUSE 9 20A FUSE 10 5 1 3 7 4 10A FUSE 12 20A FUSE 13 IN JB MODULE CONTROL BODY L4 L4 14 VT WT RD WT 14 A3 2 C6 4 C6 HEADLAMP SWITCH 62 61 15 FUSE 40A A3 12 RD WT 4 C2 C2 8W 10 3 8W 10 3 8W 12 2 8W 12 3 8W 12 12 8W 12 10 8W 12 10 8W 12 11 8W 12 11 8W 45 5 8W 50 3 JX 8W 10 POWER DISTRIBUTION 8W 10 11 JXI00138 978W 14 ...

Page 426: ...SPEED RADIATOR FAN RELAY IN PDC S103 IN PDC 49 50 17 FUSE 40A RADIATOR FAN MOTOR ASSEMBLY 88 80 98 90 39 31 2 3 C23 12 DG LG RD LG 12 A16 YL RD 12 C25 A16 12 RD LG A16 12 RD LG DB BK 14 C3 C3 14 DB BK RD LG 12 A16 1 C158 1 C113 CLUTCH COMPRESSOR A C REAR WINDOW DEFOGGER RELAY 8W 12 2 8W 47 6 8W 10 3 8W 10 3 8W 12 8 8W 42 3 8W 42 4 8W 42 4 8W 42 4 8W 42 3 8W 47 6 8W 10 12 8W 10 POWER DISTRIBUTION J...

Page 427: ...C1 DG RD 18 A81 A1 16 RD PK BK 12 A2 DB 16 A21 A41 16 YL BK WT 16 A31 A22 12 BK OR BATT A1 ST A41 ST RUN OFF A81 ST RUN A21 RUN ACC A31 C6 1 BLOCK JUNCTION 20A 19 BREAKER CIRCUIT 30A FUSE 1 15A FUSE 4 10A FUSE 16 1 C126 A2 12 PK BK RD 16 A1 8W 10 3 8W 10 3 8W 10 7 8W 10 7 8W 10 7 8W 10 7 8W 12 2 8W 12 13 8W 12 4 8W 12 5 8W 12 12 8W 10 6 8W 10 6 JX 8W 10 POWER DISTRIBUTION 8W 10 13 JXI00140 978W 14...

Page 428: ...LOCK BRAKE 20 40A FUSE 19 76 75 BATT A0 11 12 6 B120 16 BR RD BOX RELAY ABS ABS PUMP MOTOR SENSE PUMP ABS DRIVER MOTOR ABS PUMP MOTOR RELAY PUMP ABS MOTOR M 8W 10 3 8W 35 3 8W 10 3 8W 35 3 8W 35 3 8W 35 3 8W 10 14 8W 10 POWER DISTRIBUTION JX 978W 14 JXI00141 ...

Page 429: ...WT A4 12BK PK A16 12RD LG A2 12PK BK A10 12RD DG A21 16DB A21 16DB A0 4RD A142 18DG OR FEED CIRCUIT A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD A0 4RD FUSES FUNCTION CIRCUIT 33 25 3 2 1 CAVITY RELAYS NOT USED 1 2 RELAY TRANSMISSION CAVITY 4 5 6 26 34 A24 16PK YL T16 16RD BR Z13 20BK RD T15 20LG YL CIRCUIT FUNCTION 12 VOLT SUPPLY GROUND TRANS CO...

Page 430: ...PUMP FUEL CAVITY 7 8 9 27 35 A1 16RD A141 14DG WT K31 20BR LG F12 18DB WT CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT RUN START FUEL PUMP RELAY CONTROL FUSED B 3 FUEL PUMP RELAY CONTROL 4 WIPER HIGH LOW RELAY FUSED IGNITION SWITCH OUTPUT ACC RUN WIPER HIGH LOW RELAY LOW SPEED OUTPUT WIPER HIGH LOW RELAY CONTROL WIPER HIGH LOW RELAY HIGH SPEED OUTPUT WIPER RELAY COMMON WIPER RELAY COMMON FUSED B ...

Page 431: ...T A14 16RD TN A142 18DG OR CIRCUIT FUNCTION FUNCTION CIRCUIT T40 14BR A41 26YL T141 16YL RD A14 18RD TN 97 83 82 81 79 CAVITY USED NOT CAVITY 22 23 24 32 40 CIRCUIT FUNCTION 9 RELAY ENGINE STARTER MOTOR STARTER RELAY OUTPUT IGNITION SWITCH OUTPUT START IGNITION SWITCH OUTPUT START FUSED B FUSED B AUTOMATIC SHUT DOWN RELAY CONTROL FUSED B AUTOMATIC SHUT DOWN RELAY OUTPUT RELAY SHUT DOWN AUTOMATIC 1...

Page 432: ...ERATION INTRODUCTION This section covers the power distribution center and all circuits involved with it For additional infor mation on system operation refer to the appropriate section of the wiring diagrams 8W 10 18 8W 10 POWER DISTRIBUTION JX ...

Page 433: ...ay 8W 12 13 Left Fog Lamp 8W 12 16 Left Front Power Window Motor 8W 12 13 Left Headlamp 8W 12 4 11 Left Headlamp Leveling Motor 8W 12 15 Component Page Left Horn Switch 8W 12 9 Left Park Turn Signal Lamp 8W 12 15 18 Left Power Door Lock Switch 8W 12 5 7 Left Power Mirror 8W 12 8 Left Rear Turn Signal Lamp 8W 12 18 Left Side Repeater 8W 12 18 Left Tail Stop Lamp 8W 12 17 Left Visor Vanity Lamp 8W 1...

Page 434: ...ADLAMP DELAY RELAY RELAY HORN BODY CONTROL MODULE RELAY DEFOGGER REAR WINDOW JUNCTION BLOCK TOP OF SEE PAGE 8W 12 19 FOR JUNCTION BLOCK PIN OUT INFORMATION 8W 12 2 8W 12 JUNCTION BLOCK JX 978W 14 JXI00142 ...

Page 435: ...C3 C7 JUNCTION BLOCK C2 C1 C9 C8 C6 C5 C4 DRL MODULE BOTTOM OF JX 8W 12 JUNCTION BLOCK 8W 12 3 JXI00143 978W 14 ...

Page 436: ... RD OR 14 L3 3 C6 L34 18 RD OR 3 C1 6 C1 RIGHT HEADLAMP HEADLAMP LEFT LG BR 18 L33 HIGH BEAM SENSE 4 HIGH 3 LOW 0 OFF 2 PARK 1 HEAD SWITCH HEADLAMP DAYTIME RUNNING LAMP MODULE 1 1 MODULE CONTROL BODY 1 C2 C2 8W 10 13 8W 10 11 8W 42 2 8W 12 2 8W 12 3 8W 12 2 8W 12 3 8W 50 2 8W 50 2 8W 50 3 8W 50 5 8W 45 5 8W 12 4 8W 12 JUNCTION BLOCK JX 978W 14 JXI00144 ...

Page 437: ...0 WT 8 C310 WT 20 F20 F20 20 WT C9 2 SWITCH LOCK DOOR POWER LEFT RIGHT POWER DOOR LOCK SWITCH 6 POWER TOP SWITCH SWITCH TOP POWER WT 20 F20 S306 MIRROR NIGHT DAY AUTOMATIC WT 20 F20 4 F20 20 BK WT 1 6 WT 20 F20 C342 2 F20 20 WT 2 C342 F20 20 WT F20 20 WT C332 8W 10 13 8W 12 2 8W 12 3 8W 50 5 8W 31 5 8W 61 2 8W 61 2 8W 66 2 8W 66 2 8W 44 5 JX 8W 12 JUNCTION BLOCK 8W 12 5 JXI00145 978W 14 ...

Page 438: ...TA LINK CONNECTOR PK 18 M1 PK 18 M1 A A M1 18 PK LAMP VANITY VISOR RIGHT PK 18 M1 1 LAMP MAP OVERHEAD S302 1 C332 GLOVE BOX LAMP PK OR 18 M1 1 ANTENNA POWER M1 18 PK PK 18 M1 TO RELAY ENTRY ILLUMINATED OVERHEAD MAP LAMP 1 M1 18 PK OTHERS VANITY LAMPS VISOR A 8W 12 7 B 8W 12 7 C 8W 12 7 12 PK 20 M1 7 B FUSED TRAVELER S134 M1 18 PK WT C2 8W 10 5 8W 12 2 8W 44 2 8W 45 2 8W 44 3 8W 44 2 8W 47 2 8W 47 ...

Page 439: ... LEFT DOOR COURTESY LAMP 1 M1 18 PK S400 PK 18 M1 PK 20 M1 PK 20 M1 2 POWER MIRROR SWITCH SWITCH LOCK DOOR POWER LEFT 1 RIGHT DOOR COURTESY LAMP M1 18 PK 1 M1 18 PK 1 PK 18 M1 LAMP COURTESY DOOR RIGHT S401 PK 20 M1 1 RIGHT POWER DOOR LOCK SWITCH PK 18 M1 FUSE 5 JB FROM ILLUMINATED ENTRY RELAY 1 LAMP COURTESY FLOOR REAR M1 18 PK M1 18 PK 7 C342 4 A 8W 12 6 B 8W 12 6 C 8W 12 6 8W 61 2 8W 39 2 8W 39 ...

Page 440: ...10 C16 20 LB OR LB YL 20 C16 C315 3 C16 20 LB YL 3 C8 MIRROR POWER LEFT 1 RIGHT POWER MIRROR 1 DEFOGGER WINDOW REAR C9 6 C15 12 BK LB BATT A13 7 FUSE 20A 12 C7 F33 18 BK RD 2 SWITCH HEADLAMP BATT A4 C2 8W 10 12 8W 12 2 8W 47 6 8W 42 2 8W 47 6 8W 47 6 8W 47 6 8W 10 10 8W 50 3 8W 12 8 8W 12 JUNCTION BLOCK JX 978W 14 JXI00148 ...

Page 441: ...2 18 DG PK HIGH NOTE HORN HORN NOTE LOW A HORN RELAY 8 C5 LEFT HORN SWITCH SWITCH CONTROL SPEED VEHICLE SWITCH HORN RIGHT X3 18 BK RD HORN CLOCKSPRING 1 CONTROL BODY MODULE 7 HORN RELAY CONTROL 8W 12 2 8W 10 10 8W 41 2 8W 41 2 8W 41 2 8W 41 2 8W 45 12 8W 41 2 JX 8W 12 JUNCTION BLOCK 8W 12 9 JXI00149 978W 14 ...

Page 442: ...LE C1 2 IGN FUSED TRANSMISSION CONTROL MODULE ST RUN OFF RD VT 18 F11 11 6 C2 MODULE CONTROL BODY ST RUN OFF FUSED IGN ST RUN OFF A81 ST RUN OFF FUSED IGN 2 6 F11 20 RD VT 4 AUTOSTICK SWITCH C11 2 L25 18 BR 10 C2 FOG LAMP SWITCH 8W 12 2 8W 50 5 8W 40 2 8W 10 11 8W 45 2 8W 31 2 8W 45 2 8W 10 7 8W 31 3 8W 50 3 8W 12 10 8W 12 JUNCTION BLOCK JX 978W 14 JXI00150 ...

Page 443: ...A RUN ACC A31 13 10 C7 1 DB 18 F13 F13 20 DB GY 10 C2 DB GY 20 F13 IN PDC RELAY WIPER INTERMITTENT 2 2 IN PDC RELAY LOW HIGH WIPER 3 C1 4 13 C224 F13 18 DB MODULE CONTROL BELT SEAT FUSED IGN RUN ACC INTERMITTENT WIPER SWITCH COMBINATION FLASHER MODULE CONTROL BODY 4 5 HEADLAMP DELAY RELAY 11 REAR WINDOW DEFOGGER RELAY C2 C2 8W 10 11 8W 12 2 8W 12 2 8W 12 3 8W 50 2 8W 50 2 8W 50 3 8W 50 5 8W 47 2 8...

Page 444: ... YL 16 C5 ST RUN FUSED IGN BATT A3 RUN A22 SWITCH SEAT POWER A F35 16 RD 1 C9 1 C309 RD 16 F35 CIRCUIT BREAKER 18 20A DECKLID RELEASE RELAY 6 2 4 8 RD 16 F35 F35 16 RD RD 16 F35 Q2 14 LG BK DECKLID SOLENOID 1 S312 8W 12 2 8W 10 7 8W 43 2 8W 10 11 8W 10 13 8W 63 2 8W 61 4 8W 12 12 8W 12 JUNCTION BLOCK JX 978W 14 JXI00152 ...

Page 445: ...W SWITCH 1 2 RELAY MOTOR WINDOW DOOR LEFT RIGHT DOOR 2 WINDOW TIMER MODULE S410 F21 14 TN F21 14 TN F21 14 TN F21 14 TN WINDOW MOTOR RELAY 2 5 11 8 Q30 14 VT DG 14 Q29 5 Q21 14 WT 8 8 WT VT 14 Q26 1 LEFT FRONT POWER WINDOW MOTOR 8 C311 Q26 14 WT VT 4 4 C316 8W 12 2 8W 12 3 8W 10 13 8W 60 3 8W 60 2 8W 60 3 8W 60 2 8W 60 3 8W 60 4 8W 60 2 JX 8W 12 JUNCTION BLOCK 8W 12 13 JXI00153 978W 14 ...

Page 446: ...BK OR Z1 20 BK WT Z1 16 BK LB Z1 14 BK 2 ILLUMINATED ENTRY RELAY Z1 18 BK 3 C332 Z1 18 BK OVERHEAD MAP LAMP DAY NIGHT AUTOMATIC SWITCH HEADLAMP 5 BK TN 18 Z1 C4 3 LAMP MODULE 10 MIRROR MIRROR NIGHT DAY AUTOMATIC BK RD 20 Z13 C4 8 SWITCH AUTOSTICK 3 G301 C1 C2 2 8 C11 Z1 18 BK HEADLAMP LEVELING SWITCH 8W 12 2 8W 12 3 8W 45 2 8W 50 5 8W 44 3 8W 30 17 8W 10 6 8W 40 8 8W 47 4 8W 45 9 8W 44 3 8W 50 3 8...

Page 447: ...LEFT PARK TURN SIGNAL LAMP BK BR 18 L7 2 L7 18 BK YL 8 4 C300 L7 18 BK YL L7 18 BK YL TO S406 RIGHT TO BK YL 18 L7 1 BK BR 18 L7 MOTOR LEVELING HEADLAMP LEFT 1 L7 18 BK YL MOTOR LEVELING HEADLAMP RIGHT C2 TAIL STOP LAMP 8W 12 2 8W 12 3 8W 45 6 8W 50 3 8W 47 2 8W 50 4 8W 50 4 8W 45 6 8W 51 2 8W 50 4 8W 50 4 JX 8W 12 JUNCTION BLOCK 8W 12 15 JXI00155 978W 14 ...

Page 448: ...10 LB 18 L39 9 LAMP FOG SWITCH MODULE G9 G9 G9 GY DB 20 GY DG 20 IGNITION SWITCH PARK BRAKE SWITCH CLUSTER INSTRUMENT C2 L39 18 LB L39 18 LB A LAMP LEFT FOG FOG RIGHT LAMP A G9 18 GY 15 C224 BRAKE ANTI LOCK CONTROLLER C2 8W 12 3 8W 50 5 8W 50 3 8W 40 7 8W 10 6 8W 40 7 8W 40 7 8W 50 3 8W 50 3 8W 35 6 8W 12 16 8W 12 JUNCTION BLOCK JX 978W 14 JXI00156 ...

Page 449: ...3 C2 WT TN 16 L50 L50 WT TN 18 C9 9 L50 WT TN 18 2 C301 LAMP STOP TAIL RIGHT LEFT TAIL STOP LAMP C300 2 18 WT TN L50 A L50 WT TN 18 18 BK TN L50 2 L50 WT TN 18 1 C305 LAMP STOP MOUNTED HIGH CENTER S313 8W 12 3 8W 35 6 8W 33 3 8W 51 2 8W 51 2 8W 51 2 JX 8W 12 JUNCTION BLOCK 8W 12 17 JXI00157 978W 14 ...

Page 450: ...PARK TURN 1 L60 TN 18 1 L60 TN BR 18 L60 18 TN C7 8 6 WARNING SWITCH RIGHT SIDE REPEATER REPEATER SIDE LEFT 18 LG TN L61 S135 L60 18 TN BR S136 TN 18 L60 A L60 TN 18 C9 4 3 C301 LAMP SIGNAL TURN REAR RIGHT LEFT REAR TURN SIGNAL LAMP C300 3 5 C9 18 LG TN L61 A L61 18 LG TN C1 C1 8W 12 3 8W 50 4 8W 50 4 8W 40 8 8W 52 2 8W 52 2 8W 52 2 8W 52 4 8W 52 4 8W 12 18 8W 12 JUNCTION BLOCK JX 978W 14 JXI00158...

Page 451: ...WT A81 DG RD A22 BK OR A3 RD WT FUSES RELAY OUTPUT BCM FUSED B RELAY CONTROL BCM FUSED B FUNCTION CIRCUIT A3 RD WT G50 A3 RD WT L4 5 4 3 2 1 CAVITY HEADLAMP DELAY RELAY COLOR GREEN BLUE BLUE RED BLUE BLUE YELLOW YELLOW RED YELLOW BLUE BLUE YELLOW BLUE BLUE BLUE BLUE SILVER SILVER SECTION 8W 50 8W 50 8W 50 8W 50 8W 41 SECTION RELAY HORN CAVITY 6 7 8 9 10 X2 DG PK F30 RD X3 BK RD F30 RD CIRCUIT FUNC...

Page 452: ...volved with it For additional information on system oper ation please refer to the appropriate section of the wiring diagrams This section identifies the fuses relays modules and internal circuity of the junction block For additional infor mation on system operation refer to the appropriate group of the wiring diagrams ...

Page 453: ...2 Left Power Door Lock Switch 8W 15 8 Left Power Mirror 8W 15 8 Left Rear Fog Lamp 8W 15 6 Left Rear Turn Signal Lamp 8W 15 6 Component Page Left Side Repeater 8W 15 2 Left Tail Stop Lamp 8W 15 6 Low Note Horn 8W 15 4 Master Power Window Switch 8W 15 8 Overhead Map Lamp 8W 15 10 Passenger Seat Belt Solenoid 8W 15 9 Power Amplifier 8W 15 10 Power Antenna 8W 15 7 Power Mirror Switch 8W 15 8 Power Se...

Page 454: ... 18 BK B LEFT FOG LAMP Z1 18 BK 3 LEFT PARK TURN SIGNAL INTERMITTENT WIPER RELAY IN PDC BK 16 Z1 G102 TO S109 Z1 12 BK BATTERY Z0 4 BK G100 G101 Z0 6 BK 1 LAMP A 8W 15 3 Z3 18 BK 3 LEFT HEADLAMP LEVELING MOTOR 2 BK 18 Z1 LEFT SIDE REPEATER 8W 42 4 8W 53 3 8W 33 3 8W 30 10 8W 50 3 8W 50 4 8W 53 3 8W 20 2 8W 50 4 8W 52 2 8W 15 2 8W 15 GROUND DISTRIBUTION JX 978W 14 JXI00160 ...

Page 455: ...OL MODULE Z12 18 BK TN Z12 18 BK TN 10 C113 50 C1 BK TN 18 Z12 SWITCH PRESSURE WARNING BRAKE 53 BK YL 18 Z14 BK RD 20 Z13 6 S101 Z1 12 BK FROM S109 Z14 18 BK YL G102 IN PDC TRANSMISSION RELAY B BK 20 Z1 A 8W 15 2 8W 50 2 8W 31 2 8W 30 2 8W 40 7 8W 31 2 JX 8W 15 GROUND DISTRIBUTION 8W 15 3 JXI00161 978W 14 ...

Page 456: ... RIGHT Z1 18 BK WINDSHIELD WASHER PUMP MOTOR B BK 18 Z1 HIGH NOTE HORN CAPACITOR HORN NOTE LOW B Z1 18 BK BK 20 Z1 A WASHER FLUID LEVEL SWITCH BK 18 Z1 B RIGHT FOG LAMP Z1 16 BK LAMP MOTOR PUMP ABS BK 18 Z1 2 RIGHT SIDE REPEATER 3 MOTOR LEVELING HEADLAMP RIGHT Z3 18 BK 8W 50 2 8W 30 10 8W 35 2 8W 35 4 8W 35 2 8W 35 3 8W 35 2 8W 50 4 8W 53 2 8W 41 2 8W 35 3 8W 41 2 8W 40 9 8W 50 3 8W 35 3 8W 52 2 8...

Page 457: ...ION BK PK 18 Z6 AIRBAG CONTROL MODULE 8 G201 Z2 20 BK LG C2 BODY CONTROL MODULE G105 DISTRIBUTOR Z1 16 BK 2 5L 5 C2 11 C1 S200 C2 Z1 18 BK RADIO Z1 16 BK TRAVELER 5 BK 20 Z1 BK 18 Z1 IMMOBILIZER 6 8W 44 4 8W 41 2 8W 42 2 8W 44 3 8W 12 2 8W 43 2 8W 45 2 8W 30 5 8W 47 2 8W 46 2 8W 61 5 JX 8W 15 GROUND DISTRIBUTION 8W 15 5 JXI00163 978W 14 ...

Page 458: ... LAMP Z1 18 BK 2 C300 2 C301 Z1 18 BK Z1 18 BK S405 Z1 18 BK BK 14 Z1 FROM S301 Z1 18 BK RELAYS B 8W 15 7 LAMP STOP TAIL LEFT LAMP SIGNAL TURN REAR LEFT LEFT LICENSE LAMP G BK 18 Z1 RIGHT LICENSE LAMP LEFT REAR FOG LAMP LAMP STOP TAIL RIGHT LAMP SIGNAL TURN REAR RIGHT 8W 66 2 8W 30 3 8W 51 3 8W 51 4 8W 51 3 8W 51 2 8W 52 4 8W 51 2 8W 51 2 8W 51 4 8W 51 2 8W 52 4 8W 15 6 8W 15 GROUND DISTRIBUTION J...

Page 459: ...ED STOP LAMP S301 Z1 18 BK 3 C305 Z1 18 BK VTSS SOLENOID DECKLID BK 14 Z1 G300 TO SEAT BELT CONTROL MODULE 13 Z2 18 BK LG G304 G303 BK 12 Z1 DEFOGGER WINDOW REAR POWER ANTENNA 3 Z1 18 BK B 8W 15 6 8W 30 3 8W 39 2 8W 51 2 8W 61 4 8W 67 2 8W 47 6 8W 47 2 8W 47 6 JX 8W 15 GROUND DISTRIBUTION 8W 15 7 JXI00165 978W 14 ...

Page 460: ...DOOR SWITCH LOCK MOTOR RELAY WINDOW DOOR LEFT 6 6 RIGHT DOOR WINDOW RELAY MOTOR Z1 20 BK Z1 20 BK Z1 20 BK Z1 20 BK Z1 20 BK Z1 20 BK Z1 14 BK S402 Z1 14 BK 9 C311 Z1 14 BK S308 TO C 8W 15 9 8W 60 4 8W 60 2 8W 60 3 8W 47 6 8W 62 2 8W 61 2 8W 60 2 8W 60 3 8W 15 8 8W 15 GROUND DISTRIBUTION JX 978W 14 JXI00166 ...

Page 461: ...MODULE C1 S403 Z1 14 BK Z1 20 BK Z1 20 BK 9 C316 Z1 14 BK SWITCH TOP POWER 2 4 6 C342 Z1 20 BK Z1 20 BK B LED PRNDL Z1 18 BK Z1 18 BK Z1 16 BK 2 C309 Z1 16 BK Z1 18 BK PASSENGER SEAT BELT SOLENOID 1 Z1 18 BK C341 1 Z1 18 BK SEAT BELT SWITCH 2 Z1 20 BK LG Z1 14 BK FROM S402 LOCK SWITCH C 8W 15 8 D 8W 15 10 2 C340 Z1 20 BK LG 8W 61 2 8W 47 6 8W 63 2 8W 67 2 8W 12 2 8W 30 12 8W 67 2 8W 45 2 8W 66 2 8...

Page 462: ...K Z11 18 BK Z1 20 BK Z1 18 BK OR Z1 20 BK WT Z1 16 BK LB G301 TO Z1 14 BK 2 ILLUMINATED ENTRY RELAY Z1 18 BK 3 C332 Z1 18 BK OVERHEAD MAP LAMP DAY NIGHT AUTOMATIC SWITCH HEADLAMP 5 BK TN 18 Z1 C4 3 LAMP MODULE 10 MIRROR MIRROR NIGHT DAY AUTOMATIC D 8W 15 9 BK RD 20 Z13 C4 8 SWITCH AUTOSTICK 3 8W 12 3 8W 45 2 8W 50 5 8W 44 3 8W 30 17 8W 10 6 8W 40 2 8W 47 4 8W 45 9 8W 44 3 8W 50 3 8W 44 5 8W 31 3 8...

Page 463: ...ifies the grounds splices that connect to those grounds and the components that connect those grounds For additional information on system operation refer to the appropriate section of the wiring diagrams For an illustration of the physical location of each ground refer to group 8W 90 ...

Page 464: ......

Page 465: ...matic Shut Down Relay 8W 20 2 Battery 8W 20 2 Fuse 1 8W 20 2 Fuse 5 8W 20 2 Fusible Link 8W 20 2 G100 8W 20 2 G101 8W 20 2 Generator 8W 20 2 Component Page Power Distribution Center 8W 20 2 Powertrain Control Module 8W 20 2 S104 8W 20 2 S113 8W 20 2 S114 8W 20 2 S118 8W 20 2 JX 8W 20 CHARGING SYSTEM 8W 20 1 ...

Page 466: ... DG OR DG OR 18 A142 S114 RD 8 A11 2 4L 2 5L A142 18 DG OR A0 4 RD BATTERY G100 Z0 4 BK LINK FUSIBLE G101 Z0 6 BK FUSE 1 TO S113 A142 18 DG OR 5 FUSE 20A 43 53 POWER DISTRIBUTION CENTER RD TN 16 A14 AUTOMATIC SHUT DOWN RELAY IN PDC IN PDC S104 PDC 8W 30 4 8W 30 5 8W 70 5 8W 70 3 8W 10 4 8W 10 5 8W 10 3 8W 10 5 8W 20 2 8W 20 CHARGING SYSTEM JX 978W 14 JXI00169 ...

Page 467: ... circuit is controlled by the Automatic Shut Down ASD relay The ground or voltage regulated side of the generator field is controlled by the K20 circuit Cir cuit K20 connects to cavity 4 of the PCM When there is current present in the field and the rotor is turning the stator in the generator produces a B voltage that is supplied to the battery through the A11 and A0 circuits The A11 circuit is co...

Page 468: ......

Page 469: ...Inter Lock Switch 8W 21 2 Engine Starter Motor 8W 21 2 Engine Starter Motor Relay 8W 21 2 Fuse 8 8W 21 2 Ignition Switch 8W 21 2 Component Page Power Distribution Center 8W 21 2 Powertrain Control Module 8W 21 2 S102 8W 21 2 Transmission Control Module 8W 21 2 Transmission Range Switch 8W 21 2 JX 8W 21 STARTING SYSTEM 8W 21 1 ...

Page 470: ... 20A FUSE 8 54 44 S102 A1 16 RD A1 16 RD BATTERY A0 6 RD CENTER DISTRIBUTION POWER TO MODULE CONTROL POWERTRAIN 8 IGN ST TRANSMISSION CONTROL MODULE 1 2 PN A0 4 RD T41 18 BK WT YL OR 16 A41 ENGINE STARTER MOTOR 1 PULL IN 2 HOLD IN M A41 16 YL 2 1 SWITCH LOCK INTER CLUTCH MTX ATX YL 16 A41 A41 16 YL RD 8W 10 6 8W 31 5 8W 10 6 8W 10 6 8W 10 3 8W 30 13 8W 31 5 8W 10 6 8W 20 2 8W 21 2 8W 21 STARTING S...

Page 471: ...er Distribution Center PDC supplies bat tery voltage to the engine starter motor solenoid through circuit T40 when the coil side of the engine starter motor relay energizes Circuit A1 contains a 20 amp fuse and feeds the contact side of the engine starter motor relay Both the 20 amp fuse and the engine starter motor relay are located in the PDC The ignition switch supplies battery voltage to the c...

Page 472: ......

Page 473: ...5 G300 8W 30 3 G301 8W 30 12 17 G302 8W 30 3 Generator 8W 30 5 High Speed Radiator Fan Relay 8W 30 15 Idle Air Control Motor 8W 30 16 Ignition Coil Pack 8W 30 4 Intake Air Temperature Sensor 8W 30 11 Junction Block 8W 30 17 Component Page Knock Sensor 8W 30 12 Low Speed Radiator Fan Relay 8W 30 15 Manifold Absolute Pressure Sensor 8W 30 11 Noise Suppressor 8W 30 4 Power Distribution Center 8W 30 2...

Page 474: ...A21 10 FUSE 10A 70 78 POWER DISTRIBUTION CENTER DB WT 18 F12 6 C113 F12 18 DB WT DB WT 18 F12 C2 C2 C1 53 43 20A FUSE 5 FUSED B C1 46 RD TN 16 A14 A14 16 RD TN BATT A0 GROUND IN PDC S105 S104 IN PDC 8W 15 3 8W 15 3 8W 10 7 8W 10 9 8W 10 3 8W 10 5 8W 10 3 8W 10 9 8W 10 5 8W 30 2 8W 30 FUEL IGNITION SYSTEM JX 978W 14 JXI00171 ...

Page 475: ...B WT 1 3 2 4 Z1 16 BK BK LG 18 Z2 G300 MODULE PUMP FUEL DG WT 14 A141 5 C121 SIGNAL SENSOR LEVEL FUEL C5 15 DB 18 G4 ST RUN A21 S102 RD 16 A1 54 44 20A FUSE 8 A1 16 RD BATT A0 IN JB MODULE CONTROL BODY G302 Z1 14 BK BK 18 Z1 S301 M 8W 10 9 8W 10 3 8W 10 9 8W 15 6 8W 10 7 8W 10 6 8W 10 6 8W 10 3 8W 45 9 8W 15 7 8W 15 7 JX 8W 30 FUEL IGNITION SYSTEM 8W 30 3 JXI00172 978W 14 ...

Page 476: ...NOISE A142 18 DG OR 3 2 1 S118 S131 DB DG 18 K17 DRIVER NO 2 IGN COIL 3 C2 C2 2 K19 18 BK GY IGN COIL DRIVER NO 1 SPARK PLUGS TO TO PLUGS SPARK 1 2 3 4 IN PDC RELAY SHUT DOWN AUTOMATIC 5 FUSE 20A 43 53 POWER DISTRIBUTION CENTER A14 16 RD TN IN PDC S104 2 0L PACK COIL IGNITION PDC 8W 10 5 8W 10 4 8W 70 5 8W 70 7 8W 10 5 8W 10 3 8W 10 5 8W 30 4 8W 30 FUEL IGNITION SYSTEM JX 978W 14 JXI00173 ...

Page 477: ...OR SIGNAL CMP SENSOR SIGNAL C2 6 DRIVER NO 1 IGN COIL 11 C2 BK GY 18 K19 DRIVER NO 1 IGN COIL SENSOR GROUND C1 43 SENSOR GROUND 1 C2 BK LB 18 K4 10 K4 18 BK LB OR WT 20 K7 C111 5 C2 2 44 C1 K7 18 OR WT 5V SUPPLY 5V SUPPLY C2 5 BK 16 Z1 2 3 4 5 6 1 S117 S124 G105 S110 IN PDC TO SPARK PLUGS GROUND OUTPUT RELAY ASD GENERATOR FIELD AUTOMATIC SHUT DOWN RELAY DISTRIBUTOR 2 5L PDC 8W 10 5 8W 10 3 8W 10 4...

Page 478: ...G OR NO 1 INJECTOR FUEL FUEL INJECTOR NO 2 DG OR 18 A142 17 C2 INJ NO 2 DRIVER K12 18 TN 2 1 FUEL INJECTOR NO 3 DG OR 18 A142 7 C2 INJ NO 3 DRIVER K13 18 YL WT 2 1 FUEL INJECTOR NO 4 DG OR 18 A142 16 C2 INJ NO 4 DRIVER K14 18 LB BR 2 1 S114 S118 AUTOMATIC SHUT DOWN RELAY PDC 8W 10 5 8W 10 4 8W 10 3 8W 70 3 8W 70 5 8W 30 4 8W 30 6 8W 30 FUEL IGNITION SYSTEM 2 0L ENGINE JX 978W 14 JXI00175 ...

Page 479: ... FUEL INJECTOR NO 4 DG OR 18 A142 16 C2 NO 4 DRIVER K14 18 LB BR BR DG 18 K58 DRIVER NO 6 C2 14 A142 18 DG OR NO 6 INJECTOR FUEL INJ INJ INJ INJ CENTER DISTRIBUTION POWER S118 A142 18 DG OR INJ TN 18 K12 DRIVER NO 2 C2 17 A142 18 DG OR NO 2 INJECTOR FUEL DG OR 18 A142 2 S114 1 C165 DG OR 18 A142 A142 18 DG OR 2 1 2 1 2 1 S123 A142 18 DG OR AUTOMATIC SHUT DOWN RELAY PDC 8W 10 5 8W 10 4 8W 10 3 8W 7...

Page 480: ...120 GY BK 20 K24 GROUND SENSOR 2 3 SUPPLY 5V 1 1 S124 5V SUPPLY 44 C1 OR WT 18 K7 5 C111 5V SUPPLY K44 20 TN YL C2 33 CMP SENSOR SIGNAL K7 20 OR WT K7 20 OR WT BK LB 20 K4 OR WT 20 K7 CMP SENSOR SIGNAL CRANKSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR 2 0L IN PDC S110 K24 18 GY BK 8W 70 4 8W 31 4 8W 70 6 8W 70 2 8W 30 8 8W 30 FUEL IGNITION SYSTEM JX 978W 14 JXI00177 ...

Page 481: ...OR LB 20 K22 K22 18 OR LB 2 5L 2 0L S121 OR LB 18 K22 TP SENSOR SIGNAL S116 K4 18 BK LB BK LB 18 K4 BK LB 18 K4 K4 20 BK LB 10 C111 K4 18 BK LB S117 IN PDC S110 K4 18 BK LB S130 3 2 0L 1 2 5L VT WT 18 K6 K6 18 VT WT 2 5L 2 0L 1 3 8W 70 3 8W 31 4 8W 70 4 8W 70 4 8W 70 2 8W 70 7 JX 8W 30 FUEL IGNITION SYSTEM 8W 30 9 JXI00178 978W 14 ...

Page 482: ...0 Z1 BK 16 Z1 G103 S111 Z1 18 BK BK 12 Z1 S109 S118 18 A142 18 A142 DG OR DG OR S110 IN PDC 1 4 2 3 A142 18 DG OR 3 2 POWERTRAIN CONTROL MODULE 30 C2 UPSTREAM HEATED OXYGEN SENSOR SIGNAL S117 BK LB 20 K4 DG OR A142 18 2 5L 2 0L 2 5L 2 0L S130 K4 18 BK LB S116 BK LB 18 K4 K4 18 BK LB K4 18 BK LB K4 18 BK LB UPSTREAM HEATED OXYGEN SENSOR S114 1 4 8W 30 4 8W 10 5 8W 10 3 8W 15 3 8W 10 4 8W 15 4 8W 15...

Page 483: ...115 S117 S116 BK LB 18 K4 K6 18 VT WT S118 DG OR 18 A142 ASD RELAY OUTPUT A SENSOR TEMPERATURE AIR INTAKE C B A SENSOR PRESSURE ABSOLUTE MANIFOLD K4 18 BK LB 2 1 SOLENOID TRANSDUCER EGR ELECTRONIC C2 40 EGR SOLENOID CONTROL K35 18 GY YL S110 IN PDC S130 K4 18 BK LB 2 5L 2 0L DB OR 18 A142 A142 18 DG OR BK LB 18 K4 8W 70 3 8W 70 4 8W 70 4 8W 70 5 8W 70 2 8W 70 7 JX 8W 30 FUEL IGNITION SYSTEM 8W 30 ...

Page 484: ...K LB KNOCK SENSOR 2 0L IN PDC S110 POWERTRAIN CONTROL MODULE K42 18 BK LB 24 C2 C1 45 DB LG 18 K10 KNOCK SENSOR SIGNAL 2 1 Z1 18 BK 16 C121 BK 18 Z1 G301 C1 4 POWER STEERING PRESSURE SWITCH SENSE SWITCH PRESSURE STEERING POWER IN JB MODULE CONTROL BODY Z2 20 BK LG 8W 70 4 8W 70 2 8W 15 9 8W 45 2 8W 30 12 8W 30 FUEL IGNITION SYSTEM JX 978W 14 JXI00181 ...

Page 485: ... REQ MGMT TORQUE SENSE REQUIREMENT MANAGEMENT TORQUE 63 C1 YL DG 20 T10 10 TRANSMISSION CONTROL MODULE V37 20 RD LG C126 3 C1 41 RD LG 20 V37 T41 20 BK LB ST A41 4 3 2 1 SPEED CONTROL VENT SOLENOID CONTROL CONTROL SPEED CONTROL VENT SOLENOID SENSE SWITCH RANGE TRANS SIGNAL SWITCH CONTROL SPEED SWITCH 4 ON OFF 2 RESUME ACCEL 3 SET COAST VEHICLE SPEED CONTROL HORN 1 CANCEL 58 G7 18 WT OR C1 66 VSS S...

Page 486: ... 18 PK LY 52 C1 IN PDC S110 BK LB 18 K4 BK LB 18 K4 S117 K4 20 BK LB K4 18 BK LB S116 SENSOR TEMPERATURE BATTERY GROUND SENSOR SIGNAL SENSOR TEMP BATTERY SIGNAL PRESSURE A C 5V SUPPLY SIGNAL PRESSURE A C GROUND SENSOR TRANSDUCER PRESSURE A C 2 BK LB 18 K4 S130 K4 18 BK LB 8W 70 3 8W 70 2 8W 70 4 8W 70 4 8W 70 7 8W 30 14 8W 30 FUEL IGNITION SYSTEM JX 978W 14 JXI00183 ...

Page 487: ...CH COMPRESSOR A C C28 20 DB OR DB PK 20 C27 69 C1 DB TN 20 C24 55 C1 LOW IN PDC RELAY CLUTCH COMPRESSOR A C IN PDC FAN RELAY RADIATOR SPEED HIGH IN PDC FAN RELAY RADIATOR SPEED LOW IN PDC S106 CONTROL RELAY FAN RADIATOR SPEED HIGH SPEED RADIATOR FAN RELAY CONTROL 8W 10 7 8W 10 3 8W 10 8 8W 42 3 8W 42 4 8W 42 4 8W 10 8 JX 8W 30 FUEL IGNITION SYSTEM 8W 30 15 JXI00184 978W 14 ...

Page 488: ... NO 3 DRIVER BR GY K40 3 B K40 BR GY MOTOR CONTROL AIR IDLE C111 S106 IN PDC F18 20 LG BK LG BK 20 F18 68 58 9 FUSE 10A ST RUN A21 1 2 C1 68 CONTROL SOLENOID PURGE EVAP K52 20 PK GY PURGE EVAP CYCLE DUTY CENTER DISTRIBUTION POWER 20 20 20 20 20 20 IAC MOTOR NO 3 NO 4 MOTOR IAC IAC MOTOR NO 2 NO 1 MOTOR IAC SOLENOID 8W 10 8 8W 10 8 8W 10 7 8W 10 3 8W 30 16 8W 30 FUEL IGNITION SYSTEM JX 978W 14 JXI0...

Page 489: ...1 6 C1 65 TRANSMIT SCI D21 20 PK LB 51 46 PK LG 20 D21 PK LB 20 D6 CONTROLLER ANTI LOCK BRAKE S127 D21 20 PK LB TRANSMISSION CONTROL MODULE RECEIVE SCI SCI TRANSMIT 7 TRANSMIT SCI 14 BATT A7 FUSE 5 10A 11 C5 M1 18 PK WT BLOCK JUNCTION 16 CONNECTOR LINK DATA 10 11 C126 D6 20 PK LB BODY CONTROL MODULE S134 BUS CCD CCD BUS S132 S133 8W 15 9 8W 12 2 8W 12 3 8W 35 5 8W 31 8 8W 10 5 8W 12 2 8W 12 6 8W 4...

Page 490: ...M This circuit originates in the Power Distribution Center PDC and is protected by a 20 amp fuse located in cavity 5 It is also spliced and provides power for the Automatic Shut Down ASD relay coil and contact sides POWER DEVICE GROUND Circuit Z12 connects to cavities 10 and 50 of the Powertrain Control Module PCM connector The Z12 circuits provides ground for the PCM internal drivers that operate...

Page 491: ... and A141 Circuit A1 is connected to the BUS bar in the PDC HOT at all times and protected by a 20 amp fuse located in cavity 8 Circuit A141 is con nected from the relay to the fuel pump motor Ground for the fuel pump motor is provided on cir cuit Z1 HELPFUL INFORMATION Check the 20 amp fuse located in cavity 8 of the PDC Check the 10 amp fuse located in cavity 10 of the PDC Check the ground Refer...

Page 492: ...rain Control Module PCM to the camshaft position sen sor The K7 circuit connects to cavity 44 of the PCM connector Circuit K44 from the sensor provides an input sig nal to the PCM The K44 circuit connects to cavity 33 of the PCM The PCM provides a ground for the camshaft posi tion sensor signal circuit K44 through circuit K4 Circuit K4 connects to cavity 43 of the PCM connec tor HELPFUL INFORMATIO...

Page 493: ...hicle speed sensor Heated oxygen sensors INTAKE AIR TEMPERATURE SENSOR On the 2 0L engine the intake air temperature sen sor is combination unit with the map sensor The intake air temperature sensor provides an input to the Powertrain Control Module PCM on circuit K21 The K21 circuit connects to cavity 37 of the PCM connector From circuit K21 the intake air temperature sen sor draws voltage from t...

Page 494: ...cts circuits A14 and A142 Circuit A14 also supplies voltage to the coil side of the ASD relay The Powertrain Control Module PCM controls the ground path circuit for the coil side of the ASD relay on circuit K51 Circuit K51 con nects to cavity 67 of the PCM Circuit A142 supplies voltage for the ignition coil pack The coil pack consists of two individual coils molded together The PCM controls the gr...

Page 495: ...y 40 of the PCM connector Circuit A142 is spliced and connects with the fuel injectors generator and the Automatic Shut Down ASD relay This circuit is HOT when the ASD relay is energized HELPFUL INFORMATION Refer to Group 14 for system operation VAPOR CANISTER LEAK DETECTOR Power for the vapor canister leak detector is pro vided on circuit F18 This circuit is protected by a 10 amp fuse located in ...

Page 496: ......

Page 497: ... Back Up Lamp 8W 31 5 Low Reverse Pressure Switch 8W 31 6 Low Reverse Solenoid 8W 31 7 Output Shaft Speed Sensor 8W 31 3 Overdrive Pressure Switch 8W 31 6 Overdrive Solenoid 8W 31 7 Component Page Power Distribution Center 8W 31 2 6 7 Powertrain Control Module 8W 31 4 5 8 S100 8W 31 2 6 7 S101 8W 31 2 S110 8W 31 4 S120 8W 31 4 S121 8W 31 4 S125 8W 31 3 5 S127 8W 31 8 S132 8W 31 8 S133 8W 31 8 Thro...

Page 498: ...16 16 S100 3 FUSE 20A 52 42 POWER DISTRIBUTION CENTER BATT A0 56 B FUSED A24 16 PK YL A24 16 PK YL IN PDC RELAY TRANSMISSION 10A FUSE 11 RD VT 18 F11 ST RUN OFF A81 6 C2 JUNCTION BLOCK 11 ST RUN OFF IGN FUSED OUTPUT RELAY TRANSMISSION TRANSMISSION RELAY OUTPUT 8W 15 3 8W 15 3 8W 15 3 8W 15 3 8W 10 4 8W 10 4 8W 10 3 8W 10 3 8W 12 10 8W 10 7 8W 12 2 8W 31 2 8W 31 TRANSMISSION CONTROL SYSTEM JX 978W ...

Page 499: ...AL SENSOR SPEED INPUT F11 20 RD VT Z1 14 BK BK RD 20 Z13 G301 3 ST RUN OFF A81 AUTOSTICK DOWNSHIFT SWITCH SENSE SENSE SWITCH UPSHIFT AUTOSTICK LG LB 20 T5 T5 20 LG LB 5 SWITCH AUTOSTICK YL LB 20 T44 C126 13 T44 20 YL LB SWITCH EFFECT HALL 1 4 2 44 5 JUNCTION BLOCK 11 FUSE 10A C7 10 RD VT 18 F11 INSTRUMENT CLUSTER TO C9 3 C4 8 JUNCTION BLOCK 8W 70 6 8W 15 9 8W 10 7 8W 12 2 8W 12 10 8W 40 2 8W 12 3 ...

Page 500: ...AL SENSOR POSITION THROTTLE THROTTLE POSITION SENSOR SIGNAL 35 C2 OR LB 20 K22 12 C113 9 K22 20 OR LB K22 18 OR LB S121 S120 K22 18 OR LB OR LB 20 K22 POWERTRAIN CONTROL MODULE GROUND SENSOR SENSOR GROUND BK LB 20 K4 K4 20 BK LB S110 SIGNAL SENSOR SPEED VEHICLE VEHICLE SPEED SENSOR SIGNAL WT OR 18 G7 43 C1 51 58 66 C1 8W 30 8 8W 30 9 8W 30 8 8W 30 9 8W 30 13 8W 70 2 8W 31 4 8W 31 TRANSMISSION CONT...

Page 501: ...ND SENSOR SPEED S125 SENSOR TEMP TRANS 5 BK LB 18 T41 4 ACC 3 LOCK 0 OFF 2 RUN 1 START SWITCH IGNITION 4 1 2 0 3 10 7 T41 20 BK WT 81 83 8 YL OR 16 A41 A41 16 YL BATT A1 C2 BACK UP LEFT TO LAMP PARK NEUTRAL POSITION SWITCH SENSE SWITCH T42 SENSE SENSE SWITCH POSITION NEUTRAL PARK SENSE T1 SWITCH BK WT 20 T41 IN PDC RELAY MOTOR STARTER ENGINE TO MODULE CONTROL POWERTRAIN TRANS RANGE RANGE TRANS IGN...

Page 502: ...0 T50 18 DG TN YL GY 18 T47 47 8 OR BK 18 T9 9 C104 1 C104 DG TN 18 T50 T47 20 YL GY T9 20 OR BK 2 4 PRESSURE SWITCH SENSE SENSE SWITCH PRESSURE OVERDRIVE SENSE SWITCH PRESSURE REVERSE LOW 5 C104 RELAY TRANSMISSION LOW REVERSE PRESSURE SWITCH SWITCH PRESSURE 2 4 SWITCH PRESSURE OVERDRIVE 8W 10 3 8W 10 4 8W 10 4 8W 31 2 8W 31 6 8W 31 TRANSMISSION CONTROL SYSTEM JX 978W 14 JXI00191 ...

Page 503: ...ENOID REVERSE LOW T20 18 LB WT T20 20 LB WT WT PK 18 T19 19 6 2 4 SOLENOID CONTROL PK DB 18 T59 59 9 UNDERDRIVE SOLENOID CONTROL BR TN 18 T60 60 C104 10 OVERDRIVE SOLENOID CONTROL T19 20 WT PK T60 18 BR TN T59 18 PK DB RELAY TRANSMISSION LOW REVERSE SOLENOID SOLENOID 2 4 UNDERDRIVE SOLENOID OVERDRIVE SOLENOID 8W 10 3 8W 10 4 8W 10 4 8W 31 2 JX 8W 31 TRANSMISSION CONTROL SYSTEM 8W 31 7 JXI00192 978...

Page 504: ... TORQUE MANAGEMENT REQUIREMENT SENSE SCI TRANSMIT 7 PK LG 20 D21 TORQUE MANAGEMENT REQUIREMENT SENSE D6 20 PK LB D21 20 PK LG 7 14 DATA LINK CONNECTOR S127 PK LG 20 D21 6 C126 PK LG 20 D21 IN JB MODULE CONTROL BODY 11 C3 C3 1 CCD BUS CCD BUS D1 20 VT BR D2 20 WT DB 3 11 S132 S133 8W 30 13 8W 30 17 8W 30 17 8W 30 17 8W 45 3 8W 45 3 8W 45 3 8W 31 8 8W 31 TRANSMISSION CONTROL SYSTEM JX 978W 14 JXI001...

Page 505: ...involved are D1 for CCD positive and D2 for CCD negative Circuits D6 and D21 are connected from the TCM to the universal data link connector The D6 ciruit is used for SCI receive and the D21 circuit is used for SCI transmit TRANSMISSION CONTROL RELAY The Transmission Control Relay located in the Power Distribution Center PDC is used to power the Trans mission Solenoids and Pressure Switches Power ...

Page 506: ...ector Ground for the sensor is supplied on circuit T13 This circuit is spliced with the turbine speed and out put speed sensor This circuit connects to cavity 13 of the TCM connector TRANSMISSION RANGE SENSOR The Transmission Range Sensor TRS is located internal to the transmission This sensor provides the Transmission Control Module TCM with informa tion on shift lever position contains the trans...

Page 507: ...ng 8W 33 3 Cruise Engaged Lamp 8W 33 2 Fuse 11 8W 33 2 G102 8W 33 3 Instrument Cluster 8W 33 2 Junction Block 8W 33 2 Powertrain Control Module 8W 33 2 3 Component Page S109 8W 33 3 S132 8W 33 2 S133 8W 33 2 Stop Lamp Switch 8W 33 3 Vehicle Speed Control Servo 8W 33 3 Vehicle Speed Control Horn Switch 8W 33 3 JX 8W 33 VEHICLE SPEED CONTROL 8W 33 1 ...

Page 508: ...ST RUN OFF CRUISE ENGAGED LAMP CONTROL CCD BUS BUS CCD BUS CCD CCD BUS BUS CCD CCD BUS F11 18 RD VT D1 20 VT BR D2 20 WT BK ST RUN OFF A81 WT DB 18 D2 VT BR 20 D1 C2 7 C2 8 C3 11 BUS CCD CCD BUS 1 C3 D1 20 VT BR D2 18 WT DB S132 S133 8W 12 10 8W 12 2 8W 40 2 8W 40 3 8W 30 17 8W 45 3 8W 10 7 8W 45 3 8W 45 3 8W 33 2 8W 33 VEHICLE SPEED CONTROL JX 978W 14 JXI00194 ...

Page 509: ...ET COAST 2 RESUME ACCEL 4 ON OFF 4 3 2 1 V37 20 RD LG 3 C126 1 2 4 3 GROUND BODY CONTROL MODULE IN JB 22 C3 C1 12 GROUND SWITCH LAMP STOP Z2 20 BK LG K29 18 WT RD V32 20 YL PK V32 20 YL PK 8 C113 3 4 1 2 V36 20 WT VT V35 20 LG RD V30 20 DB RD SERVO CONTROL SPEED VEHICLE Z1 20 BK Z1 12 BK S109 G102 SWITCH CLOCKSPRING 3 BR TN 18 Z2 CLOCKSPRING 2 RD LG 20 V37 8W 30 13 8W 45 4 8W 45 9 8W 15 2 8W 15 3 ...

Page 510: ...and uses this information to apply volt age on the V35 circuit which is the vent side of the vehicle speed control servo Circuit V35 connects to cavity 80 of the PCM Grounding for the vehicle speed control servo is supplied on the Z2 circuit Circuit Z2 terminates at the left strut tower An additional input to the servo is provided by the stop lamp switch on the V30 cir cuit When the operator press...

Page 511: ...35 2 Fuse 11 8W 35 6 Fuse 19 8W 35 3 G102 8W 35 6 G103 8W 35 2 3 4 G301 8W 35 6 Ignition Switch 8W 35 6 Component Page Instrument Cluster 8W 35 2 6 Junction Block 8W 35 6 Left Front Decay Solenoid 8W 35 4 Left Front Wheel Speed Sensor 8W 35 5 Left Rear Decay Solenoid 8W 35 4 Left Rear Wheel Speed Sensor 8W 35 5 Park Brake Switch 8W 35 6 Power Distribution Center 8W 35 2 3 6 Right Front Decay Solen...

Page 512: ...LG BK 15 ABS WARNING LAMP DRIVER G19 20 LG OG 15 C126 G19 20 LG OR OUTPUT RELAY SYSTEM ABS 47 57 ABS SYSTEM RELAY CONTROL B47 16 RD LB B57 20 BR BK 10 4 9 1 ABS RELAY BOX 20A FUSE 2 55 65 BATT A0 A20 16 RD DB Z1 14 BK G103 S112 G19 20 LG OR A20 16 RD DB A21 16 DB F18 18 LG BK TO ABS PUMP MOTOR RELAY A 8W 35 3 8W 10 9 8W 10 3 8W 10 8 8W 40 6 8W 10 9 8W 10 8 8W 10 4 8W 15 4 8W 15 4 8W 10 7 8W 10 3 8...

Page 513: ...0 3 5 ABS RELAY BOX 40 FUSE 19 75 76 BATT A0 A10 12 RD DG Z1 14 BK G103 S112 Z1 14 BK 6 GROUND 5 Z1 18 BK 51 SCI TRANSMIT 7 S127 D21 20 PK LG D21 20 PK LG 6 C126 D21 20 PK LG CONNECTOR DATA LINK CAPACITOR FROM ABS SYSTEM RELAY A 8W 35 2 PUMP ABS MOTOR 8W 10 3 8W 10 14 8W 15 4 8W 15 4 8W 30 17 8W 30 17 8W 10 3 JX 8W 35 ANTI LOCK BRAKES 8W 35 3 JXI00197 978W 14 ...

Page 514: ...REAR CONTROL SOLENOID DECAY RIGHT REAR 1 6 2 3 4 LEFT FRONT DECAY 5 MODULATOR HYDRAULIC ABS B142 20 BR YL BR LB 20 B146 DG YL 20 B143 DG LB 20 B148 Z1 18 BK Z1 18 BK Z1 14 BK S112 G103 SOLENOID SOLENOID DECAY REAR LEFT SOLENOID DECAY FRONT RIGHT RIGHT REAR DECAY SOLENOID 8W 15 4 8W 15 4 8W 35 4 8W 35 ANTI LOCK BRAKES JX 978W 14 JXI00198 ...

Page 515: ...EEL REAR LEFT 1 2 7 RIGHT FRONT WHEEL SPEED SENSOR SENSOR SPEED WHEEL FRONT RIGHT 6 SENSOR SPEED WHEEL FRONT RIGHT 1 2 2 RIGHT REAR WHEEL SPEED SENSOR SENSOR SPEED WHEEL REAR RIGHT 1 SENSOR SPEED WHEEL REAR RIGHT B8 20 OR DB OR 20 B9 WT DB 20 B6 WT 20 B7 B3 20 LG DB B3 20 LG DB 3 C121 4 LG 20 B4 LG 20 B4 1 YL DB 20 B1 YL DB 20 B1 C121 2 YL 20 B2 YL 20 B2 JX 8W 35 ANTI LOCK BRAKES 8W 35 5 JXI00199 ...

Page 516: ... C1 1 C1 6 C5 RED BRAKE WARNING LAMP DRIVER 14 G9 20 GY DG SWITCH BRAKE PARK G9 18 GY B A SWITCH PRESSURE WARNING BRAKE G9 20 GY DB G9 22 GY DB G102 S101 Z1 20 BK Z13 14 BK RD BLOCK JUNCTION JUNCTION BLOCK Z1 20 BK G301 Z1 14 BK C9 3 C4 6 BLOCK JUNCTION 15 C224 3 LOCK 4 ACC 0 OFF 2 RUN 1 START SWITCH IGNITION 1 4 3 0 2 1 C2 2 C2 8W 10 3 8W 12 10 8W 40 7 8W 10 5 8W 12 2 8W 33 3 8W 12 3 8W 15 3 8W 1...

Page 517: ...res Manual ABS WARNING LAMP The ABS warning lamp is controlled by the Con troller Anti Lock Brake CAB and or the Hydraulic control unit It is used to alert the operator of a prob lem in the ABS system The G19 circuit from the CAB and the ABS system relay is used to detect a problem If a problem is detected the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster Circuit G...

Page 518: ...input to the Controller Anti Lock Brake CAB The L50 connects to cavity 13 of the CAB connector Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied DATA LINK CONNECTOR Circuit D21 is used for diagnostics of a fault within the ABS system It is spliced in with the Powertrain Control Module PCM circuits and is used as an ou...

Page 519: ... 8W 40 3 High Beam Indicator Lamp 8W 40 5 Ignition Switch 8W 40 7 Instrument Cluster 8W 40 2 3 4 5 6 7 8 9 Junction Block 8W 40 2 7 8 Component Page Lamp 8W 40 3 Left Turn Signal Indicator 8W 40 8 Low Fuel Warning Lamp 8W 40 4 Low Washer Fluid Level Lamp 8W 40 9 Malfunction Indicator Lamp Check Engine 8W 40 3 Odometer 8W 40 5 Oil Pressure Lamp 8W 40 6 Oil Pressure Switch 8W 40 6 Park Brake Switch ...

Page 520: ... G301 Z1 14 BK BODY CONTROL MODULE JUNCTION BLOCK 7 FUSE 20A C7 11 BATT A13 PK RD 20 F33 C1 5 FUSED B 3 C9 10 CCD BUS BUS CCD C2 7 C2 8 C3 11 BUS CCD CCD BUS 1 C3 D1 20 VT BR D1 20 VT BR D2 20 WT DB D2 20 WT DB S133 S132 8W 12 10 8W 12 2 8W 15 9 8W 12 2 8W 12 3 8W 45 2 8W 45 3 8W 12 6 8W 10 10 8W 10 7 8W 45 3 8W 45 3 8W 12 14 8W 40 2 8W 40 INSTRUMENT CLUSTER JX 978W 14 JXI00204 ...

Page 521: ...TROL ENGINE COOLANT TEMPERATURE SYSTEM WARNING CHARGING LAMP CONTROL LAMP SYSTEM WARNING CHARGING MALFUNCTION INDICATOR LAMP CHECK ENGINE LAMP CONTROL MALFUNCTION INDICATOR CHECK ENGINE LAMP CONTROL ENGAGED VEHICLE SPEED CRUISE CONTROL LAMP ENGAGED CRUISE C2 7 C2 8 C3 11 BUS CCD CCD BUS 1 C3 C1 59 60 C1 CCD BUS BUS CCD IN JB MODULE CONTROL BODY D1 20 VT BR D1 20 VT BR D2 20 WT DB D2 20 WT DB S133 ...

Page 522: ... 4 2 FUEL PUMP MODULE G4 18 DB Z2 18 BK LG G300 WARNING LOW FUEL LAMP CONTROL WARNING LAMP LOW FUEL G302 Z1 14 BK Z1 18 BK S301 S308 Z1 14 BK C2 7 C2 8 C3 11 BUS CCD CCD BUS 1 C3 IN JB MODULE CONTROL BODY D1 20 VT BR D1 20 VT BR D2 20 WT DB D2 20 WT DB S133 S132 1 C340 LG RD 20 G10 2 C340 Z1 20 BK LG 8W 15 9 8W 30 3 8W 15 6 8W 15 7 8W 15 7 8W 15 9 8W 45 3 8W 45 9 8W 45 3 8W 45 3 8W 40 4 8W 40 INST...

Page 523: ...ODOMETER TRIP ODOMETER CONTROL TRIP ODOMETER AIRBAG AIRBAG WARNING LAMP HIGH BEAM HIGH BEAM LAMP CONTROL INDICATOR INDICATOR LAMP CONTROL DOOR AJAR DOOR AJAR INDICATOR LAMP LAMP INDICATOR 4 3 C3 12 2 C3 WT DB 18 D2 VT BR 18 D1 BUS CCD CCD BUS AIRBAG CONTROL MODULE BUS CCD CCD BUS C1 C1 C2 7 C2 8 C3 11 BUS CCD CCD BUS 1 C3 IN JB MODULE CONTROL BODY D1 20 VT BR D1 20 VT BR D2 20 WT DB D2 20 WT DB S1...

Page 524: ... 20 GY 8 C111 G6 20 GY G6 18 GY VT LAMP WARNING ABS C2 13 15 G19 20 LG OR 7 ABS RELAY BOX G19 20 LG OR 15 BRAKE ANTI LOCK CONTROLLER ABS WARNING LAMP DRIVER G19 20 LG OR 6 TRAVELER F18 20 LG BK WT BK 20 D2 3 C2 2 1 C2 4 D1 20 VT FUSED IGN ST RUN CCD BUS BUS CCD CCD BUS BUS CCD 8W 10 8 8W 10 7 8W 10 3 8W 10 8 8W 35 2 8W 35 2 8W 46 2 8W 40 6 8W 40 INSTRUMENT CLUSTER JX 978W 14 JXI00208 ...

Page 525: ... G9 18 GY B A SWITCH PRESSURE WARNING BRAKE G9 20 GY DB 2 0 3 4 1 C2 1 C2 2 IGNITION SWITCH 1 START 2 RUN 0 OFF 4 ACC 3 LOCK G9 22 GY DB G102 S101 Z1 20 BK Z13 14 BK RD BLOCK JUNCTION Z1 20 BK G301 Z1 14 BK C9 3 C4 6 BLOCK JUNCTION IN JB MODULE LAMP RUNNING DAYTIME G9 15 C224 G9 18 GY 8W 12 10 8W 12 2 8W 35 6 8W 10 6 8W 15 3 8W 15 3 8W 12 3 8W 15 9 8W 12 3 8W 50 5 8W 10 7 8W 12 14 JX 8W 40 INSTRUM...

Page 526: ...NDICATOR FOG LAMP INDICATOR INDICATOR RIGHT TURN SIGNAL 1 C1 1 C2 C7 9 C7 7 BLOCK JUNCTION 8 C7 3 C7 L61 18 LG TN TN BR 18 L60 L36 18 LG 7 6 HAZARD SIGNAL TURN 5 L61 18 LG L60 18 TN 10 C1 4 BK LG 18 Z2 14 GROUND C3 WARNING SWITCH C2 SWITCH LAMP FOG REAR 8W 15 9 8W 12 2 8W 12 3 8W 45 2 8W 45 7 8W 12 3 8W 52 2 8W 51 4 8W 12 14 8W 12 18 8W 12 18 8W 40 8 8W 40 INSTRUMENT CLUSTER JX 978W 14 JXI00210 ...

Page 527: ...L LAMP FLUID LEVEL LOW WASHER S111 Z1 16 BK TRUNK AJAR SWITCH SENSE 13 C1 C1 8 SENSE SWITCH WASHER FLUID G78 20 TN BK 10 C224 G78 20 TN BK S304 G78 20 TN BK C126 BK TN 20 G29 10 BK TN 20 G29 SWITCH Z1 20 BK TRUNK AJAR SWITCH 2 LAMP TRUNK G78 20 TN BK 8W 15 4 8W 15 4 8W 44 3 JX 8W 40 INSTRUMENT CLUSTER 8W 40 9 JXI00211 978W 14 ...

Page 528: ...ted in cavity 12 of the Power Distribution Center PDC Circuit A13 also supplies power to the fuses for the horns and the cigar lighter The second power source for the cluster is the F11 circuit This circuit is HOT in the OFF START and RUN positions The F11 circuit is protected by a 10 amp fuse located in cavity 11 of the junction block Illumination lamps internal to the cluster receive battery vol...

Page 529: ...e the proper milage for the vehicle the BCM receives information from the Powertrain Control Module PCM and the Transmission Control Module TCM over the CCD Bus It then calculates this information and sends the proper signal over the CCD Bus to the instrument cluster TRIP ODOMETER The trip odometer function of the instrument clus ter is controlled by the Body Control Module BCM All information is ...

Page 530: ...redetermined level The switch is case grounded to the engine block Power for the lamp is supplied on the F18 circuit This circuit also powers the Anti Lock lamp located internal to the cluster high speed fan relay A C Clutch relay and the Powertrain Control Module PCM This circuit is protected by a 10 amp fuse located in cavity 9 of the Power Distribution Center PDC The ground side of the lamp is ...

Page 531: ... FLUID LAMP The low washer fluid lamp is used to alert the operator that the washer fluid level is below a prede termined level Power for the switch is supplied on circuit G29 from the instrument cluster When the washer fluid level is low the switch CLOSES completing a path to ground through the switch illuminating the lamp HIGH BEAM INDICATOR LAMP Operation of the high beam indicator lamp is con ...

Page 532: ......

Page 533: ...hter Power Outlet 8W 41 2 Clockspring 8W 41 2 Fuse 8 8W 41 2 G103 8W 41 2 G200 8W 41 2 High Note Horn 8W 41 2 Horn Relay 8W 41 2 Component Page Junction Block 8W 41 2 Left Horn Switch 8W 41 2 Low Note Horn 8W 41 2 Right Horn Switch 8W 41 2 S111 8W 41 2 S200 8W 41 2 Vehicle Speed Control Horn Switch 8W 41 2 JX 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 ...

Page 534: ...H NOTE HORN X2 18 DG PK X2 18 DG PK Z1 18 BK Z1 18 BK S111 G103 Z1 16 BK LEFT HORN SWITCH SWITCH CONTROL SPEED VEHICLE SWITCH HORN RIGHT X3 18 BK RD B A A B HORN RELAY CONTROL BATT A13 HORN S200 Z1 16 BK 7 CLOCKSPRING 1 8W 12 9 8W 12 2 8W 15 5 8W 45 12 8W 15 4 8W 15 4 8W 10 10 8W 15 5 8W 41 2 8W 41 HORN CIGAR LIGHTER POWER OUTLET JX 978W 14 JXI00212 ...

Page 535: ...s spliced to the Body Control Module BCM For operation of the VTSS refer to section 8W 39 HELPFUL INFORMATION Check the 20 amp fuse in cavity 8 of the junc tion block Check the 40 amp fuse located in cavity 12 of the PDC Press the horn switch and listen for the horn relay to click A clicking relay indicates voltage is present up to the switch Check for a good ground at the left strut tower for the...

Page 536: ......

Page 537: ...or Resistor Block 8W 42 2 Body Control Module 8W 42 2 3 Fuse 1 8W 42 2 Fuse 9 8W 42 3 4 Fuse 17 8W 42 3 4 G102 8W 42 4 G200 8W 42 2 High Speed Radiator Fan Relay 8W 42 4 Component Page Junction Block 8W 42 2 Low Speed Radiator Fan Relay 8W 42 4 Mode Door Actuator 8W 42 2 Power Distribution Center 8W 42 3 4 Powertrain Control Module 8W 42 3 4 Radiator Fan Motor Assembly 8W 42 4 S103 8W 42 3 4 S106 ...

Page 538: ... 9 HIGH 10 A C OFF 11 A C ON GROUND SENSOR DRIVER DOOR MODE SUPPLY 5V COMMON DOOR DRIVER SIGNAL FEEDBACK DOOR MODE HVAC MODE SENSE MODE DOOR DRIVER SUPPLY 5V DRIVER DOOR COMMON SIGNAL FEEDBACK DOOR MODE SENSOR GROUND C4 18 TN DG 12 C1 LG 18 C5 LB 18 C6 C7 12 BK TN GY TN 22 C57 C37 20 YL DB YL 22 C34 C26 20 PK DB DG YL 22 C35 C58 22 RD BK PK 22 Z2 19 C3 GROUND OR 18 E2 6 C2 G200 C2 1 Z1 12 BK DRIVE...

Page 539: ... C1 59 D1 20 VT BR CCD BUS C TRANSDUCER PRESSURE A C A B A C PRESSURE SIGNAL SENSOR GROUND 5V SUPPLY 42 C1 SIGNAL PRESSURE A C SENSOR GROUND C1 43 61 C1 SUPPLY C18 20 DB YL C18 20 DB YL 7 C113 K4 20 BK LB K4 20 BK LB K4 18 BK LB 10 S117 S116 K6 20 VT WT K6 20 VT WT C111 9 K6 20 VT WT S115 1 SENSOR TEMPERATURE EVAPORATOR A C 7 C3 C3 21 2 C12 20 LG BK C57 22 GY EVAP TEMP SENSOR SIGNAL GROUND SENSOR ...

Page 540: ... MOTOR FAN RADIATOR C23 12 DG LG YL RD 12 C25 Z1 12 BK Z1 12 BK G102 S109 C1 69 S106 LG BK 20 F18 S103 A16 12 RD LG C27 20 DB PK POWERTRAIN CONTROL MODULE HIGH SPEED RADIATOR FAN RELAY CONTROL CONTROL RELAY FAN RADIATOR SPEED LOW DB TN 20 C24 55 C1 CENTER DISTRIBUTION POWER M M 8W 10 8 8W 10 12 8W 15 3 8W 15 2 8W 10 8 8W 10 12 8W 30 15 8W 10 3 8W 10 7 8W 10 3 8W 42 4 8W 42 AIR CONDITIONING HEATER ...

Page 541: ...or defrost door Power for the mode door actuator is provided by the Body Control Module BCM on the C26 circuit This is a 5 volt feed Circuit C35 is the mode drive circuit from the BCM to the actuator The C37 circuit is the feedback from the actuator to the BCM The BCM uses this information to adjust the door to the proper position Circuit C57 is the sensor return to the BCM This circuit is spliced...

Page 542: ...n motor Ground for the motor is pro vided on circuit Z1 which terminates at the left strut tower When HIGH speed fan operation is required the PCM grounds circuit C27 This causes the contacts in the relay to CLOSE connecting circuits A16 and C25 Circuit C25 connects from the relay to the high speed portion of the fan motor Ground for the motor is pro vided on circuit Z1 which terminates at the lef...

Page 543: ...2 3 Airbag Warning Lamp 8W 43 3 Body Control Module 8W 43 3 Data Link Connector 8W 43 3 Driver Side Airbag 8W 43 2 Fuse 11 8W 43 3 Fuse 16 8W 43 2 Fuse 17 8W 43 2 Component Page G201 8W 43 2 Instrument Cluster 8W 43 3 Junction Block 8W 43 2 3 Passenger Side Airbag 8W 43 2 S132 8W 43 3 S133 8W 43 3 JX 8W 43 AIRBAG SYSTEM 8W 43 1 ...

Page 544: ...18 DG LB BK YL 18 R42 DG YL 18 R44 2 C2 LINE 1 AIRBAG PASSENGER PASSENGER AIRBAG LINE 2 C2 1 1 2 AIRBAG SIDE DRIVER DRIVER AIRBAG LINE 1 LINE 2 AIRBAG DRIVER PASSENGER AIRBAG LINE 2 LINE 1 AIRBAG PASSENGER PASSENGER SIDE AIRBAG 2 1 RUN A22 17 FUSE 10A C5 16 ST RUN A21 11 C1 GROUND G201 Z6 18 BK PK 8W 12 12 8W 12 2 8W 12 12 8W 10 13 8W 10 7 8W 43 2 8W 43 AIRBAG SYSTEM JX 978W 14 JXI00216 ...

Page 545: ... BUS BUS CCD F11 18 RD VT D1 20 D2 20 ST RUN OFF A81 WT DB 18 D2 VT BR 18 D1 BUS CCD CCD BUS BUS CCD CCD BUS 4 3 AIRBAG CONTROL MODULE 12 C3 C3 2 C1 C1 C2 7 C2 8 C3 11 BUS CCD CCD BUS 1 C3 DATA S132 S133 WT DB 20 D2 WT DB 20 D2 VT BR 20 D1 VT BR WT DB VT BR 20 D1 8W 12 10 8W 12 2 8W 40 5 8W 30 17 8W 45 3 8W 10 7 8W 45 3 8W 45 3 JX 8W 43 AIRBAG SYSTEM 8W 43 3 JXI00217 978W 14 ...

Page 546: ...Z6 The dedicated ground con nects to the floor pan near the ACM The ACM is also interfaced with the CCD Bus Cir cuit D1 is used for CCD and circuit D2 is used for CCD AIRBAG IMPACT SENSOR The Airbag system uses a sensor internal to the Airbag Control Module ACM to detect impact For information regarding operation of this sensor refer to the appropriate group of the Service Manual AIRBAG SQUIB AIRB...

Page 547: ...W 44 4 Junction Block 8W 44 2 3 4 5 6 Key In Halo Lamp 8W 44 2 Left Back Up Lamp 8W 44 5 Left Door Courtesy Lamp 8W 44 6 Left Visor Vanity Lamp 8W 44 2 Overhead Map Lamp 8W 44 3 Panel Lamps Dimmer Switch 8W 44 4 Component Page Power Top Switch 8W 44 4 PRNDL Led 8W 44 4 Radio 8W 44 6 Rear Floor Courtesy Lamp 8W 44 2 3 5 6 Right Door Courtesy Lamp 8W 44 6 Right Visor Vanity Lamp 8W 44 2 S134 8W 44 2...

Page 548: ...CKOUT S302 M1 18 PK 1 C332 PK WT 18 M1 C5 11 KEY IN HALO LAMP 1 2 M50 20 YL RD DRIVER LAMP KEY IN 7 C2 4 ILLUMINATED ENTRY RELAY M1 18 PK M1 18 PK M1 18 PK 1 LAMP COURTESY FLOOR REAR S134 M1 20 PK WT 7 C342 5 C332 2 DECKLID RELEASE SWITCH G38 18 GY C342 5 MODULE CONTROL BODY IN JB 8W 12 6 8W 12 2 8W 10 5 8W 12 6 8W 44 3 8W 44 6 8W 12 6 8W 61 4 8W 45 9 8W 44 2 8W 44 INTERIOR LIGHTING JX 978W 14 JXI...

Page 549: ...10 JUNCTION BLOCK 2 S307 M2 18 YL 4 8 RELAY ENTRY ILLUMINATED Z1 18 BK M2 18 YL Z1 18 BK MODULE CONTROL BODY ILLUMINATED ENTRY RELAY 9 CONTROL GROUND 10 M1 18 PK 1 C10 6 M112 20 BR LG M112 20 BR LG M1 18 PK 2 C332 M2 18 YL REAR FLOOR COURTESY LAMP 1 PK 18 M1 LAMP C342 7 S134 M1 20 PK WT C9 3 G301 Z1 14 BK 8W 12 6 8W 12 2 8W 10 5 8W 15 5 8W 40 9 8W 15 5 8W 12 6 8W 12 2 8W 12 3 8W 70 7 8W 45 2 8W 45...

Page 550: ... PANEL LAMPS PANEL C4 2 C2 3 DRIVER LAMPS PANEL 10 C2 C2 11 CLUSTER ILLUMINATION LAMPS Z1 18 BK OR OR YL 18 E2 INSTRUMENT CLUSTER C2 C2 0 OFF 2 PARK 1 HEAD SWITCH HEADLAMP Z1 18 BK Z1 12 BK 10 Z1 16 BK S200 C224 E2 18 OR BK 16 9 C342 NOT USED G301 4 2 POWER TOP SWITCH Z1 20 BK Z1 20 BK 6 C342 Z1 18 BK S308 Z1 14 BK Z1 18 BK E2 18 OR BK C2 C1 C2 8W 12 8 8W 12 2 8W 10 10 8W 45 2 8W 45 7 8W 12 2 8W 1...

Page 551: ...NGE SWITCH L1 18 VT BK 10 C105 6 C121 6 C332 L1 18 BK VT C10 4 G301 Z1 14 BK 3 C9 M2 18 BK YL VT BK 18 L1 3 C332 Z1 18 BK L1 18 VT BK 2 Z1 18 BK Z1 18 BK GROUND ILLUM ENTRY INPUT B FUSED SENSE REVERSE M1 18 PK 7 C342 MIRROR NIGHT DAY AUTOMATIC TO LAMP BACK UP LEFT PK 18 M1 1 LAMP COURTESY FLOOR REAR RUN IGN FUSED 8W 12 6 8W 12 2 8W 10 5 8W 12 3 8W 12 6 8W 44 3 8W 70 7 8W 12 5 8W 10 13 8W 12 5 8W 3...

Page 552: ...RIGHT DOOR COURTESY 1 2 JUNCTION BLOCK 7 C9 C8 2 M1 18 PK 2 C310 M1 18 PK S400 M1 18 PK PK 18 M1 S401 PK 18 M1 C315 2 PK 18 M1 YL 18 M2 M2 18 YL YL 18 M2 M2 18 YL 1 C310 C315 1 C2 4 OR BR 18 E2 RADIO 5 C2 DRIVER LAMPS PANEL 12 TO S302 M1 18 PK 1 C332 FUSED B 8W 45 2 8W 45 7 8W 10 5 8W 12 6 8W 70 7 8W 12 2 8W 12 7 8W 12 7 8W 47 2 8W 44 3 8W 12 6 8W 44 6 8W 44 INTERIOR LIGHTING JX 978W 14 JXI00222 ...

Page 553: ... located in the junction block is used to control the ground path for the inte rior lamps Power for the relay is supplied on circuit M1 This is the Ignition Off Draw IOD circuit and is protected by a 10 amp fuse located in cavity 5 of the junction block Ground for the relay is supplied on circuit M112 This circuit connects from the relay to the Body Con trol Module BCM When the BCM provides a grou...

Page 554: ...ound through the switch and the lamp on circuit Z1 This ground ter minates at the instrument panel left side cowl ASH RECEIVER LAMP The ash receiver lamp receives power on the E2 circuit from the Body Control Module BCM This circuit is HOT when the operator has turned the headlamp switch to the PARK or ON position Lamp intensity is controlled by the input of the dimmer switch to the BCM on circuit...

Page 555: ... Left Power Door Lock Motor 8W 45 10 Left Power Door Lock Switch 8W 45 10 Left Remote Keyless Entry Antenna 8W 45 10 Component Page Left Tail Stop Lamp 8W 45 6 Left Visor Vanity Lamp 8W 45 9 Mode Door Actuator 8W 45 8 Panel Lamps Dimmer Switch 8W 45 7 Power Distribution Center 8W 45 4 9 Power Steering Pressure Switch 8W 45 2 Powertrain Control Module 8W 45 3 PRNDL Led 8W 45 7 Radio 8W 45 6 7 Rear ...

Page 556: ... IGN ST RUN OFF 10A FUSE 11 9 FUSE 15A B FUSED BATT A3 BATT A7 FUSED B 10A FUSE 5 4 1 2 0 3 2 C1 2 C7 A81 18 DG RD 4 C1 GROUND Z1 18 BK 11 6 2 12 BATT A1 10 Z2 20 BK LG 2 16 C121 C2 8 GROUND Z2 20 BK LG G200 ST RUN IGN FUSED 8W 10 6 8W 12 2 8W 15 9 8W 10 6 8W 30 12 8W 12 10 8W 12 10 8W 10 11 8W 10 5 8W 12 6 8W 10 6 8W 15 5 8W 12 14 8W 10 7 8W 45 2 8W 45 BODY CONTROL MODULE JX 978W 14 JXI00223 ...

Page 557: ...G 20 D1 MODULE CONTROL TRANSMISSION 43 BUS CCD CCD BUS 4 C1 6 14 C1 CCD BUS BUS CCD C2 7 C2 8 INSTRUMENT CLUSTER CCD BUS BUS CCD C3 11 BUS CCD CCD BUS 1 C3 D1 20 VT BR D1 20 VT BR D2 20 WT DB D2 20 WT DB S132 DATA LINK CONNECTOR WT DB 20 D2 VT BR 20 D1 11 3 S133 4 Z2 20 BK VT C3 4 GROUND VT BR 20 D1 D2 20 WT DB CCD BUS BUS CCD IMMOBILIZER 3 4 8W 43 2 8W 30 17 8W 31 8 8W 40 2 8W 30 17 8W 61 5 JX 8W...

Page 558: ...WER DISTRIBUTION CENTER CONTROL CONTROL WIPER ON OFF RELAY 7 C1 V16 20 VT PK V14 20 PK VT MOTOR PUMP WASHER WINDSHIELD PARK SENSE SWITCH WIPER WT GY 20 V55 D WINDSHIELD WIPER MOTOR RUN ACC F13 10 13 SWITCH LAMP STOP 2 GROUND C1 12 BK LG 20 Z2 F13 20 DB GY BODY CONTROL MODULE IN JB INTERMITTENT SIGNAL C1 C1 8W 53 2 8W 53 3 8W 53 3 8W 10 3 8W 53 2 8W 53 3 8W 12 11 8W 33 3 8W 45 4 8W 45 BODY CONTROL ...

Page 559: ... 2 5 RELAY DELAY HEADLAMP CONTROL HEADLAMP DELAY RELAY BEAM LOW DIM OUTPUT OUTPUT DIM HIGH BEAM BATT A3 3 1 BATT A3 1 4 5 SWITCH SWITCH 9 RELAY ENTRY ILLUMINATED CONTROL 1 C10 M112 20 BR LG 6 BATT M1 ILLUMINATED ENTRY RELAY C2 C2 8W 12 2 8W 50 3 8W 10 11 8W 10 11 8W 12 6 8W 44 3 8W 12 4 8W 12 11 JX 8W 45 BODY CONTROL MODULE 8W 45 5 JXI00226 978W 14 ...

Page 560: ...FT 1 LAMP 10 C9 BK YL 18 L7 4 C300 L7 18 BK YL S406 L7 18 BK YL L7 18 BK YL 1 18 BK YL L7 B STOP TAIL RIGHT LAMP 8 OUTPUT SWITCH LAMP PARK L7 18 BK YL C301 4 C2 1 BK BR 18 L7 MOTOR LEVELING HEADLAMP LEFT 1 BK YL 18 L7 RIGHT HEADLAMP LEVELING MOTOR LEFT LICENSE LAMP LAMP LICENSE RIGHT 8W 12 2 8W 12 3 8W 50 3 8W 12 8 8W 50 4 8W 50 4 8W 47 2 8W 51 2 8W 51 2 8W 50 4 8W 50 4 8W 51 2 8W 51 2 8W 45 6 8W ...

Page 561: ...E2 18 OR E2 18 OR DRIVER LAMPS PANEL LAMPS PANEL C3 14 C2 3 DRIVER LAMPS PANEL 10 C2 C1 4 Z2 18 BK LG OR YL 18 E2 INSTRUMENT CLUSTER C2 0 OFF 2 PARK 1 HEAD SWITCH HEADLAMP PRNDL LED LAMP ASH 1 RECEIVER GROUND BATT F33 GENERAL ILLUMINATION 16 C224 E2 18 OR BK 9 C342 E2 18 OR BK NOT USED C2 8W 12 2 8W 47 2 8W 42 2 8W 40 8 8W 50 3 8W 44 4 8W 44 4 8W 12 8 JX 8W 45 BODY CONTROL MODULE 8W 45 7 JXI00228 ...

Page 562: ... C3 C3 7 SENSOR TEMP EVAP SIGNAL 1 2 SENSOR TEMPERATURE EVAPORATOR A C C12 20 LG BK C57 22 GY ACTUATOR DOOR MODE DRIVER DOOR MODE DOOR FEEDBACK SIGNAL GROUND SENSOR MODE 5V SUPPLY COMMON DOOR DRIVER C2 6 2 3 1 4 5 SENSOR GROUND SIGNAL MODE DOOR FEEDBACK MODE DOOR DRIVER 5V SUPPLY COMMON DOOR DRIVER C57 22 GY TN C37 20 YL C35 22 DG YL C26 20 PK DB C34 22 DB YL 8W 42 2 8W 42 2 8W 45 8 8W 45 BODY CON...

Page 563: ...CLE Z2 18 BR TN 3 HORN 10 Z1 20 BK LG Z1 14 BK S308 CENTER DISTRIBUTION POWER BATT F35 Q33 18 BR LB 3 C1 DECKLID RELEASE CONTROL DECKLID RELAY 4 6 RELEASE 1 C342 2 1 SWITCH RELEASE DECKLID 5 C342 OPENER DOOR GARAGE UNIVERSAL RIGHT VISOR VANITY LAMP B LAMP VANITY VISOR LEFT B 5 C332 S303 G38 18 GY G38 18 GY 10 C121 LOCKOUT OPENER DOOR GARAGE 14 C5 G38 18 GY Q33 18 BR LB G38 18 GY 8W 12 2 8W 12 3 8W...

Page 564: ...18 RIGHT FRONT DOOR SWITCH P97 20 WT DG P97 20 WT DG P96 20 WT LG P96 20 WT LG P55 16 DB WT P55 16 DB WT MOTOR LOCK DOOR POWER LEFT RIGHT POWER DOOR LOCK MOTOR DOOR LOCK SWITCH SWITCH LOCK DOOR POWER RIGHT DRIVER LOCK DOOR DOOR UNLOCK DRIVER C4 4 WIRE ANTENNA RKE ENTRY KEYLESS REMOTE LEFT ANTENNA P58 20 BK ANTENNA RIGHT REMOTE KEYLESS ENTRY RD 20 P158 RKE WIRE 3 C4 ANTENNA 11 11 8W 61 2 8W 61 2 8W...

Page 565: ...TCH G71 20 VT YL ARM DISARM 7 C5 17 C5 LEFT DOOR AJAR SWITCH SWITCH AJAR DOOR RIGHT G75 18 TN TN PK 20 G74 AJAR SWITCH SENSE G75 20 TN 2 3 TN 18 G75 S305 LEFT DOOR AJAR SWITCH SENSE AJAR DOOR SENSE SWITCH MODULE CONTROL BELT SEAT C5 6 G74 18 TN RD AJAR DOOR SWITCH SENSE DOOR AJAR SWITCH SENSE KEY DISARM ARM RIGHT DOOR SWITCH DOOR LEFT TRUNK 8W 39 2 8W 39 2 8W 67 2 8W 39 2 JX 8W 45 BODY CONTROL MOD...

Page 566: ...HORN CONTROL SPEED VEHICLE SWITCH HORN RIGHT RELAY HORN 7 REAR WINDOW DEFOGGER RELAY 12 JUNCTION BLOCK MODULE CONTROL BODY CONTROL RELAY HORN CONTROL REAR WINDOW DEFOGGER RELAY 8W 10 10 8W 10 7 8W 12 9 8W 12 11 8W 41 2 8W 41 2 8W 47 6 8W 12 2 8W 45 12 8W 45 BODY CONTROL MODULE JX 978W 14 JXI00233 ...

Page 567: ...d in cavity 9 of the junction block This circuit is used for the feed to the power door lock motors Ground for the BCM is provided by circuits Z1 and Z2 These circuits terminate at the instrument panel left side cowl CCD Bus interface is accomplished on circuits D1 and D2 The D1 circuit is used for Bus and D2 is for Bus ILLUMNATED ENTRY The illuminated entry relay located in the junction block is ...

Page 568: ... and the dimmer switch is moved to the high end of it s travel the BCM sends a message over the CCD Bus to the instrument cluster for full lamp intensity INSTRUMENT PANEL LAMP DIMMING The Body Control Module BCM controls the instrument panel lamp intensity using input from the dimmer switch circuit E19 The BCM uses the CCD Bus to send a signal to the instrument cluster for proper lamp intensity VE...

Page 569: ...e Body Control Module 8W 46 2 Data Link Connector 8W 46 2 Fuse 5 8W 46 2 Fuse 9 8W 46 2 G200 8W 46 2 Instrument Cluster 8W 46 2 Junction Block 8W 46 2 Component Page Power Distribution Center 8W 46 2 S106 8W 46 2 S132 8W 46 2 S133 8W 46 2 S200 8W 46 2 Traveler 8W 46 2 JX 8W 46 TRAVELER 8W 46 1 ...

Page 570: ... ST RUN IGN FUSED FUSED B 7 D1 20 VT WT BK 20 D2 F18 20 LG BK GROUND M1 20 PK IGN FUSED ST RUN S200 Z1 16 BK D2 20 WT DB C3 11 BUS CCD CCD BUS 1 C3 BODY CONTROL MODULE VT BR 20 D1 CCD BUS BUS CCD C2 7 8 C2 IN PDC D2 20 WT DB D1 20 VT BR 3 11 D1 20 VT BR D2 20 WT DB CONNECTOR DATA LINK S132 S133 8W 10 3 8W 12 6 8W 10 8 8W 12 2 8W 15 5 8W 10 5 8W 10 7 8W 40 2 8W 45 3 8W 10 8 8W 30 17 8W 15 5 8W 45 3...

Page 571: ...attery voltage to the traveler when the ignition switch is in the START RUN position Ground for the traveler is supplied on circuit Z1 To allow the traveler to send and receive informa tion it is interfaced with the CCD Bus Circuit D1 is used for CCD and circuit D2 is used for CCD Illumination lamps internal to the traveler are con trolled by circuit E2 This circuit is an output form the Body Cont...

Page 572: ......

Page 573: ...Speaker 8W 47 3 5 Left Front Instrument Panel Speaker 8W 47 3 5 Left Power Mirror 8W 47 6 Left Rear Speaker 8W 47 3 5 Power Amplifier 8W 47 4 5 6 Component Page Power Antenna 8W 47 2 6 Power Distribution Center 8W 47 6 Radio 8W 47 2 3 4 6 Rear Window Defogger 8W 47 6 Rear Window Defogger Relay 8W 47 6 Right Door Speaker 8W 47 3 5 Right Front Instrument Panel Speaker 8W 47 3 5 Right Power Mirror 8W...

Page 574: ...ODY CONTROL MODULE IN JB DRIVER LAMPS PANEL C2 5 E2 18 OR BR PANEL LAMPS DRIVER OUTPUT PARK LAMP SWITCH RADIO C9 11 M1 18 PK OR 1 2 POWER ANTENNA RADIO 12V OUTPUT C1 1 DG RD 20 X60 9 C224 X60 20 DG RD 3 G303 Z1 18 BK BK 18 Z1 G200 GROUND ANTENNA BASE M1 18 PK WT S134 8W 50 3 8W 12 11 8W 12 2 8W 12 3 8W 12 6 8W 45 7 8W 15 7 8W 15 5 8W 12 8 8W 10 7 8W 10 5 8W 12 6 8W 12 15 8W 47 2 8W 47 AUDIO SYSTEM...

Page 575: ... 1 2 VT 18 X54 X51 18 BR YL X57 18 BR LB X52 18 DB WT X58 18 DB OR 8 5 1 4 C224 2 C1 LEFT REAR REAR LEFT 6 C1 7 RIGHT REAR REAR RIGHT 3 C1 C1 X87 18 LG VT X85 18 LG DG X82 18 LB VT X80 18 LB DG LEFT FRONT INSTRUMENT PANEL SPEAKER SPEAKER PANEL INSTRUMENT FRONT RIGHT X55 18 BR RD X53 18 DG RADIO X58 18 DB OR DB WT 18 X52 BR LB 18 X57 BR YL 18 X51 DB RD 18 X56 LEFT FRONT JX 8W 47 AUDIO SYSTEM STANDA...

Page 576: ...T REAR 6 C1 1 X91 WT BK RADIO 12V OUTPUT 1 C1 4 X60 DG RD RADIO 12V OUTPUT B FUSED 1 13 C5 9 C224 M1 16 PK DB 20 20 20 20 GROUND G200 RADIO Z1 18 BK S134 M1 18 PK WT INPUT AMP FRONT LEFT LEFT FRONT AMP INPUT INPUT AMP FRONT RIGHT LEFT REAR AMP INPUT 20 TN BK X92 2 C1 7 INPUT AMP REAR RIGHT REAR RIGHT 20 WT RD X93 6 C1 2 INPUT AMP REAR LEFT REAR LEFT 20 TN RD X94 7 C1 3 INPUT AMP REAR RIGHT REAR RI...

Page 577: ...ANEL SPEAKER SPEAKER PANEL INSTRUMENT FRONT RIGHT FRONT LEFT RIGHT FRONT FRONT RIGHT C224 2 3 6 7 18 18 18 AMPLIFIED LEFT I P I P LEFT AMPLIFIED AMPLIFIED RIGHT I P I P RIGHT AMPLIFIED C224 REAR RIGHT RIGHT REAR LEFT REAR REAR LEFT DB WT 18 X52 12 4 X58 18 DB OR 13 X57 18 BR LB BR YL 18 X51 14 1 2 2 1 SPEAKER REAR LEFT RIGHT REAR SPEAKER 5 8 4 1 C2 C2 C2 C2 C2 C2 C2 C2 C2 C2 C2 C2 JX 8W 47 AUDIO S...

Page 578: ...0 YL BK P6 20 RD WT P6 20 RD WT RADIO 12V OUTPUT 4 C224 9 X60 20 DG RD X60 20 DG RD 1 2 C1 1 RADIO POWER ANTENNA RADIO 12V OUTPUT X60 20 DG RD PK OR 18 M1 C9 11 BATT A7 10A FUSE 5 3 BK 18 Z1 G303 POWER TOP SIGNAL DOWN UP SIGNAL TOP POWER POWER AMPLIFIER C1 C1 C1 C2 8W 12 2 8W 12 3 8W 15 9 8W 66 2 8W 66 2 8W 60 4 8W 12 6 8W 15 7 8W 10 5 8W 12 14 8W 47 6 8W 47 AUDIO SYSTEM PREMIUM JX 978W 14 JXI0023...

Page 579: ...e is removed during vehicle shipping to prevent excessive battery draw RADIO ILLUMINATION When the parking lamps or the headlamps are ON circuits E2 and L7 are used to power the radio illu mination lamps Circuit E2 is controlled by the Body Control Module BCM Circuit L7 is controlled by the park lamp switch CCD BUS The CCD Bus and the universal data link connec tor are used for access to the diagn...

Page 580: ... X80 supply power and ground for the right front door speaker POWER ANTENNA The power antenna is used on the premium sys tems only Battery feed for the antenna is provided from two different circuits One is the M1 circuit The M1 circuit is used to supply power to the Body Control Module BCM Power Mirrors and the Power Door Locks This fuse is also used in several other circuits refer to section 8W ...

Page 581: ... 48 2 Fuse 6 8W 48 2 Fuse 15 8W 48 2 Fuse 16 8W 48 2 G200 8W 48 2 G301 8W 48 2 G303 8W 48 2 Junction Block 8W 48 2 Component Page Left Power Mirror 8W 48 2 Power Distribution Center 8W 48 2 Rear Window Defogger 8W 48 2 Rear Window Defogger Relay 8W 48 2 Right Power Mirror 8W 48 2 S308 8W 48 2 S402 8W 48 2 S403 8W 48 2 JX 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

Page 582: ... 2 1 LEFT POWER MIRROR MIRROR POWER RIGHT 2 1 G301 BODY CONTROL MODULE C16 20 LB OR C16 20 LB YL 3 C315 3 C310 C16 20 LB YL C16 20 LB OR Z1 20 BK 9 C311 Z1 14 BK S402 A4 12 BK PK REAR WINDOW DEFOGGER RELAY 3 1 C2 G200 Z1 12 BK BK 20 Z1 S308 S403 BK 14 Z1 C316 9 REAR WINDOW DEFOGGER RELAY CONTROL 8W 12 2 8W 12 3 8W 12 11 8W 10 12 8W 10 3 8W 42 2 8W 15 7 8W 12 8 8W 15 9 8W 45 8 8W 45 12 8W 15 8 8W 1...

Page 583: ...The A31 circuit receives power from the A1 circuit which originates in the Power Distribution Center PDC and is protected by a 20 amp fuse located in cavity 8 As current flows through the relay contacts in the relay CLOSE connecting circuits A4 and C15 The A4 circuit is protected by a 40 amp fuse located in cavity 16 of the PDC Circuit C15 connects from the relay to the rear window defogger grid a...

Page 584: ......

Page 585: ... Headlamp Delay Relay 8W 50 2 Headlamp Leveling Switch 8W 50 4 Headlamp Switch 8W 50 2 3 Junction Block 8W 50 2 3 4 5 Component Page Left Fog Lamp 8W 50 3 Left Headlamp 8W 50 2 5 Left Headlamp Leveling Motor 8W 50 4 Left Park Turn Signal Lamp 8W 50 4 Park Brake Switch 8W 50 5 Power Distribution Center 8W 50 2 Right Fog Lamp 8W 50 3 Right Headlamp 8W 50 2 5 Right Headlamp Leveling Motor 8W 50 4 Rig...

Page 586: ...E 3 3 C1 C1 6 3 C6 10 FUSE 20A DAYTIME RUNNING LAMP MODULE A3 14 RD WT L4 14 VT WT L3 14 RD OR 3 1 2 2 1 3 LEFT HEADLAMP RIGHT HEADLAMP FUSED G102 Z1 18 BK Z1 18 BK G103 L43 18 VT OR L33 18 LG BR L44 18 VT RD L34 18 RD OR DIMMER SWITCH HIGH BEAM OUTPUT OUTPUT BEAM LOW SWITCH DIMMER RIGHT LOW BEAM OUTPUT OUTPUT BEAM LOW LEFT B C2 C2 C2 8W 12 2 8W 12 3 8W 10 11 8W 10 3 8W 12 11 8W 45 5 8W 50 3 8W 12...

Page 587: ... 18 BK Z1 18 BK Z1 12 BK Z1 16 BK 6 5 3 C4 3 C9 G301 Z1 14 BK Z1 18 BK TN DIMMER SWITCH SIGNAL C3 18 E19 20 RD 8 RD OR 14 L3 TO FUSE 2 C1 C2 C2 C2 C2 C2 C2 C1 C1 B 8W 50 4 LEFT HEADLAMP LEVELING MOTOR TO TO MOTOR LEVELING HEADLAMP RIGHT E 8W 50 4 G 8W 50 4 TO S136 F 8W 50 4 RIGHT PARK TURN SIGNAL LAMP TO S135 TO D 8W 50 4 TO LAMP SIGNAL TURN PARK LEFT C 8W 50 4 20A FUSE 10 FUSE 13 TO L7 18 BK YL A...

Page 588: ...N B 8W 50 3 E 8W 50 3 JUNCTION BLOCK FROM L7 18 BK YL 2 1 3 LEFT PARK TURN SIGNAL LAMP C 8W 50 3 JUNCTION BLOCK FROM L7 18 BK BR FROM BLOCK JUNCTION D 8W 50 3 L61 18 LG TN L61 18 LG TN S135 G102 Z1 18 BK Z1 12 BK S109 2 1 3 RIGHT PARK TURN SIGNAL LAMP F 8W 50 3 JUNCTION BLOCK FROM L7 18 BK YL FROM BLOCK JUNCTION G 8W 50 3 L60 18 TN BR L60 18 TN BR S136 G102 Z1 18 BK Z1 16 BK S111 8W 15 2 8W 15 4 8...

Page 589: ...N A22 G301 C1 12 3 C1 1 HEADLAMP LEFT RIGHT HEADLAMP 3 L43 18 VT OR RD OR 18 L34 15 C224 G9 18 GY RED BRAKE WARNING LAMP SENSE OUTPUT BEAM HIGH RIGHT FUSED IGN RUN LEFT LOW BEAM OUTPUT B 8W 12 2 8W 12 10 8W 12 5 8W 15 9 8W 50 2 8W 50 2 8W 10 11 8W 10 13 8W 12 14 8W 12 4 8W 12 11 8W 12 16 JX 8W 50 FRONT LIGHTING 8W 50 5 JXI00244 978W 14 ...

Page 590: ...ut to the Body Control Module BCM indicating the lamps are ON to the radio for illumination and to the dimmer switch HELPFUL INFORMATION Check for a blown 40 amp fuse located in cavity 12 of the PDC Check for a blown 20 amp fuse located in cavity 7 of the junction block For the left front lamps check the grounding point at the left strut tower For the right front lamps check the grounding point at...

Page 591: ...mps Circuit L39 connects from the switch to the fog lamps Ground for the lamps is different for the left and right lamps For the right fog lamp the ground is provided on circuit Z1 and terminates at the right frame rail For the left fog lamp the ground is pro vided on circuit Z1 and terminates at the left strut tower HELPFUL INFORMATION Check for a blown 40 amp fuse in cavity 14 and 15 of the PDC ...

Page 592: ......

Page 593: ... 4 Junction Block 8W 51 2 3 4 Left Back Up Lamp 8W 51 3 Left License Lamp 8W 51 2 Left Rear Fog Lamp 8W 51 4 Left Tail Stop Lamp 8W 51 2 Power Distribution Center 8W 51 2 Component Page Rear Fog Lamp Switch 8W 51 4 Right Back Up Lamp 8W 51 3 Right License Lamp 8W 51 2 Right Rear Fog Lamp 8W 51 4 Right Tail Stop Lamp 8W 51 2 S301 8W 51 2 S313 8W 51 2 S404 8W 51 2 3 4 S405 8W 51 2 3 4 S406 8W 51 2 S...

Page 594: ...ICENSE LAMP L50 18 WT TN L50 18 WT TN 2 C300 S313 L50 18 WT TN L50 18 BK TN 1 C305 1 2 CENTER HIGH MOUNTED STOP LAMP G300 Z1 18 BK Z1 14 BK 3 C305 S301 L50 18 WT TN L50 18 WT TN C301 2 9 C9 L50 18 WT TN 6 5 STOP LAMP SWITCH 3 C2 C2 2 L50 16 WT TN A7 16 RD BK 1 C3 4 FUSE 20A 56 BATT A0 66 CENTER DISTRIBUTION POWER A7 16 RD BK 8W 12 2 8W 12 3 8W 45 6 8W 50 3 8W 15 6 8W 15 6 8W 15 6 8W 45 6 8W 12 8 8...

Page 595: ...1 C105 F20 18 WT YL 1 C300 RUN A22 3 AUTOMATIC REVERSE SENSE RIGHT BACK UP LAMP L1 18 VT BK L1 18 VT BK LAMP BACK UP LEFT L1 18 VT BK Z1 18 BK Z1 18 BK MIRROR NIGHT DAY R M T Z1 18 BK L1 18 VT BK 8W 12 2 8W 15 6 8W 15 6 8W 15 6 8W 12 5 8W 10 13 8W 44 5 8W 31 5 JX 8W 51 REAR LIGHTING 8W 51 3 JXI00246 978W 14 ...

Page 596: ...1 L36 18 LG L36 18 LG 6 C300 INSTRUMENT CLUSTER REAR FOG LAMP L36 18 LG 6 C301 L36 18 LG S407 G A A G G300 Z1 18 BK Z1 18 BK S404 5 C301 Z1 18 BK Z1 18 BK Z1 18 BK 5 C300 S405 LAMP FOG REAR LEFT RIGHT REAR FOG LAMP 8W 12 10 8W 12 2 8W 10 11 8W 40 8 8W 15 6 8W 15 6 8W 15 6 8W 51 4 8W 51 REAR LIGHTING JX 978W 14 JXI00247 ...

Page 597: ...the deck lid ground COMBINED REAR LIGHTING MODULE The combined rear lighting module is used to direct the voltage to the proper lamps Power for the module is supplied on circuit A15 This circuit is pro tected by a 20 amp fuse located in the Power Distri bution Center PDC cavity 6 Ground for the module is supplied on circuit Z1 STOP LAMPS Circuit A7 supplies power for the stop lamp switch This circ...

Page 598: ......

Page 599: ...iper Switch 8W 52 3 Junction Block 8W 52 2 3 Left Park Turn Signal Lamp 8W 52 2 Left Rear Turn Signal Lamp 8W 52 4 Left Side Repeater 8W 52 2 Component Page Power Distribution Center 8W 52 3 Right Park Turn Signal Lamp 8W 52 2 Right Rear Turn Signal Lamp 8W 52 4 Right Side Repeater 8W 52 2 S109 8W 52 2 S111 8W 52 2 S135 8W 52 2 S136 8W 52 2 S404 8W 52 4 S405 8W 52 4 Seat Belt Control Module 8W 52 ...

Page 600: ...RN LEFT 2 C2 1 C1 C7 9 3 C7 L61 18 LG TN L60 18 TN BR FLASHER COMBINATION C1 C1 A 8W 52 4 TO C300 C301 TO B 8W 52 4 3 S135 2 1 REPEATER SIDE LEFT L61 18 LG TN L61 18 LG G102 Z1 18 BK Z1 18 BK S109 Z1 12 BK BK 16 Z1 BK 18 Z1 G103 TN BR 18 L60 3 RIGHT PARK TURN SIGNAL LAMP 1 S111 BK 18 Z1 TN 18 L60 RIGHT SIDE REPEATER 1 2 S136 8W 12 3 8W 50 4 8W 40 8 8W 52 3 8W 12 18 8W 15 3 8W 15 2 8W 15 4 8W 50 4 ...

Page 601: ... 18 BK TN 3 C9 3 C4 JUNCTION BLOCK Z1 14 BK G301 1 3 INTERMITTENT WIPER SWITCH 4 MODULE CONTROL BELT SEAT SWITCH WARNING HAZARD SIGNAL TURN FUSED IGN RUN ACC A15 18 PK F13 18 DB F13 18 DB 13 C224 C1 C1 C1 C1 IMMOBILIZER 8W 12 2 8W 12 11 8W 10 3 8W 10 5 8W 12 3 8W 15 9 8W 53 2 8W 67 2 8W 52 2 8W 10 7 8W 10 3 8W 61 5 8W 12 14 JX 8W 52 TURN SIGNALS 8W 52 3 JXI00249 978W 14 ...

Page 602: ...FT REAR TURN SIGNAL LAMP Z1 18 BK S404 Z1 18 BK 5 C300 G300 Z1 18 BK BK 18 Z1 S405 BK 18 Z1 LAMP SIGNAL TURN REAR RIGHT A G C301 3 TN 18 L60 LG TN 18 L60 FROM BLOCK JUNCTION B 8W 52 2 5 C301 Z1 18 BK 8W 15 6 8W 15 6 8W 15 6 8W 52 4 8W 52 TURN SIGNALS JX 978W 14 JXI00250 ...

Page 603: ...s power for the front lamp and also provides an input to the com bined rear lighting module and side repeater lamp This circuit also splices and supplies power to the instrument cluster indicator lamp Circuit L63 connects from the combined rear light ing module to the left rear lamps Ground for the rear lamp is provided on circuit Z1 and terminates at the left rear wheel well The ground for the fr...

Page 604: ...mps Circuit L63 con nects from the combined rear lighting module to the left rear lamps HELPFUL INFORMATION Check the 20 amp fuses located in cavities 6 and 8 of the PDC Check the 10 amp fuse located in cavity 15 of the junction block For the left front lamp check the grounding point at the left strut tower For the right front lamp check the grounding point at the right frame rail For the left and...

Page 605: ... 3 G103 8W 53 2 Instrument Cluster 8W 53 2 Intermittent Wiper Relay 8W 53 3 Intermittent Wiper Switch 8W 53 2 Junction Block 8W 53 2 3 Component Page Power Distribution Center 8W 53 3 S109 8W 53 3 S111 8W 53 2 Seat Belt Control Module 8W 53 2 Washer Fluid Level Switch 8W 53 2 Windshield Washer Pump Motor 8W 53 2 Windshield Wiper Motor 8W 53 3 Wiper High Low Relay 8W 53 3 JX 8W 53 WIPERS 8W 53 1 ...

Page 606: ...4 5 5 MIST 3 HIGH 4 WASH WIPER SWITCH 0 OFF 1 INT 2 LOW M F13 18 DB V10 18 BR DB V52 22 DG RD A B SWITCH LEVEL FLUID WASHER BK 20 Z1 8 C1 SENSE LEVEL FLUID CLUSTER INSTRUMENT 10 C126 G29 20 BK TN G29 20 BK TN WASHER 3 FLASHER COMBINATION 4 MODULE CONTROL BELT SEAT FUSED IGN RUN ACC INTERMITTENT F13 18 DB F13 18 DB 13 C224 C1 C1 C1 C1 8W 12 11 8W 12 2 8W 45 4 8W 15 4 8W 15 4 8W 40 9 8W 52 3 8W 67 2...

Page 607: ...Y HIGH LOW WIPER SENSE SWITCH PARK WIPER CONTROL RELAY ON OFF WIPER B C M D A MOTOR WIPER WINDSHIELD 14 29 S109 G102 Z1 16 BK Z1 16 BK Z1 12 BK A5 12 RD GY V55 20 WT GY V3 14 BR OR V4 14 RD YL V14 20 PK VT V16 20 VT PK F13 20 DB GY F13 20 DB GY V5 14 DG VT WIPER HIGH LOW RELAY IN PDC 1 PARK 1 8W 12 11 8W 12 2 8W 10 13 8W 10 3 8W 45 4 8W 15 2 8W 15 3 8W 10 7 8W 10 3 JX 8W 53 WIPERS 8W 53 3 JXI00252...

Page 608: ...f the wiper motor Ground for the wiper motor is provided on circuit Z1 When the wiper motor completes one cycle the BCM turns OFF the motor by deactivating the wiper relays The amount of delay between wipes is depen dent on the voltage level being sent to the BCM from the wiper switch As the windshield wiper motor turns the park switch internal to the motor moves from its grounded position to the ...

Page 609: ...ystem operation HI SPEED OPERATION When HIGH speed operation is selected a multi plexed signal is sent to the Body Control Module BCM on circuit V52 The BCM then turns the wip ers ON by grounding the V14 and V16 circuits By grounding the V14 circuit the intermittent wiper relay is switched from its normally grounded position to connect circuits A5 and V5 The A5 cir cuit which originates in the PDC...

Page 610: ......

Page 611: ...Motor 8W 60 2 Left Rear Power Window Motor 8W 60 4 Master Power Window Switch 8W 60 2 3 4 Power Top Switch 8W 60 4 Right Door Window Motor Relay 8W 60 2 3 Right Front Power Window Motor 8W 60 3 Component Page Right Power Window Switch 8W 60 3 Right Rear Power Window Motor 8W 60 4 S308 8W 60 2 3 4 S310 8W 60 4 S311 8W 60 4 S402 8W 60 2 3 4 S410 8W 60 2 3 Timer Circuit 8W 60 4 Window Timer Module 8W...

Page 612: ...14 WT Q29 14 DG Q11 14 LB TO MODULE TIMER WINDOW TN 14 F21 2 F21 14 TN BK 20 Z1 4 6 TIMER WINDOW FROM MODULE S402 Z1 20 BK G10 20 LG RD 1 2 1 2 1 2 BLOCK JUNCTION F21 14 TN G10 20 LG RD Z1 14 BK TN VT 14 F21 RELAY 1 RELAY MOTOR WINDOW DOOR RIGHT TN 14 F21 A 8W 60 4 B 8W 60 4 F21 14 TN 8W 15 9 8W 12 13 8W 12 13 8W 15 9 8W 15 8 8W 12 2 8W 12 3 8W 60 3 8W 10 13 8W 60 2 8W 60 POWER WINDOWS JX 978W 14 ...

Page 613: ...2 14 BR 1 DOWN 2 UP 6 4 C311 8 10 C316 F21 14 TN 3 BR WT 14 Q16 C316 BLOCK JUNCTION F21 14 TN WT Q26 14 VT WT Z1 14 BK 1 DOWN SWITCH WINDOW POWER MASTER 2 UP 1 2 6 C8 10 C311 S410 TIMER WINDOW FROM MODULE 1 2 1 2 1 2 F21 14 TN G10 20 LG RD TN VT 14 F21 1 RELAY MOTOR WINDOW DOOR LEFT TN 14 F21 VT 14 Q30 Q16 14 BR WT BR WT 14 Q16 B 8W 60 4 M 8W 15 9 8W 12 13 8W 15 9 8W 15 8 8W 12 2 8W 12 3 8W 12 13 ...

Page 614: ... 8 5 7 6 MODULE TIMER WINDOW G10 20 LG RD TN 14 F21 2 TIMER CIRCUIT 3 1 M Q28 14 DG WT 6 Q28 14 DG WT RD BK 14 Q27 5 RD BK 14 Q27 BR 14 Q32 Q31 14 OR BK 20 Z1 9 C311 S402 G301 S308 Z1 14 BK Q18 14 GY BK Q18 14 GY BK Q17 14 DB WT 3 C311 4 P5 20 YL RD P6 20 RD WT RUN F21 A 8W 60 2 B 8W 60 2 RIGHT DOOR WINDOW MOTOR RELAY TO S410 FROM M 8W 66 2 8W 66 2 8W 66 2 8W 15 8 8W 15 9 8W 15 9 8W 12 13 8W 60 3 ...

Page 615: ...rcuit Q29 connects from the switch to the left power window down relay The feed is passed through the normally CLOSED contacts in the relay to circuit Q21 Circuit Q21 connects from the relay to the motor Ground for the motor is sup plied on circuit Q11 back to the master switch to the Z1 ground circuit For window UP operation the circuits are reversed Circuit Q11 is the feed and circuits Q21 and Q...

Page 616: ... vehicle operate automatically in the down mode when the power top switch is activated Refer to the following circuit descriptions for operation in this mode For regular power window operation refer to the previous cir cuit description The power window system on this vehicle utilizes a pair of external relays 2 and a window timer mod ule located in the left door to control the operation of the win...

Page 617: ...trument Cluster 8W 61 5 Junction Block 8W 61 2 4 Left Power Door Lock Motor 8W 61 3 Left Power Door Lock Switch 8W 61 2 Left Remote Keyless Entry Antenna 8W 61 3 Component Page Left Visor Vanity Lamp 8W 61 4 Power Distribution Center 8W 61 5 Power Seat Switch 8W 61 4 Right Power Door Lock Motor 8W 61 3 Right Power Door Lock Switch 8W 61 2 Right Remote Keyless Entry Antenna 8W 61 3 Right Visor Vani...

Page 618: ... SWITCH 11 C310 11 C315 Z1 14 BK M1 18 PK M1 18 PK F20 20 WT F20 20 WT F20 20 WT 8 C310 F20 20 WT C310 2 S400 M1 20 PK 3 S306 C315 8 WT 20 F20 3 2 C315 PK 20 M1 S401 M1 18 PK M1 18 PK P96 20 WT LG P97 20 WT DG BK 14 Z1 S308 BK 14 Z1 S403 9 G301 C316 Z1 20 BK SWITCH RIGHT FRONT DOOR 8W 12 6 8W 12 2 8W 45 10 8W 15 8 8W 12 5 8W 12 7 8W 12 5 8W 12 7 8W 15 9 8W 15 9 8W 15 9 8W 10 5 8W 10 13 8W 61 2 8W ...

Page 619: ... RIGHT REMOTE KEYLESS ENTRY ANTENNA ANTENNA ENTRY KEYLESS REMOTE LEFT P58 20 BK P158 20 RD WIRE WIRE C409 2 1 P33 16 OR BK P55 16 DB WT P55 16 DB WT PK BK 16 P34 PK BK 16 P34 OR WT 16 P33 1 2 C416 OR WT 16 P33 C315 9 10 LOCK DOOR POWER RIGHT 11 C5 C5 1 DOOR LOCK DRIVER DRIVER UNLOCK DOOR MOTOR MOTOR M M 8W 45 10 JX 8W 61 POWER DOOR LOCKS 8W 61 3 JXI00257 978W 14 ...

Page 620: ... F35 16 RD BK Z1 18 BK BATT A3 DECKLID RELEASE RELAY S312 BK 14 Z1 G300 Q33 18 BR LB C5 14 GARAGE DOOR OPENER LOCKOUT OPENER DOOR GARAGE UNIVERSAL RIGHT VISOR VANITY LAMP B LAMP VANITY VISOR LEFT B 5 C332 S303 F35 16 RD F35 16 RD F35 16 RD G38 18 GY G38 18 GY G38 18 GY G38 18 GY G38 18 GY 10 C121 Q33 18 BR LB 8W 45 9 8W 12 2 8W 12 12 8W 15 7 8W 15 7 8W 63 2 8W 10 11 8W 15 6 8W 44 2 8W 44 2 8W 44 2...

Page 621: ...5 FUSED B FUSED IGN ST RUN 2 IMMOBILIZER CCD BUS 3 4 BUS CCD 3 11 CCD BUS BUS CCD D1 20 VT BR D1 20 VT BR D2 20 WT DB D2 20 WT DB S132 S133 DATA LINK CONNECTOR C3 9 MODULE CONTROL BODY P102 20 TN POWER DOOR LOCK ENABLE POWER DOOR LOCK ENABLE 6 GROUND G200 Z1 18 BK C1 8W 10 5 8W 10 3 8W 10 8 8W 10 3 8W 10 7 8W 10 8 8W 52 3 8W 40 2 8W 45 3 8W 45 3 8W 30 17 8W 45 10 8W 15 5 JX 8W 61 POWER DOOR LOCKS ...

Page 622: ...through the CLOSED contacts in the switch through the appropriate resistor to the P96 circuit for the right front door and circuit P97 for the left front door These circuits then connect to the Body Control Module BCM The BCM then process this request and supplies power and ground to the appropriate circuits When the LOCK function is selected power is supplied on circuit P33 to all the motors Grou...

Page 623: ... Check the 40 amp fuse located in cavity 15 of the PDC Check the 15 amp fuse located in cavity 9 of the junction block Check the IOD fuse located in cavity 5 of the PDC Check for a good door switch ground at the instrument panel left side cowl Refer to the appropriate group of the Service Manual or the Diagnostic Test Procedures Manual for further diagnostic procedures JX 8W 61 POWER DOOR LOCKS 8W...

Page 624: ......

Page 625: ...DESCRIPTION AND OPERATION 3 Component Page Fuse 5 8W 62 2 G301 8W 62 2 Junction Block 8W 62 2 Left Power Mirror 8W 62 2 Power Mirror Switch 8W 62 2 Component Page Right Power Mirror 8W 62 2 S308 8W 62 2 S400 8W 62 2 S402 8W 62 2 JX 8W 62 POWER MIRRORS 8W 62 1 ...

Page 626: ... BK 20 P90 4 5 3 3 P94 20 WT YL 7 7 P94 20 WT YL WT BK 20 P91 C315 5 C310 5 WT BK 20 P91 4 5 6 5 6 3 UP 4 DOWN POWER MIRROR SWITCH 1 LEFT 2 RIGHT 1 2 3 4 Z1 20 BK Z1 14 BK 9 C311 Z1 14 BK G301 M M 6 RIGHT MIRROR 5 LEFT MIRROR S402 S400 M1 20 PK 1 S308 Z1 14 BK P91 20 WT BK P94 20 WT YL P90 20 LG BK P92 20 YL 8W 12 2 8W 12 6 8W 15 9 8W 15 8 8W 12 7 8W 15 9 8W 10 5 8W 62 2 8W 62 POWER MIRRORS JX 978...

Page 627: ...and ground are reversed When the switch is moved to the RIGHT position and mirror movement UP is selected voltage is sup plied through the P92 circuit and the ground path is through circuit P90 When the DOWN movement is selected the power and ground are reversed If a RIGHT door mirror movement LEFT is selected voltage is supplied through the P94 circuit and the ground is passed through circuit P91...

Page 628: ......

Page 629: ...ND OPERATION 3 Component Page Circuit Breaker 18 8W 63 2 Front Vertical Motor 8W 63 2 G301 8W 63 2 Horizontal Motor 8W 63 2 Junction Block 8W 63 2 Component Page Power Seat Switch 8W 63 2 Rear Vertical Motor 8W 63 2 S308 8W 63 2 S312 8W 63 2 JX 8W 63 POWER SEAT 8W 63 1 ...

Page 630: ...ERTICAL UP S308 Z1 14 BK J A N D M K L B 1 3 4 4 3 5 6 2 5 FWD 6 BACK 3 UP 4 DOWN 1 2 MOTOR VERTICAL FRONT REAR VERTICAL MOTOR 1 2 2 1 MOTOR HORIZONTAL P19 16 YL LG P21 16 RD LG P11 16 YL WT P13 16 RD WT P15 16 YL LB P17 16 RD LB S312 1 C309 M M M 8W 12 2 8W 12 12 8W 15 9 8W 15 9 8W 10 11 8W 12 12 8W 63 2 8W 63 POWER SEAT JX 978W 14 JXI00261 ...

Page 631: ...tion power is passed on the F35 circuit through the CLOSED contacts in the switch to the P15 circuit The P15 circuit connects to the motor Ground is provided on the P17 circuit back to the switch A ground BUS bar internal to the switch then connects to the Z1 circuit For HORIZONTAL REARWARD function the cir cuits are reversed P17 is the feed and P15 is the ground When the operator selects the REAR...

Page 632: ......

Page 633: ...00 8W 66 2 G301 8W 66 2 Junction Block 8W 66 2 Power Amplifier 8W 66 2 Power Distribution Center 8W 66 2 Power Top Pump Motor 8W 66 2 Power Top Switch 8W 66 2 Component Page Power Top Up Down Relays 8W 66 2 PRNDL Led 8W 66 2 S306 8W 66 2 S308 8W 66 2 S310 8W 66 2 S311 8W 66 2 Window Timer Module 8W 66 2 JX 8W 66 POWER TOP 8W 66 1 ...

Page 634: ...N 2 CLOSE C A F D B E 11 FUSE 40A BATT A0 46 45 POWER DISTRIBUTION CENTER A25 12 DB 9 C121 1 2 M G300 P4 12 RD 3 1 WINDOW TIMER MODULE TIMER CIRCUIT TIMER CIRCUIT 12 C311 11 P5 20 YL BK P6 20 RD WT P6 20 RD WT P5 20 YL BK MOTOR PUMP TOP POWER P3 12 YL Z1 12 BK P5 20 YL BK P6 20 RD WT P5 20 YL BK P6 20 RD WT 2 C342 F20 20 WT F20 20 WT POWER TOP UP DOWN RELAYS C1 C1 A25 12 DB 8W 47 4 8W 12 2 8W 12 5...

Page 635: ...P5 circuit connects from the switch to the power top DOWN relay Volt age flowing through the coil side of the relay causes the contacts in the relay to CLOSE connecting cir cuits A25 and P4 The A25 circuit is protected by a 40 amp fuse located in cavity 11 of the PDC Circuit P4 connects from the relay to the pump motor Voltage flows through the motor to circuit P3 The P3 circuit provides the groun...

Page 636: ......

Page 637: ...lt Solenoid 8W 67 2 Fuse 13 8W 67 2 Fuse 15 8W 67 2 G301 8W 67 2 G304 8W 67 2 Intermittent Wiper Switch 8W 67 2 Junction Block 8W 67 2 Component Page Left Door Ajar Switch 8W 67 2 Passenger Seat Belt Solenoid 8W 67 2 Power Distribution Center 8W 67 2 Right Door Ajar Switch 8W 67 2 S305 8W 67 2 S308 8W 67 2 Seat Belt Control Module 8W 67 2 JX 8W 67 RESTRAINT SYSTEM 8W 67 1 ...

Page 638: ... AJAR DOOR G74 18 TN RD 7 G74 18 TN RD G75 18 TN G75 20 TN G75 18 TN S305 SENSE SWITCH DOOR AJAR LEFT FRONT C5 C5 DRIVER LATCH SIGNAL 8 1 2 SOLENOID BELT SEAT PASSENGER DRIVER SEAT BELT SOLENOID 2 1 7 S308 SIGNAL LATCH PASSENGER R8 18 OR RD R8 18 OR RD R7 18 OR BK 2 C341 Z1 18 BK Z1 14 BK Z1 18 BK Z1 18 BK 1 C341 F13 18 DB 3 INTERMITTENT WIPER SWITCH 3 FLASHER COMBINATION 13 C224 F13 18 DB F13 18 ...

Page 639: ...zed Ground for the solenoids is supplied on circuit Z1 Power for the seatbelt control module is supplied on circuits A45 and F13 The A45 circuit is a direct battery feed and is protected by a 20 amp fuse located in cavity 13 of the Power Distribution Center PDC Circuit F13 is HOT when the ignition switch is in the ACCESSORY and RUN position only This circuit is protected by a 10 amp fuse located i...

Page 640: ......

Page 641: ...l Injector No 6 8W 70 3 Fuse 1 8W 70 5 Generator 8W 70 3 5 Ignition Coil Pack 8W 70 7 Illuminated Entry Relay 8W 70 7 Intake Air Temperature Sensor 8W 70 4 Left Door Courtesy Lamp 8W 70 7 Manifold Absolute Pressure Sensor 8W 70 3 4 Component Page Noise Suppressor 8W 70 7 Output Shaft Speed Sensor 8W 70 6 Overhead Map Lamp 8W 70 7 Powertrain Control Module 8W 70 2 3 5 6 Rear Floor Courtesy Lamp 8W ...

Page 642: ...4 20 BK LB 20 K4 K4 18 BATTERY TEMPERATURE SENSOR 3 SENSOR OXYGEN HEATED DOWNSTREAM K4 20 BK LB 10 C111 K4 18 BK LB IN PDC S110 BK LB BK LB BK LB 18 K4 S117 FROM A 8W 70 4 8W 30 10 8W 30 14 8W 31 4 8W 30 14 8W 30 10 8W 70 2 8W 70 SPLICE INFORMATION JX 978W 14 JXI00264 ...

Page 643: ...8 A142 2 2 SENSOR OXYGEN HEATED UPSTREAM 1 C165 S123 TO A142 18 DG OR 2 2 DG OR 18 A142 B SENSOR PRESSURE ABSOLUTE MANIFOLD K6 18 VT WT 2 VT WT 20 K6 A C PRESSURE TRANSDUCER SENSOR POSITION THROTTLE POWERTRAIN CONTROL MODULE S115 K6 18 VT WT 1 61 C1 K6 20 VT WT 9 C111 VT WT 20 K6 D 8W 70 5 S118 FROM B 8W 70 5 C 8W 70 5 FROM S118 8W 30 6 8W 30 6 8W 30 6 8W 30 6 8W 20 2 8W 30 7 8W 30 7 8W 30 7 8W 30...

Page 644: ...7 BK LB 20 K4 SENSOR POSITION CRANKSHAFT 2 1 A SENSOR TEMPERATURE COOLANT ENGINE 2 K4 20 BK LB BK LB 18 K4 K4 18 BK LB BK LB 18 K4 S110 TO 2 5L DISTRIBUTOR C2 CAMSHAFT POSITION SENSOR 2 4L BK LB 18 K4 MANIFOLD ABSOLUTE PRESSURE SENSOR A 3 1 BK LB 18 K4 TO S130 A 8W 70 2 G 8W 70 7 S130 FROM H 8W 70 7 8W 30 11 8W 30 10 8W 42 3 8W 30 9 8W 30 8 8W 30 12 8W 30 5 8W 30 8 8W 30 11 8W 70 4 8W 70 SPLICE IN...

Page 645: ...1 TO A142 18 DG OR 18 A142 S114 TO S114 TO S118 C2 DG OR GENERATOR 2 5L 2 4L 2 5L TO S131 1 C1 2 4L 2 5L DG OR A142 18 DISTRIBUTOR DG OR A142 18 NO 5 INJECTOR FUEL 2 2 5L S123 2 FUEL INJECTOR NO 3 18 A142 DG OR 2 FUEL INJECTOR NO 1 18 A142 DG OR DG OR A142 18 FROM S114 B 8W 70 3 E 8W 70 7 C 8W 70 3 D 8W 70 3 PDC 8W 30 11 8W 30 10 8W 30 4 8W 30 11 8W 30 4 8W 10 4 8W 20 2 8W 30 5 8W 30 7 8W 30 7 8W ...

Page 646: ... OR WT CAMSHAFT POSITION SENSOR C2 DB BR T13 18 1 S125 1 TURBINE SPEED SENSOR 3 TRANSMISSION RANGE SWITCH 18 T13 DB BR 18 T13 DB BR 20 T13 DB BR SENSOR SPEED SHAFT OUTPUT CONTROL MODULE 13 TRANSMISSION 4 C105 DB BR T13 18 8W 30 5 8W 30 8 8W 30 8 8W 30 5 8W 30 8 8W 31 3 8W 31 5 8W 31 3 8W 31 3 8W 31 5 8W 70 6 8W 70 SPLICE INFORMATION JX 978W 14 JXI00268 ...

Page 647: ...DOOR COURTESY LAMP YL M2 18 18 M2 YL LAMP COURTESY FLOOR REAR 8 C342 YL M2 18 2 18 M2 YL 8 ILLUMINATED ENTRY RELAY YL M2 18 2 C332 MAP LAMP OVERHEAD NIGHT MIRROR AUTOMATIC DAY AUTOMATIC 6 18 M2 YL YL M2 18 A OVERHEAD MAP LAMP DAY NIGHT MIRROR H 8W 70 4 S116 FROM G 8W 70 4 S118 FROM E 8W 70 5 8W 30 4 8W 30 4 8W 44 6 8W 44 6 8W 44 6 8W 44 3 8W 44 3 8W 44 5 JX 8W 70 SPLICE INFORMATION 8W 70 7 JXI0026...

Page 648: ...fies all splices shown in the dia grams It also shows the splices in there entirity All circuits that are part of the splices are shown and the systems they affect are referanced For viewing the splices location in the vehicle refer to section 8W 95 8W 70 8 8W 70 SPLICE INFORMATION JX ...

Page 649: ...nted Stop Lamp CHMSL 8W 80 16 Clockspring 8W 80 16 Clutch Interlock Switch 8W 80 16 Controller Anti Lock Brake 8W 80 17 Crankshaft Position Sensor 2 0L Engine 8W 80 18 Crankshaft Position Sensor 2 5L Engine 8W 80 18 Datalink Connector 8W 80 19 Decklid Release Relay 8W 80 19 Decklid Release Switch 8W 80 19 Decklid Solenoid 8W 80 19 Distributor C1 2 5L Engine 8W 80 20 Distributor C2 2 5L Engine 8W 8...

Page 650: ...assenger Seat Belt Solenoid 8W 80 35 Passenger Side Airbag Squib 8W 80 35 Component Page Power Amplifier C1 Premium Sound 8W 80 36 Power Amplifier C2 Premium Sound 8W 80 36 Power Antenna 8W 80 36 Power Mirror Switch 8W 80 37 Power Seat Switch 8W 80 37 Power Steering Pressure Switch 8W 80 38 Power Top Pump Motor 8W 80 38 Power Top Switch 8W 80 38 Power Top Up Down Relay 8W 80 38 Powertrain Control ...

Page 651: ...h VTSS 8W 80 50 Trunk Lamp 8W 80 50 Turbine Speed Sensor 8W 80 50 Upstream Heated Oxygen Sensor 8W 80 51 Component Page Vapor Canister Leak Detector 2 0L Engine 8W 80 51 Vehicle Speed Control Servo 8W 80 51 Vehicle Speed Control And Horn Switches 8W 80 51 Washer Fluid Level Switch 8W 80 51 Window Timer Module 8W 80 52 Windshield Washer Pump Motor 8W 80 52 Windshield Wiper Motor 8W 80 52 JX 8W 80 C...

Page 652: ...7 8 BLACK BLACK FUNCTION CIRCUIT A C SWITCH SENSE REAR DEFOGGER LAMP DRIVER HVAC MODE SENSE GROUND CAV 1 2 3 4 5 6 7 8 C21 22DB OR C16 22LB YL C58 22RD Z2 22BK PK FUNCTION CIRCUIT GROUND HI BLOWER MOTOR DRIVER M2 BLOWER MOTOR DRIVER M1 BLOWER MOTOR DRIVER LO BLOWER MOTOR DRIVER PANEL LAMPS DRIVER PANEL LAMPS DRIVER CAV 1 2 3 4 5 6 7 Z1 12BK C7 12BK TN C6 18LB C5 18LG C4 18TN E2 18OR E2 18OR 1 4 CI...

Page 653: ...ELAY BOX DARK GRAY CIRCUIT FUNCTION FUSED B ABS PUMP MOTOR RELAY CONTROL ABS SYSTEM RELAY CONTROL FUSED B ABS PUMP MOTOR SENSE ABS WARNING LAMP DRIVER ABS SYSTEM RELAY OUTPUT GROUND CAV 1 2 3 4 5 6 7 8 9 10 A20 16RD DB B116 20GY LB B57 20BR BK A10 12RD DG B120 16BR RD G19 20LG OR B47 16RD LB Z1 14BK 10 6 1 5 AIRBAG CONTROL MODULE C1 7 13 1 6 GRAY CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT RUN S...

Page 654: ...OUND CAV 1 2 E2 18OR Z1 18BK ASH RECEIVER LAMP BLACK 1 2 CIRCUIT FUNCTION AUTOSTICK DOWNSHIFT SWITCH SENSE AUTOSTICK UPSHIFT SWITCH SENSE GROUND FUSED IGNITION SWITCH OUTPUT OFF RUN START CAV 1 2 3 4 T44 20YL LB T5 20LG LB Z13 20BK RD F11 20RD VT AUTOSTICK SWITCH 1 4 BLACK CIRCUIT FUNCTION AUTOMATIC DAY NIGHT MIRROR BATTERY FEED MAP LAMP GROUND BACKUP LAMP SENSE COURTESY LAMP FEED LAMP FEED CAV 1 ...

Page 655: ...WIPER ON OFF RELAY CONTROL WIPER HI LO RELAY CONTROL WASHER PUMP CONTROL GROUND CCD BUS CCD BUS CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 V55 20WT GY Q33 18BR LB Z2 20BK LG D1 20VT BR D1 20VT DG V14 20PK VT V16 20VT PK V10 18BR DB Z2 20BK LG D2 20WT BK D2 20WT DG 6 14 1 7 BLACK CIRCUIT FUNCTION HI BLOWER MOTOR DRIVER M2 BLOWER MOTOR DRIVER FUSED IGNITION SWITCH OUTPUT RUN LO BLOWER MOTOR DRIVER M1 BLOW...

Page 656: ...0 21 22 D1 20VT BR D1 18VT BR Z2 20BK VT C58 22RD C37 20YL C12 20LG BK P102 20TN V52 22DG RD D2 20WT DB D2 18WT DB Z2 18BK LG V10 18 BR DB C21 22DB OR G26 22LB E19 20RD Z2 22BK PK C57 22GY TN C57 22GY Z2 18BR TN CIRCUIT FUNCTION RIGHT RKE ANTENNA LEFT RKE ANTENNA CAV 1 2 3 4 5 6 P158 20RD P58 20BK BODY CONTROL MODULE C4 1 6 BLACK 1 5 4 10 BODY CONTROL MODULE C2 WHITE FUNCTION CIRCUIT MODE DOOR DRI...

Page 657: ... LEFT VTSS ARM DISARM SENSE RIGHT VTSS ARM DISARM SENSE CAV 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 P34 16PK BK P34 16DB WT P55 16DB WT G10 20LG RD G74 18TN RD G75 18TN P97 20WT DG G71 20VT YL P33 16OR BK P33 16OR WT G38 18GY G4 18DB G74 20TN PK P96 20WT LG G73 18LG OR G72 18DG OR BLACK CIRCUIT FUNCTION RED BRAKE WARNING LAMP DRIVER GROUND CAV A B G9 20GY DB Z1 20BK BRAKE WARNING PRES...

Page 658: ...16BK Z1 18BK K39 20GY RD K40 18BR GY K59 20VT GY K7 18OR WT K7 20OR WT A142 18DG OR K60 20YL BK G6 18GY VT K6 20VT WT K4 18BK LB CIRCUIT CAV 1 1 2 3 4 5 6 7 8 9 10 Z1 16BK Z1 18BK K39 20GY RD K40 20BR GY K59 20VT GY K7 18OR WT A142 18DG OR K60 20YL BK G6 20GY K6 20VT WT K4 18BK LB 1 5 6 10 5 1 10 6 LIGHT GRAY LIGHT GRAY C113 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 9 10 C3 14DB BK K24 18GY BK T40 14BR F12 18...

Page 659: ...5 18PK G29 20BK TN D6 20PK LB L13 18BR VT T44 20YL LB 9 1 1 9 16 8 8 16 BLACK BLACK C165 2 5L ENGINE ONLY CIRCUIT CAV 1 2 3 4 A142 18DG OR K11 18WT LB K13 18YL WT K38 18GY CIRCUIT CAV 1 2 3 4 A142 18DG OR K11 18WT LB K13 18YL WT K38 18GY 1 2 3 1 3 4 2 4 C126 AUTOSTICK MTX C165 2 5L ENGINE ONLY GREEN GREEN C121 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B1 20YL DB B2 20YL B3 20LG DB B4 20LG A141 ...

Page 660: ...13 14 15 16 X52 18DB WT X56 20DB RD X56 18DB RD X80 18LB DG X54 20VT X54 18VT X82 18LB VT X58 18DB OR X51 18BR YL X55 20BR RD X55 18BR RD X85 18LG DG X53 20DG X53 18DG X87 18LG VT X57 18BR LB X60 20DG RD X60 20DG RD X60 20DG RD G78 20TN BK P5 20YL BK P6 20RD WT F13 18DB L36 18LG L36 18LG G9 18GY E2 18OR BK 9 1 1 9 16 8 8 16 C224 X60 20DG RD 9 9 3 2 6 7 L1 18VT BK L50 18WT TN L7 18BK YL CIRCUIT CAV...

Page 661: ...AV 1 2 F35 16RD Z1 16BK CIRCUIT CAV 1 2 F35 16RD Z1 16BK C310 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 M2 18YL M1 18PK C16 20LB OR P90 20LG BK P91 20WT BK P92 20YL P94 20WT YL F20 20WT P33 16OR BK P55 16DB WT P97 20WT DG G73 18LG OR 1 2 GRAY 1 8 1 8 7 16 7 16 BROWN BROWN 1 2 GRAY WITH VTSS C309 WITH POWER SEAT C310 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 M2 18YL M1 18PK C16 LB...

Page 662: ...3 14 15 16 M2 18YL M1 18PK C16 20LB YL P90 20LG BK P91 20 WT BK P92 20YL P94 20WT YL F20 20WT P33 16OR WT P34 16PK BK P96 20WT LG G72 18DG OR CIRCUIT C311 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 X85 18LG DG X87 18LG VT Q17 14DB WT Q18 14GY BK Q27 14RD BK Q28 14DG WT Q16 14BR WT Q26 14VT WT Z1 14BK F21 14TN VT P5 20YL BK P6 20RD WT 1 6 5 12 BLUE 5 12 1 6 BLUE C311 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11...

Page 663: ...8BK R8 18OR RD C341 C341 CIRCUIT CAV 1 2 3 4 5 5 6 6 7 8 9 10 Q33 18BR LB F20 20WT P5 20YL BK P6 20RD WT G38 18GY G38 18GY Z1 20BK Z1 20BK M1 18PK M2 18YL CIRCUIT CAV 1 2 3 4 5 6 6 7 8 9 9 10 Q33 18BR LB F20 20WT P5 20YL BK P6 20RD WT G38 18GY Z1 18BK Z1 18BK M1 18PK M2 18YL E2 18OR BK E2 18OR BK AUTOMATIC DAY NIGHT MIRROR REMOTE DECKLID RELEASE C342 C342 CIRCUIT CAV 1 2 3 4 5 5 6 M1 18PK M2 18YL ...

Page 664: ...ON SENSOR 3 CIRCUIT FUNCTION BRAKE LAMP SWITCH OUTPUT GROUND CAV 1 2 3 L50 18WT TN Z1 18BK CENTER HIGH MOUNTED STOP LAMP CHMSL 4 1 CIRCUIT FUNCTION HORN RELAY CONTROL SPEED CONTROL SWITCH SIGNAL GROUND CAV 1 2 3 4 X3 18BK RD V37 20RD LG Z2 18BR TN CLOCKSPRING NATURAL RED 1 3 1 2 BLACK CIRCUIT FUNCTION IGNITION SWITCH OUTPUT START IGNITION SWITCH OUTPUT START CAV 1 2 A41 16YL OR T141 16YL RD CLUTCH...

Page 665: ...SENSOR STOP LAMP SWITCH OUTPUT RED BRAKE WARNING LAMP DRIVER ABS WARNING LAMP DRIVER ABS PUMP MOTOR RELAY CONTROL ABS PUMP MOTOR SENSE CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 B1 20YL DB B2 20YL B3 20LG DB B4 20LG Z1 18BK B6 20WT DB B7 20WT B8 20OR DB B9 20OR L50 18WT BR G9 20GY DG G19 20LG OR B116 20GY LB B120 16BR RD 41 21 1 ...

Page 666: ...ON LEFT REAR DECAY SOLENOID CONTROL ABS SYSTEM RELAY OUTPUT CAV 46 47 B146 20BR LB B47 16RD LB CIRCUIT FUNCTION 5 VOLT SUPPLY SENSOR GROUND CRANKSHAFT POSITION SENSOR SIGNAL CAV 1 2 3 K7 20OR WT K4 20BK LB K24 20GY BK 3 1 CRANKSHAFT POSITION SENSOR 2 0L ENGINE ONLY BLACK BLACK CIRCUIT FUNCTION 5 VOLT SUPPLY SENSOR GROUND CRANKSHAFT POSITION SENSOR SIGNAL CAV 1 2 3 K7 20OR WT K4 20BK LB K24 20GY BK...

Page 667: ... DB D6 20PK LB M1 18PK WT DECKLID RELEASE RELAY FUNCTION CIRCUIT DECKLID SOLENOID FEED FUSED B REMOTE DECKLID RELEASE CONTROL GARAGE DOOR OPENER LOCKOUT FUSED B CAV 1 2 3 4 5 7 8 9 Q2 14LG BK F35 16RD Q33 18BR LB Q33 18BR LB F35 16RD 6 1 2 FUNCTION CIRCUIT FUSED B DECKLID RELEASE SWITCH OUTPUT CAV 1 2 Q33 18BR LB G38 18GY BLACK DECKLID RELEASE SWITCH FUNCTION CIRCUIT DECKLID RELEASE SWITCH OUTPUT ...

Page 668: ... YL Z1 16BK K19 18BK GY DISTRIBUTOR C2 6 1 BLACK 2 5L ENGINE DOWNSTREAM HEATED OXYGEN SENSOR CIRCUIT FUNCTION GROUND DRIVER LATCH SIGNAL CAV 1 2 Z1 18BK R7 18OR BK DRIVER SEAT BELT SOLENOID 1 2 DRIVER SIDE AIRBAG SQUIB YELLOW CIRCUIT FUNCTION DRIVER AIRBAG LINE 1 DRIVER AIRBAG LINE 2 CAV 1 2 R43 18BK LB R45 18DG LB BLACK 1 2 1 3 6 4 NATURAL CIRCUIT FUNCTION DOWNSTREAM HEATED WXYGEN SENSOR SIGNAL S...

Page 669: ... K35 18GY YL A142 18DG OR A142 18DB OR BLACK 2 1 ELECTRONIC EGR TRANSDUCER SOLENOID CIRCUIT FUNCTION SENSOR GROUND ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CAV 1 2 K4 18BK LB K2 18TN BK BLACK 2 ENGINE COOLANT TEMPERATURE SENSOR 1 1 2 FRONT VERTICAL MOTOR RED CIRCUIT FUNCTION POWER SEAT FRONT VERTICAL DOWN POWER SEAT FRONT VERTICAL UP CAV 1 2 P21 16RD LG P19 16YL LG CIRCUIT FUNCTION INJECTOR NO 1 D...

Page 670: ...18YL WT A142 18DG OR 2 1 FUEL INJECTOR NO 3 BLACK 2 1 FUEL INJECTOR NO 4 BLACK CIRCUIT FUNCTION INJECTOR NO 4 DRIVER AUTOMATIC SHUT DOWN RELAY OUTPUT CAV 1 2 K14 18LB BR A142 18DG OR CIRCUIT FUNCTION FUNCTION INJECTOR NO 5 DRIVER AUTOMATIC SHUT DOWN RELAY OUTPUT CAV 1 2 2 5L ENGINE K38 18GY A142 18DG OR CIRCUIT INJECTOR NO 6 DRIVER AUTOMATIC SHUT DOWN RELAY OUTPUT CAV 1 2 K58 18BR DG A142 18DG OR ...

Page 671: ... 18DG OR K20 18DG BLACK 1 3 2 GENERATOR CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M1 20PK WT Z1 20BK GLOVE BOX LAMP 2 1 BLACK HIGH NOTE HORN BLACK CIRCUIT FUNCTION HORN RELAY OUTPUT GROUND CAV A B X2 18DG PK Z1 18BK A B CAV 1 2 CIRCUIT FUNCTION POWER SEAT HORIZONTAL MOTOR POWER SEAT HORIZONTAL MOTOR P15 16YL LB P17 16RD LB 1 2 BLACK HORIZONTAL MOTOR CIRCUIT FUNCTION HD LP LAMP SWITCH OUTPUT GROUND H...

Page 672: ... 1 2 3 K17 18DB DG A142 18DG OR K19 18BK GY 3 1 BLACK IGNITION COIL PACK 2 0L ENGINE IGNITION SWITCH C1 1 2 BLACK CIRCUIT FUNCTION FUSED B IGNITION SWITCH OUTPUT OFF RUN START CAV 1 2 A1 16RD A81 18DG RD 1 6 5 10 IGNITION SWITCH C2 BLACK FUNCTION CIRCUIT GROUND RED BRAKE WARNING LAMP DRIVER FUSED B IGNITION SWITCH OUTPUT RUN FUSED B FUSED B IGNITION SWITCH OUTPUT ACC RUN IGNITION SWITCH OUTPUT RUN...

Page 673: ...UNCTION REAR FOG LAMP LEFT TURN SIGNAL TRAVELER CCD BUS TRAVELER CCD BUS FUSED IGNITION SWITCH OUTPUT RUN START FUSED IGNITION SWITCH OUTPUT RUN START RED BRAKE WARNING LAMP DRIVER CCD BUS CCD BUS PANEL LAMPS DRIVER GROUND OIL PRESSURE SWITCH SENSE ABS WARNING LAMP DRIVER CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 L36 18LG L61 18LG TN D2 20WT BK D1 20VT F18 18LG BK F18 20LG BK G9 22GY DB D2 20WT DB D1 20VT...

Page 674: ... OUTPUT FOG LAMP SWITCH OUTPUT FOG LAMP FEED FUSED LEFT LOW BEAM OUTPUT CAV 1 2 3 4 5 6 7 8 8 9 9 10 11 12 G9 20GY DB G9 20GY DG L34 18RD OR L60 18TN BR L61 18LG TN L33 18LG BR L7 18BK YL L7 18BK YL L7 18BK BR L7 18BK BR L39 18LB L39 18 LB L43 18VT OR CIRCUIT FUNCTION STOP LAMP SWITCH OUTPUT FUSED B BRAKE LAMP SWITCH OUTPUT FUSED IGNITION SWITCH OUTPUT RUN FUSED RIGHT LOW BEAM OUTPUT FUSED IGNITIO...

Page 675: ...ART FOG LAMP SWITCH OUTPUT FUSED B FUSED B FUSED B IGNITION SWITCH OUTPUT ACC RUN GROUND FUSED IGNITION SWITCH OUTPUT RUN START CAV 1 2 3 4 5 6 7 8 F30 18RD L7 18BK YL L7 18BK DG G9 18GY G9 22GY DB X3 18BK RD A21 16DB L39 18LB M1 18PK WT M1 20PK M1 16PK DB A31 16BK WT Z11 18BK F14 18LG YL 13 14 15 16 9 10 11 12 JUNCTION BLOCK C6 1 4 3 6 WHITE CIRCUIT FUNCTION IGNITION SWITCH OUTPUT RUN DIMMER SWIT...

Page 676: ...TION BLOCK C7 NATURAL JUNCTION BLOCK C8 1 5 4 8 BLACK FUNCTION CIRCUIT FUSED IGNITION SWITCH OUTPUT RUN FUSED B REAR WINDOW DEFOGGER LAMP DRIVER REAR WINDOW DEFOGGER LAMP DRIVER FUSED IGNITION SWITCH OUTPUT RUN FUSED IGNITION SWTICH OUTPUT RUN FUSED IGNITION SWITCH OUTPUT RUN CAV 1 2 3 4 5 6 7 8 F21 14TN M1 18PK C16 20LB YL C16 20LB OR F21 14TN F21 14TN VT F21 14TN WT CIRCUIT FUNCTION FUSED B FUSE...

Page 677: ...ED B KEY IN LAMP DRIVER CAV 1 2 M1 20PK WT M50 20YL RD KEY IN SWITCH 1 2 GREEN CIRCUIT FUNCTION KEY IN IGNITION SWITCH SENSE GROUND CAV 1 2 G26 22LB Z1 20BK WT CIRCUIT FUNCTION BACK UP LAMP FEED GROUND CAV A G L1 18VT BK Z1 18BK LEFT BACK UP LAMP CAV 1 2 CIRCUIT FUNCTION LEFT VTSS DISARM SENSE FUSED B G73 18 LG OR M1 18PK LEFT DOOR ARM DISARM SWITCH BLACK 1 2 GRAY G A B PREMIUM SOUND 3 8 1 4 CIRCU...

Page 678: ...L LEFT FRONT WINDOW DRIVER DOWN GROUND LEFT FRONT WINDOW DRIVER DOWN CAV 1 2 3 4 5 6 7 8 9 F21 14TN G10 20LG RD Q29 14DG Z1 20BK Q21 14WT CIRCUIT LEFT DOOR WINDOW MOTOR RELAY CIRCUIT FUNCTION FOG LAMP SWITCH OUTPUT GROUND CAV A B L39 18 LB Z1 18BK LEFT FOG LAMP BLACK A B CIRCUIT FUNCTION LEFT FRONT AMPLIFIED LEFT INSTRUMENT PANEL LEFT FRONT AMPLIFIED LEFT INSTRUMENT PANEL CAV PREMIUM SOUND X53 18D...

Page 679: ...LAMP CIRCUIT FUNCTION LEFT TURN SIGNAL PARK LAMP RELAY OUTPUT GROUND CAV 1 2 3 L61 18LG TN L7 18BK BR Z1 18BK BLACK CIRCUIT FUNCTION LEFT FRONT WHEEL SPEED SENSOR LEFT FRONT WHEEL SPEED SENSOR CAV 1 2 B8 20OR DB B9 20OR LEFT FRONT WHEEL SPEED SENSOR 2 1 LEFT HEADLAMP LEVELING MOTOR BLACK 3 2 1 CIRCUIT FUNCTION HD LP LAMP SWITCH OUTPUT HEADLAMP ADJUST SIGNAL INSTRUMENT PANEL GROUND CAV 1 2 3 L7 18B...

Page 680: ... Q27 14RD BK Q17 14DB WT CIRCUIT LEFT REAR POWER WINDOW MOTOR BLACK 1 2 CIRCUIT CAV 1 2 X57 18BR LB X51 18BR YL LEFT REAR SPEAKER BLACK 1 2 FUNCTION LEFT REAR LEFT REAR NATURAL 1 6 3 4 CIRCUIT FUNCTION FUSED B FUSED IGNITION SWITCH OUTPUT GROUND LEFT FRONT DOOR SWITCH MUX CAV 1 2 3 4 M1 20 PK F20 20WT Z1 20BK P97 22WT DG LEFT POWER DOOR LOCK SWITCH 1 4 WHITE BLACK CIRCUIT FUNCTION LEFT FRONT DOOR ...

Page 681: ...TY LAMP BLACK 2 1 BLACK B A LOW NOTE HORN BLACK CIRCUIT FUNCTION HORN RELAY OUTPUT GROUND CAV A B X2 18DG PK Z1 18BK A B LEFT REAR TURN SIGNAL LAMP GRAY G A B FUNCTION LEFT TURN SIGNAL GROUND CAV A G L61 18LG TN Z1 18BK CIRCUIT LEFT TAIL STOP LAMP GRAY G A B FUNCTION STOP LAMP SWITCH OUTPUT HD LP LAMP SWITCH OUTPUT GROUND CAV A B G L50 18WT TN L7 18BK YL Z1 18BK CIRCUIT FUNCTION CIRCUIT LEFT TURN ...

Page 682: ...1 18BK TN L60 18TN L61 18LG MULTI FUNCTION SWITCH C2 1 6 5 10 BLUE FUNCTION CIRCUIT PARK LAMP SWITCH OUTPUT PARK LAMP SWITCH OUTPUT FUSED B FUSED B REAR FOG LAMP DIMMER SWITCH SIGNAL DIMMER SWITCH LOW BEAM OUTPUT DIMMER SWITCH HIGH BEAM OUTPUT FOG LAMP SWITCH OUTPUT REAR FOG LAMP FEED CAV 1 2 3 4 5 6 7 8 9 10 L7 18BK YL L7 18BK YL F33 18BK RD A3 14RD WT L36 18LG E19 20RD L4 14VT WT L3 14RD OR L39 ...

Page 683: ...1 2 T13 18DB BR T14 18LG VT 2 1 OUTPUT SHAFT SPEED SENSOR CIRCUIT FUNCTION COURTESY LAMPS DRIVER GROUND FUSED B CAV A B C D M2 18YL Z1 18BK M1 18PK BLACK OVERHEAD MAP LAMP B A CIRCUIT FUNCTION GROUND PASSENGER LATCH SIGNAL CAV 1 2 Z1 18BK R8 18OR RD PASSENGER SEAT BELT SOLENOID PASSENGER SIDE AIRBAG SQUIB 1 2 YELLOW CIRCUIT FUNCTION PASSENGER AIRBAG LINE 1 PASSENGER AIRBAG LINE 2 CAV 1 2 R42 18BK ...

Page 684: ...C1 CIRCUIT FUNCTION FUSED BATT FEED TO AMP RIGHT REAR SPEAKER AMP OUTPUT RIGHT PANEL SPEAKER LEFT PANEL SPEAKER RIGHT DOOR SPEAKER LEFT DOOR SPEAKER AMP GROUND RIGHT REAR SPEAKER AMP OUTPUT LEFT REAR SPEAKER AMP OUTPUT LEFT REAR SPEAKER AMP OUTPUT RIGHT PANEL SPEAKER LEFT PANEL SPEAKER RIGHT DOOR SPEAKER LEFT DOOR SPEAKER CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 M1 16PK DB X58 18DB OR X84 ...

Page 685: ... 3 4 7 8 Z1 20BK M1 20PK P94 20WT YL P92 20YL P90 20LG BK P90 20LG BK P91 20WT BK P91 20WT BK P95 20DB WT P93 20YL BK 4 8 1 5 BLACK POWER MIRROR SWITCH 5 6 CIRCUIT FUNCTION FUSED B GROUND POWER SEAT FRONT VERTICAL DOWN POWER SEAT FRONT VERTICAL UP POWER SEAT HORIZONTAL FORWARD POWER SEAT HORIZONTAL REARWARD POWER SEAT REAR VERTICAL DOWN POWER SEAT REAR VERTICAL UP CAV A B C D E F G H J K L M N F35...

Page 686: ...POWER TOP SIGNAL UP PUMP MOTOR CONTROL UP FUSED B GROUND PUMP MOTOR CONTROL DOWN POWER TOP SIGNAL DOWN CAV A B C D E F P6 20RD WT P3 12YL A25 12DB Z1 12BK P4 12RD P5 20YL BK CIRCUIT POWER TOP UP DOWN RELAYS CIRCUIT FUNCTION POWER STEERING PRESSURE SWITCH SENSE GROUND CAV 1 2 K10 18DB LG Z1 18BK 1 2 BLACK POWER STEERING PRESSURE SWITCH BLACK F A CIRCUIT FUNCTION CONVERTIBLE TOP UP CONVERTIBLE TOP R...

Page 687: ...SIGNAL AUTOMATIC SHUT DOWN RELAY CONTROL EVAP PURGE SOLENOID CONTROL HIGH SPEED RADIATOR FAN RELAY CONTROL FUEL PUMP RELAY CONTROL SCI RECEIVE PARK NEUTRAL POSITION SWITCH SENSE SPEED CONTROL VACUUM SOLENOID CONTROL SPEED CONTROL VENT SOLENOID CONTROL CAV 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 V37 20RD LG C18 20DB YL ...

Page 688: ...ENGINE COOLANT TEMPERATURE SENSOR SIGNAL UPSTREAM HEATED OXYGEN SENSOR SIGNAL CRANKSHAFT POSITION SENSOR SIGNAL CAMSHAFT POSITION SENSOR SIGNAL CAMSHAFT POSITION SENSOR SIGNAL THROTTLE POSITION SENSOR SIGNAL THROTTLE POSITION SENSOR SIGNAL MAP SENSOR SIGNAL INTAKE AIR TEMPERATURE SENSOR SIGNAL EGR SOLENOID CONTROL CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...

Page 689: ... 3 4 5 6 7 X60 20DG RD X51 18BR YL X52 18DB WT X53 20DG X54 20VT X57 18BR LB X58 18DB OR FUNCTION CIRCUIT LEFT FRONT DOOR RIGHT FRONT DOOR PARK LAMP SWITCH OUTPUT PANEL LAMPS DRIVER FUSED IGNITION SWITCH OUTPUT ACC RUN FUSED B CAV 1 2 3 4 5 6 7 X55 20BR RD X56 20DB RD L7 18BK DG E2 18OR BR X12 18RD WT M1 18PK WT RADIO C2 1 7 GRAY BLACK 1 3 RADIO C1 PREMIUM 1 7 BLACK FUNCTION CIRCUIT RADIO 12 VOLT ...

Page 690: ...2 REAR VERTICAL MOTOR RED FUNCTION POWER SEAT RECLINER MOTOR POWER SEAT RECLINER MOTOR CAV 1 2 P41 16GY WT P43 16GY LB CIRCUIT 1 2 RECLINE MOTOR GREEN FUNCTION BACK UP LAMP FEED GROUND CAV A G L1 18VT BK Z1 18BK CIRCUIT RIGHT BACK UP LAMP CIRCUIT FUNCTION RIGHT VTSS DISARM SENSE FUSED B CAV 1 2 G72 18DG OR M1 18PK RIGHT DOOR ARM DISARM SWITCH BLACK 1 2 CIRCUIT FUNCTION FUSED B COURTESY LAMPS DRIVE...

Page 691: ...RONT WINDOW DRIVER DOWN CAV 1 2 3 5 6 7 8 9 F21 14TN G10 20LG RD G10 20LG RD Q30 14VT Z1 20BK Q26 14VT WT CIRCUIT RIGHT DOOR WINDOW MOTOR RELAY RIGHT FOG LAMP BLACK CIRCUIT FUNCTION FOG LAMP SWITCH OUTPUT GROUND CAV A B L39 18LB Z1 18BK A B CIRCUIT FUNCTION RIGHT FRONT AMPLIFIED RIGHT INSTRUMENT PANEL AMPLIFIED RIGHT INSTRUMENT PANEL RIGHT FRONT CAV 1 1 2 2 X54 18VT X84 18OR BK X86 18OR RD X56 18D...

Page 692: ... 2 3 L34 18RD OR L44 18VT RD Z1 18BK RIGHT HEADLAMP CIRCUIT FUNCTION RIGHT TURN SIGNAL PARK LAMP SWITCH OUTPUT GROUND CAV 1 2 3 L60 18TN BR L7 18BK YL Z1 18BK RIGHT PARK TURN SIGNAL LAMP CIRCUIT FUNCTION RIGHT FRONT DOOR UNLOCK DRIVER RIGHT FRONT DOOR LOCK DRIVER CAV 1 2 P34 16PK BK P33 16OR WT RIGHT POWER DOOR LOCK MOTOR BLACK 1 2 1 2 3 BLACK BLACK 1 3 FUNCTION PARK LAMP SWITCH OUTPUT GROUND CAV ...

Page 693: ...16 20LB YL Z1 20BK P94 20WT YL P91 20WT BK P90 20LG BK P92 20YL RIGHT POWER MIRROR CIRCUIT FUNCTION RIGHT FRONT WINDOW DRIVER DOWN RIGHT FRONT WINDOW DRIVER UP RIGHT FRONT WINDOW DRIVER DOWN RIGHT FRONT WINDOW DRIVER UP FUSED IGNITION SWITCH OUTPUT RUN CAV 1 2 3 4 5 6 Q22 14VT Q16 14BR WT Q26 14VT WT Q12 14BR F21 14TN RIGHT POWER WINDOW SWITCH FUNCTION RIGHT REAR WINDOW DRIVER DOWN RIGHT REAR WIND...

Page 694: ... SENSOR CIRCUIT FUNCTION FUSED B VISOR VANITY LAMP CAV A B M1 18PK G38 18GY RIGHT VISOR VANITY LAMP BLACK B A BLACK 1 2 BLACK 1 2 FUNCTION BACK UP LAMP FEED GROUND CAV A G L60 18TN Z1 18BK CIRCUIT RIGHT REAR TURN SIGNAL LAMP GRAY G A B FUNCTION STOP LAMP SWITCH OUTPUT HD LP LAMP SWITCH OUTPUT GROUND CAV A B G L50 18WT TN L7 18BK YL Z1 18BK CIRCUIT RIGHT TAIL STOP LAMP GRAY G A B FUNCTION CIRCUIT R...

Page 695: ...6 13 1 7 SEAT BELT CONTROL MODULE NATURAL STOP LAMP SWITCH GRAY CIRCUIT FUNCTION STOP LAMP SWITCH SENSE GROUND SPEED CONTROL ON OFF SWITCH SENSE SPEED CONTROL BRAKE SWITCH OUTPUT STOP LAMP SWITCH OUTPUT FUSED B CAV 1 2 3 4 5 6 K29 18WT RD Z2 20BK LG V32 20YL PK V30 20DB RD L50 16WT TN A7 16RD BK 6 1 CIRCUIT FUNCTION SENSOR GROUND 5 VOLT SUPPLY THROTTLE POSITION SENSOR SIGNAL 5 VOLT SUPPLY SENSOR G...

Page 696: ...POSITION SENSOR SIGNAL SPEED SENSOR GROUND OUTPUT SHAFT SPEED SENSOR SIGNAL 12 VOLT SUPPLY TRANS OUTPUT CTRL RLY SWITCHED B TRANS OUTPUT CTRL RLY SWITCHED B 2 4 SOLENOID CONTROL LOW REVERSE SOLENOID CONTROL CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 T1 20LG GY T3 18VT D2 20WT DG T5 20LG LB K24 18GY BK D21 20PK LB A41 16YL OR T9 20OR BK T10 20YL...

Page 697: ...52 53 54 55 56 57 58 59 60 CONTINUED T41 20BK WT T42 18VT TN D1 20VT DG T44 20YL LB D6 20PK LB T47 20YL GY T50 18DG TN K4 20BK LB T52 20RD YL Z14 18BK YL T54 18VT WT A24 16PK YL Z13 16BK RD G7 18WT OR T59 18PK DB T60 18BR TN BLACK CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT RUN SPEED SENSOR GROUND TRANSMISSION TEMPERATURE SENSOR SIGNAL PARK NEUTRAL POSITION SWITCH SENSE REVERSE LAMP SENSE TRANSM...

Page 698: ... T19 18WT PK TRANSMISSION SOLENOID AND PRESSURE SWITCH ASSEMBLY BLACK 3 4 5 6 2 1 8 7 TRAVELER 5 8 BLACK 1 4 CIRCUIT FUNCTION GROUND TRUNK KEY CYLINDER SENSE CAV 1 2 WITH VTSS Z1 18BK G71 20VT YL TRUNK KEY CYLINDER SWITCH 1 2 BLACK CIRCUIT FUNCTION FUSED B TRUNK AJAR SWITCH SENSE CAV 1 2 M1 18PK VT G78 20TN BK TRUNK LAMP CIRCUIT FUNCTION TRAVELER CCD BUS TRAVELER CCD BUS D1 20VT D2 20WT BK CIRCUIT...

Page 699: ...CAV 1 2 3 4 F18 18LG BK K106 18WT DG K107 18OR 4 1 VAPOR CANISTER LEAK DETECTOR CIRCUIT FUNCTION SPEED CONTROL VACUUM SOLENOID CONTROL SPEED CONTROL VENT SOLENOID CONTROL SPEED CONTROL ON OFF SWITCH OUTPUT GROUND CAV 1 2 3 4 V36 20WT VT V35 20LG RD V30 20DB RD Z1 20BK VEHICLE SPEED CONTROL SERVO 4 1 CIRCUIT FUNCTION HORN RELAY CONTROL SPEED CONTROL SWITCH SIGNAL GROUND CAV 1 2 3 4 X3 18BK RD V37 2...

Page 700: ... CAV A B C D V4 14RD YL V3 14BR OR Z1 16BK V55 20WT GY D C B A CIRCUIT POWER TOP SIGNAL DOWN FUSED IGNITION SWITCH OUTPUT RUN POWER TOP SIGNAL UP LEFT REAR WINDOW DRIVER DOWN MOTOR RIGHT REAR WINDOW DRIVER DOWN SWITCH RIGHT REAR WINDOW DRIVER DOWN MOTOR WINDOW MOTOR RELAY CONTROL LEFT REAR WINDOW DRIVER DOWN SWITCH GROUND CAV 1 2 3 4 5 6 7 8 9 P5 20YL BK F21 14TN P6 20RD WT Q27 14RD BK Q32 14BR Q2...

Page 701: ...cupies Individual connector numbers are referenced on diagram pages through out Group 8W WIRING DIAGRAM INDEX The following index covers all components found in this section of the wiring diagrams If the component you are looking for is not found here refer to section 8W 02 for a complete list of all components shown in the wiring diagrams JX 8W 80 CONNECTOR PIN OUTS 8W 80 53 ...

Page 702: ......

Page 703: ...At Module 14 Ash Receiver Lamp BK Rear of Lamp N S Automatic Day Night Mirror BK At Mirror 12 Autostick Switch BK Base of Shifter N S Back Up Lamp Switch GY Rear of Transmission 6 Battery Temp Sensor BK Near Battery 2 Blower Motor Resistor Block BK RT Side of HVAC 11 Body Control Module C1 BK At Module 10 Body Control Module C2 WT At Module 9 Body Control Module C3 WT At Module 9 Connector Name Nu...

Page 704: ...Rear of Clockspring 7 Duty Cycle EVAP Purge Solenoid GY At Solenoid 2 Electronic EGR Transducer Solenoid BK At Solenoid 4 5 Connector Name Number Color Location Fig Engine Coolant Temp Sensor BK At Sensor 4 5 Front Vertical Motor BK At Motor N S Fuel Injector 1 2 0L 2 4L BK At Injector 4 Fuel Injector 1 2 5L BK At Injector N S Fuel Injector 2 2 0L 2 4L BK At Injector 4 Fuel Injector 2 2 5L BK At i...

Page 705: ...ion Block 9 Junction Block C7 NAT At Junction Block 9 Junction Block C8 BK At Junction Block 10 Connector Name Number Color Location Fig Junction Block C9 WT At Junction Block 10 Junction Block C10 BK At Junction Block 13 Key In Halo Lamp WT At Lamp 7 Key In Switch GN At Switch 7 Left Back Up Lamp BK At Lamp N S Left Fog Lamp GY At Lamp 1 Left Door Arm Disarm Switch BK At Switch 17 Left Door Court...

Page 706: ...PDC 1 Powertrain Control Module C2 BK Side of PDC 2 PRNDL Illumination LED BK Base of Gearshifter N S Connector Name Number Color Location Fig Radiator Fan Motor BK Rear of Motor 1 Radio C1 BK Rear of Radio 8 Radio C2 GY Rear of Radio 8 Radio CCD Bus C3 BK Rear of Radio 8 Rear Floor Courtesy Lamp BK At Lamp N S Rear Vertical Motor BK At Motor N S Recline Motor BK At Motor N S Right Back Up Lamp BK...

Page 707: ...ule BK Next to PDC 2 Transmission Range Switch BK Front of Transmision 6 Transmission Solenoids and Pressure Switches BK Front of Transmission 6 Connector Name Number Color Location Fig Traveler BK Rear of Traveler N S Trunk Key Cylinder Switch BK At Switch 16 Trunk Lamp BK At Lamp 15 Turbine Speed Sensor BK Front of Transmission 6 Upstream Heated O2 Sensor BK Rear of Generator 4 5 Vapor Canister ...

Page 708: ...Fig 1 Engine Compartment Connections Left Side 8W 90 6 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 709: ...Fig 2 Engine Compartment Connections Left Side JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 7 DESCRIPTION AND OPERATION Continued ...

Page 710: ...Fig 3 Engine Compartment Connections Right Side 8W 90 8 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 711: ...Fig 4 Engine Connections 2 4L JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued ...

Page 712: ...Fig 5 Engine Connections 2 5L 8W 90 10 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 713: ...Fig 6 Transmission Connections JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Page 714: ...Fig 7 Steering Column Connections 8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 715: ...Fig 8 Instrument Panel Connections JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued ...

Page 716: ...Fig 9 Instrument Panel Connections 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 717: ...Fig 10 Junction Block Connections JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Page 718: ...Fig 11 HVAC Connections 8W 90 16 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 719: ...Fig 12 Windshield Header Connections JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued ...

Page 720: ...Fig 13 Cowl Panel Connections 8W 90 18 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 721: ...Fig 14 Console Connections JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued ...

Page 722: ...Fig 15 Trunk Connections 8W 90 20 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 723: ...Fig 16 Body Connections JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued ...

Page 724: ...Fig 17 Door Connections Left 8W 90 22 8W 90 CONNECTOR GROUND LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 725: ...Fig 18 Door Connections Right JX 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 23 DESCRIPTION AND OPERATION Continued ...

Page 726: ......

Page 727: ...S118 2 5L Near T O for ECT Sensor 6 S119 In Starter Motor T O N S S120 Near T O for PCM 2 6 S121 2 5L In T O for PCM 2 S122 In T O for PCM 2 S123 In Fuel Rail Harness 6 S124 2 4L Near T O for Nosie Suppressor N S S124 2 5L Near Distributor T O 6 S125 Near T O for Turbine Speed Sensor 4 S126 Near EGR T O N S S127 Near T O for PDC 1 Splice Number Location Fig S129 Near Stop Lamp SW T O N S S130 Near...

Page 728: ...Fig 1 Engine Compartment Splices Fig 2 Engine Compartment Splices 8W 95 2 8W 95 SPLICE LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 729: ...Fig 3 Engine Compartment Splices Fig 4 Transmission Splices JX 8W 95 SPLICE LOCATIONS 8W 95 3 DESCRIPTION AND OPERATION Continued ...

Page 730: ...Fig 5 Engine Splices 2 4L 8W 95 4 8W 95 SPLICE LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 731: ...Fig 6 Engine Splices 2 5L JX 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued ...

Page 732: ...Fig 7 Instrument Panel Splices 8W 95 6 8W 95 SPLICE LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 733: ...Fig 8 Body Splices JX 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued ...

Page 734: ...Fig 9 Rear Body Splices 8W 95 8 8W 95 SPLICE LOCATIONS JX DESCRIPTION AND OPERATION Continued ...

Page 735: ...Fig 10 Door Splices JX 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued ...

Page 736: ......

Page 737: ...ges separated as much as possible MOPAR SILICONE RUBBER ADHESIVE SEALANT Mopar Silicone Rubber Adhesive Sealant or equiv alent normally black in color is available in three ounce tubes Moisture in the air causes the Mopar Silicone Rubber Adhesive Sealant material to cure This material is normally used on flexible metal flanges It has a shelf life of one year and will not properly cure if over age ...

Page 738: ...ool and remove plug Fig 1 CAUTION Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems INSTALLATION Thoroughly remove all rust and clean inside of cup plug hole in cylinder block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with sealer Make certain the new plug is cleaned of all oil or grease Using proper drive plug ...

Page 739: ...ervice procedures 6 Inspect and adjust accessory belt drives refer ring to Group 7 Cooling System Accessory Drive Belts for proper adjustments 7 Road test vehicle as a final test HONING CYLINDER BORES 1 Used carefully the cylinder bore resizing hone C 823 equipped with 220 grit stones is the best tool for this job In addition to deglazing it will reduce taper and out of round as well as removing l...

Page 740: ...NOTE REMOVE ALL SHIMS BEFORE REASSEM BLING ENGINE ALTERNATIVE METHOD The weight of the crankshaft can be supported by a jack under the counterweight adjacent to the bearing being checked PLASTIGAGE PROCEDURE 1 Remove oil film from surface to be checked Plastigage is soluble in oil 2 Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6 35 mm 1 4 in off...

Page 741: ...hat the tapped holes maintain the original centerline Heli Coil tools and inserts are readily available from automotive parts jobbers HYDROSTATIC LOCKED ENGINE When an engine is suspected to be hydrostatically locked regardless of what caused the problem these steps should be used CAUTION Do Not Use Starter Motor To Rotate Engine severe damage may occur 1 Inspect air cleaner induction system and i...

Page 742: ...ection of engine oil The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans Fig 7 ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule TO CHANGE ENGINE OIL Run engine until achieving normal operating tem perature 1 Position the vehicle on a level surface and turn engine off 2 Hoist and suppo...

Page 743: ... the suspected leak has been found 4 Repair as required CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc tions Ensure the battery is completely charged and the engine starter motor is in good operating condition Otherwise the indicated compression pressures may not be valid for diagnosis purposes 1 Check engin...

Page 744: ...o the tester manufacturer s instructions While testing listen for pressurized air escaping through the throttle body tailpipe and oil filler cap opening Check for bubbles in the radiator coolant All gauge pressure indications should be equal with no more than 25 leakage FOR EXAMPLE At 552 kPa 80 psi input pres sure a minimum of 414 kPa 60 psi should be main tained in the cylinder LASH ADJUSTER TAP...

Page 745: ...pproximately 24 km 15 miles Inspect the engine for signs of an oil leak by using a black light INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak If the leakage occurs at the crankshaft rea...

Page 746: ... necessary refer to Group 8D Ignition System ENGINE LOSS OF POWER 1 Dirty or incorrectly gapped spark plugs 1 Clean plugs and set gap refer to Group 8D Ignition System 2 Dirt or water in fuel system 2 Clean system and replace fuel filter 3 Faulty fuel pump 3 Install new fuel pump 4 Incorrect valve timing 4 Correct valve timing 5 Blown cylinder head gasket 5 Install new cylinder head gasket 6 Low c...

Page 747: ...sure bearings for correct clearance Repair as necessary 5 Excessive end play 5 Check thrust bearing for wear on flanges 6 Crankshaft journal out of round worn 6 Grind journals or replace crankshaft 7 Loose flywheel or torque converter 7 Tighten to correct torque OIL PRESSURE DROP 1 Low oil level 1 Check engine oil level 2 Faulty oil pressure sending unit 2 Install new sending unit 3 Low oil pressu...

Page 748: ...NGINE MOUNT RIGHT ENGINE SUPPORT BRACKET 20 ENGINE SUPPORT MODULE FRONT AND REAR MOUNTS 19 FRONT CAMSHAFT OIL SEAL 36 FRONT CRANKSHAFT OIL SEAL 36 HYDRAULIC LASH ADJUSTER 29 LEFT SIDE MOUNT 20 OIL FILTER 40 OIL PAN 34 OIL PUMP 40 PISTON AND CONNECTING ROD 42 REAR CRANKSHAFT SEAL 37 TIMING BELT COVER 32 TIMING BELT TENSIONER 34 TIMING BELT 33 VALVE SPRINGS AND VALVE SEALS IN VEHICLE 29 VALVES AND V...

Page 749: ...pe In Line OHV DOHC Bore 87 5 mm 3 444 Inch Stroke 101 mm 3 976 Inches Compression Ratio 9 4 1 Displacement 2 4 Liters 148 Cubic Inches Firing Order 1 3 4 2 Compression Pressure 1069 1172 kPa 170 225 psi Maximum Variation Between Cylinders 25 Lubrication Pressure Feed Full Flow Filtration Direct Crankshaft Driven Pump Engine Oil Capacity Including Oil Filter 4 25 Liter 4 5 Qts Without Oil Filter 3...

Page 750: ...s oil to the hydraulic lash adjusters camshaft and valve mecha nisms CAMSHAFTS The nodular iron camshafts have six bearing journals and 2 cam lobes per cylinder Flanges at the rear journals control camshaft end play Provision for cam position sensor is located on the intake camshaft at the rear of cylinder head A hydrodynamic oil seal is used for oil control at the front of the camshaft VALVES 4 v...

Page 751: ...Run engine at 3000 RPM 3 Oil Pressure Curb Idle 25 kPa 4 psi mini mum 3000 RPM 170 550 kPa 25 80 psi 4 If oil pressure is 0 at idle Shut off engine check for pressure relief valve stuck open or a clogged oil pickup screen SERVICE PROCEDURES CYLINDER BORE AND SIZING PISTON Piston and cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to piston pin about 14 mm 9 16 inc...

Page 752: ...lower side rail 4 Install No 2 piston ring and then No 1 piston ring 5 Position piston ring end gaps as shown in Fig 9 6 Position oil ring expander gap at least 45 from the side rail gaps but not on the piston pin cen ter or on the thrust direction Staggering ring gap is important for oil control Fig 5 Piston Ring Gap PISTON RING SPECIFICATIONS Ring Position Ring Gap Wear Limit Upper Ring 0 025 to...

Page 753: ...er Differ ences in readings between the ends indicate the amount of taper present Record all readings taken Refer to Engine Specifications Plastigage gener ally is accompanied by two scales One scale is in inches the other is a metric scale 6 Plastigage is available in a variety of clearance ranges The 0 025 0 076 mm 001 003 in is usually the most appropriate for checking engine bearing proper spe...

Page 754: ...ells with the lubri cation groove in the cylinder block Fig 12 2 Make certain oil holes in block line up with oil holes in bearings Bearing tabs must seat in the block tab slots CAUTION Do not get oil on the bedplate mating surface It will may effect the sealer ability to seal the bedplate to cylinder block 3 Oil the bearings and journals and install crankshaft CAUTION Use only the specified anaer...

Page 755: ...the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to dam age any bearing surface DO NOT loosen main bear ing cap 2 Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play CAMSHAFT END PLAY 1 Oil camshaft journals and install camshaft WITHOUT cam follower assemblies Install r...

Page 756: ...luid 1 Support the transmission with a transmission jack 2 Remove the three vertical bolts from the mount to the transmission 3 Remove the transmission mount fasteners and remove mount 4 Reverse removal procedure for installation Refer to Fig 21 for bolt tightening specifications 5 Engine support assemblies adjustment Refer to Engine Support Assembly Adjustment of this sec tion ENGINE MOUNT RIGHT ...

Page 757: ...d remove air cleaner and hoses 3 Drain cooling system Refer to Draining Cool ing System in Group 7 4 Discharge Air Conditioning System 5 Disconnect automatic transmission cooler lines and plug if equipped 6 Remove cooling module assembly radiator fan module and condenser 7 Disconnect transmission shift linkage 8 Disconnect throttle body linkage 9 Disconnect engine and transmission wiring harness 1...

Page 758: ...Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission 2 Align engine and transmission mounts to attaching points Install mounting bolts at the right engine and left transmission mounts Refer to proce dures outlined in this section 3 Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135 and 6710 4 Install...

Page 759: ...gine Cradle SupportPost Mounts SPECIAL TOOLS POST 6848 FRONT VIEW SPECIAL TOOLS POST 6848 WITH ADAPTERS 6909 REAR VIEW SPECIAL TOOL 6135 DOLLY SPECIAL TOOL 6710 CRA DLE JX 2 4L ENGINE 9 23 REMOVAL AND INSTALLATION Continued ...

Page 760: ...ners to 12 N m 105 in lbs 4 Install ignition coil pack and plug wires Tighten fasteners to 12 N m 105 in lbs 5 Install ground strap CAMSHAFT REMOVAL 1 Remove cylinder head cover using procedure outlined in this section 2 Remove timing belt sprockets and covers Refer to Timing Belt Service outlined in this section 3 Bearing caps are identified for location Remove the outside bearing caps first Fig ...

Page 761: ...afts with clean oil Install right and left camshaft bearing caps 2 thru 5 and right 6 Tighten M6 fasteners to 12 N m 105 in lbs in sequence shown in Fig 30 2 Apply Mopar Gasket Maker to No 1 and No 6 bearing caps Fig 31 Install bearing caps and tighten M8 fasteners to 28 N m 250 in lbs 3 Bearing end caps must be installed before seals can be installed 4 Install timing belt sprockets and covers Ref...

Page 762: ...section To repair balance shafts carrier assembly 1 Remove chain cover guide and tensioner Fig 34 Also see Carrier Assembly Removal for service procedures requiring only temporary relocation of assembly 2 Remove gear cover retaining stud double ended to also retain chain guide Remove cover and balance shaft gears Fig 34 3 Remove balance shaft gear and chain sprocket retaining screws and crankshaft...

Page 763: ...ttaching bolts and tighten to 54 N m 40 ft lbs 2 Turn balance shafts until both shaft key ways are up Parallel to vertical centerline of engine Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft After instal lation gear and balance shaft keyways must be up with gear timing marks meshed as shown in Fig 39 Fig 35 Drive Chain and Sprockets NICKEL PLATED LINK ...

Page 764: ...CKET THE LOWER NICKEL PLATED LINK AND THE ARROW ON THE SIDE OF THE GEAR COVER SHOULD LINE UP WHEN THE BALANCE SHAFTS ARE TIMED CORRECTLY 9 If the sprockets are timed correctly install the balance shaft bolts and tighten to 28 N m 250 in lbs A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation CHAIN TENSIONING 1 Install chain tensioner loosel...

Page 765: ...S AND VALVE SEALS IN VEHICLE REMOVAL 1 Remove camshafts as previously outlined in this section 2 Rotate crankshaft until piston is at TDC on compression 3 With air hose attached to adapter tool installed in spark plug hole apply 90 120 psi air pressure 4 Using Special Tool MD 998772 A with adapter 6779 Fig 43 compress valve springs and remove valve locks 5 Remove valve spring 6 Remove valve stem s...

Page 766: ...nder head from engine block 16 Inspect and clean cylinder head Refer to Cleaning and Inspection outlined in this section for procedures INSTALLATION NOTE The Cylinder head bolts should be exam ined BEFORE reuse If the threads are necked down the bolts should be replaced Fig 45 Necking can be checked by holding a scale or straight edge against the threads If all the threads do not contact the scale...

Page 767: ...d Inspection outlined in this section for procedure INSTALLATION 1 Coat valve stems with clean engine oil and insert in cylinder head 2 Install new valve stem seals on all valves using a valve stem seal tool Fig 47 The valve stem seals should be pushed firmly and squarely over valve guide CAUTION When oversize valves are used the cor responding oversize valve seal must also be used Excessive guide...

Page 768: ... to crankshaft damper installation for procedure REAR COVER REMOVAL 1 Remove Front Cover Refer to Front Cover Removal procedure outlined in this section 2 Remove Timing Belt Refer to procedure out lined in this section 3 Remove idler pulleys Fig 52 4 Remove both camshaft sprockets 5 Remove rear timing belt fasteners and remove cover from engine Fig 52 INSTALLATION 1 Install rear timing belt cover ...

Page 769: ... this section CAUTION When aligning crankshaft and camshaft timing marks always rotate engine from crankshaft Camshaft should not be rotated after timing belt is removed Damage to valve components may occur Always align timing marks before removing timing belt 8 Align crankshaft and camshafts timing marks Fig 54 to TDC Fig 52 Rear Timing Belt Cover Fasteners REAR COVER TO CYLINDER HEAD FASTENERS R...

Page 770: ...ley camshaft sprockets and then around the tensioner Fig 58 4 Move the exhaust camshaft sprocket counter clockwise Fig 58 to align marks and take up belt slack NOTE A new tensioner is held in the wound posi tion by a pull pin 5 Remove the pull pin or Allen wrench from the belt tensioner 6 Rotate crankshaft 2 revolutions and check the alignment of the timing marks Fig 54 7 Install right engine moun...

Page 771: ...r to transmission bolts and tighten to 108 N m 80 ft lbs 6 Install the 2 remaining collar to pan bolts Starting with the center bolts and working outward torque all 4 bolts to 34 N m 250 in lbs 7 Install engine support module Refer to Removal and Installation procedure in this section Fig 57 Camshaft Sprocket Alignment CAMSHAFT SPROCKET EXHAUST CAMSHAFT SPROCKET INTAKE 1 2 NOTCH LOCATION Fig 58 Ti...

Page 772: ...OIL SEAL REMOVAL 1 Using large side of Special Tool 1026 and Insert 6827 A remove crankshaft damper Fig 64 2 Remove outer timing belt cover and timing belt Refer to Timing Belt System outlined in this section 3 Remove crankshaft sprocket using Special Tool 6793 and insert C 4685 C2 Fig 65 CAUTION Do not nick shaft seal surface or seal bore 4 Using Tool 6771 to remove front crankshaft oil seal Fig ...

Page 773: ...KSHAFT SEAL REMOVAL 1 Insert a 3 16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal Angle the screwdriver Fig 70 through the dust lip against metal case of the seal Pry out seal CAUTION Do not permit the screwdriver blade to contact crankshaft seal surface Contact of the screwdriver blade against crankshaft edge cham fer is permitted Fig 65 Crankshaft Sprocke...

Page 774: ...f the seal is driven into the block past flush this may cause an oil leak 3 Drive the seal into the block using Special Tool 6926 2 and handle C 4171 Fig 72 until the tool bot toms out against the block Fig 73 Fig 69 Crankshaft Damper Installation M12 1 75 3 150 MM BOLT WASHER AND THRUST BEARING FROM SPECIAL TOOL 6792 Fig 70 Rear Crankshaft Oil Seal Removal REAR CRANKSHAFT SEAL ENGINE BLOCK ENGINE...

Page 775: ... holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots CAUTION Do not get oil on the bedplate mating surface It will may effect the sealer ability to seal the bedplate to cylinder block 3 Oil the bearings and journals Install crank shaft CAUTION Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine 4 Apply 1 5 to 2 0 mm 0 ...

Page 776: ... OIL PUMP REMOVAL 1 Disconnect negative battery cable 2 Remove Timing Belt Refer to Timing Belt Removal in this section 3 Remove collar and Oil Pan Refer to Oil Pan Removal in this section 4 Remove Crankshaft Sprocket using Special Tool 6793 and insert C 4685 C2 L Fig 77 5 Remove oil pick up tube 6 Remove oil pump Fig 78 and front crank shaft seal INSTALLATION 1 Make sure all surfaces are clean an...

Page 777: ...O RING OIL PUMP BODY FILTER OIL PICK UP TUBE DRAIN PLUG OIL PAN COLLAR Fig 79 Oil Pump Sealing APPLY GASKET MAKER TO OIL PUMP BODY FLANGE Fig 80 Front Crankshaft Seal Installation PROTECTOR SEAL SPECIAL TOOL 6780 JX 2 4L ENGINE 9 41 REMOVAL AND INSTALLATION Continued ...

Page 778: ...n the front half of the piston facing towards the front of engine 4 Pistons and connecting rods must be removed from top of cylinder block Rotate crankshaft so that each connecting rod is centered in cylinder bore 5 Remove Balance Shaft Assembly Refer to Bal ance Shaft Removal in this section 6 Remove connecting rod cap bolts Push each piston and rod assembly out of cylinder bore NOTE Be careful n...

Page 779: ...eaded plug and gasket from the oil pump Fig 87 b Remove spring and relief valve Fig 87 2 Remove oil pump cover screws and lift off cover 3 Remove pump rotors 4 Wash all parts in a suitable solvent and inspect carefully for damage or wear ASSEMBLY 1 Assemble pump using new parts as required Install the inner rotor with chamfer facing the cast iron oil pump cover 2 Prime oil pump before installation...

Page 780: ...cracked valves Fig 87 Oil Pressure Relief Valve OIL PAN GASKET WITH WINDAGE TRAY O RING OIL PUMP BODY FILTER OIL PICK UP TUBE DRAIN PLUG OIL PAN COLLAR Fig 88 Checking Cylinder Head Flatness FEELER GAUGE STRAIGHT EDGE Fig 89 Checking Wear on Valve Guide Typical TOP MIDDLE BOTTOM CUT AWAY VIEW OF VALVE GUIDE MEA SUREMENT LOCA TIONS Fig 90 Valve Guide Specifications 9 44 2 4L ENGINE JX CLEANING AND ...

Page 781: ... 148 inches or less replace outer rotor 4 If inner rotor measures 9 40 mm 370 inch or less replace inner rotor Fig 95 5 Slide outer rotor into pump housing press to one side with fingers and measure clearance between rotor and housing Fig 96 If measurement is 0 39 mm 0 015 inch or more replace housing only if outer rotor is in specification 6 Install inner rotor into pump housing If clear ance bet...

Page 782: ...g remove rough edges from crankshaft oil holes and clean out all pas sages CAUTION With the nodular cast iron crankshafts used it is important that the final paper or cloth pol ish after any journal regrind be in the same direc tion as normal rotation in the engine CYLINDER BLOCK 1 Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking Fig 94 Measuring Outer Rotor Th...

Page 783: ... Replace as necessary ADJUSTMENTS ENGINE SUPPORT ADJUSTMENT The right and left support assemblies are slotted to allow for right left drive train adjustment in relation to drive shaft assembly length Check and reposition right and left engine support assemblies as required Adjust drive train position if required for the following conditions Drive shaft distress See Group 2 Suspension and Driveshaf...

Page 784: ...5 4 719 mm 0 180 0 185 in No 3 4 097 4 236 mm 0 161 0 166 in Piston Pins Clearance in Piston 0 005 0 018 mm In Rod Interference 0 018 0 043 mm 0 0007 0 0017 in Diameter 21 998 22 003 mm 0 8660 0 8662 in End Play None Length 72 75 73 25 mm 2 864 2 883 in Piston Ring Gap Top Compression Ring 0 25 0 51 mm 0 0098 0 020 in 2nd Compression Ring 0 23 0 48 mm 0 009 0 018 in Oil Control Steel Rails 0 25 0 ...

Page 785: ...ake 5 934 5 952 mm 0 233 0 234 in Exhaust 5 906 5 924 mm 0 233 0 233 in Valve Margin Intake 1 285 1 615 mm 0 050 0 063 in Exhaust 0 985 1 315 mm 0 038 0 051 in Valve Stem Tip Height Intake 48 04 mm 1 891 in Exhaust 47 99 mm 1 889 in Stem Diameter Intake 5 934 5 952 mm 0 234 0 234 in Exhaust 5 906 5 924 mm 0 233 0 233 in Stem to Guide Clearance Intake 0 048 0 066 mm 0 0018 0 0025 in Exhaust 0 0736 ...

Page 786: ...e Mount Bracket Bolts 41 N m 30 ft lbs Exhaust Manifold to Cylinder Head Bolts 23 N m 200 in lbs DESCRIPTION TORQUE Exhaust Manifold Heat Shield Bolts 12 N m 105 in lbs Front Torque Bracket 2 0 2 4L Engine Bolts 33 N m 24 ft lbs Front Torque Bracket Strut 2 0 2 4L Engine Long Bolts 110 N m 80 ft lbs Short Bolt 61 N m 45 ft lbs Intake Manifold Bolts 27 N m 20 ft lbs Oil Filter Filter 20 N m 15 ft l...

Page 787: ...AL TOOLS ENGINE 2 4L Puller 1026 Crankshaft Damper Removal Insert6827 A Dolly 6135 Cradle 6710 Post Kit Engine Cradle 6848 Camshaft Sprocket Remover C 4687 Camshaft Seal Remover C 4679 A JX 2 4L ENGINE 9 51 ...

Page 788: ...aller 6792 Valve Spring Compressor MD 998772 A Valve Spring Compressor Adapter 6779 Cylinder Bore Gage C 119 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover InsertC 4685 C2 Crankshaft Seal Remover 6771 9 52 2 4L ENGINE JX SPECIAL TOOLS Continued ...

Page 789: ... Rear Crankshaft Seal Guide and Installer6926 1 and 6926 2 Balance Shaft Sprocket Installer6052 Post Kit Engine Cradle 6848 Post Adapter 8130 Front Crankshaft Oil Seal Installer6780 JX 2 4L ENGINE 9 53 SPECIAL TOOLS Continued ...

Page 790: ...T ENGINE SUPPORT BRACKET 63 ENGINE SUPPORT MODULE FRONT AND REAR MOUNTS 62 FRONT CRANKSHAFT OIL SEAL 76 LEFT SIDE MOUNT 63 OIL FILTER 79 OIL PAN 75 OIL PUMP 79 PISTON AND CONNECTING ROD 80 REAR CRANKSHAFT SEAL AND RETAINER 79 ROCKER ARM AND HYDRAULIC ADJUSTER 67 TIMING BELT COVERS 71 TIMING BELT 72 VALVE AND VALVE SEALS HEAD OFF 69 VALVE SPRINGS AND SEALS IN VEHICLE 69 DISASSEMBLY AND ASSEMBLY OIL...

Page 791: ...IDENTIFICATION The engine identification number is located on the rear of the cylinder block just below the cylinder head Fig 1 ENGINE 2 5L Fig 1 Engine Identification OIL FILTER ENGINE SERIAL NUMBER AND VIN NUMBER JX 2 5L ENGINE 9 55 ...

Page 792: ...s it is supported by four main bearings with number three being the thrust bearing The six separate con necting rod throws pins reduce torque fluctuations while a dynamic damper is used to control torsional vibration of the crankshaft Rubber lipped seals are used at front and rear The front seal is retained in Fig 2 Engine Oiling CYLINDER WALLS SPLASH LUBRI CATED FROM DIRECTED HOLES IN CONNECTING ...

Page 793: ...st the camshaft The valve actuating end of the rocker arms are machined for hydraulic lash adjusters eliminating the need for periodic valve lash adjustment VALVES Four valves per cylinder are actuated by die cast aluminum roller rocker arms and hydraulic lash adjusters assemblies which pivot on rocker arm shafts All valves have 6 mm diameter chrome plated valve stems The valve train has 33 mm 1 2...

Page 794: ...ITTING PISTONS Measure approximately 2mm 080 inch above the bottom of the piston skirt and across the thrust face Fig 5 See Boring Cylinder Block FITTING PISTON RINGS 1 Wipe cylinder bore clean Insert ring and push down with piston to ensure it is square in bore The ring gap measurement must be made with the ring positioning at least 16mm 0 63 in from bottom of cylinder bore Check gap with feeler ...

Page 795: ... to be installed until side rail is in position Do Not use a piston ring expander Fig 10 8 Install upper side rail first and then the lower side rail 9 Install No 2 piston ring and then No 1 piston ring Fig 11 10 Position piston ring end gaps as shown in Fig 12 Fig 8 Piston Ring Groove Clearance Fig 9 Piston Ring Installation NO 1 PISTON RING NO 2 PISTON RING SPACER EXTENDER OIL RING SIDE RAIL Fig...

Page 796: ...shaft or the Plasti gage may be smeared CONNECTING ROD SIDE CLEARANCE Using a feeler gauge check connecting rod side clearance Fig 14 Refer to Fig 15 for specifica tions FITTING MAIN BEARINGS MAIN BEARING JOURNAL MEASUREMENT Measure the journal outside diameter Fig 16 If the clearance exceeds the specifications limit Fig 17 Replace the main bearing s and if necessary replace the crankshaft Fig 13 ...

Page 797: ...andard Service Procedures CRANKSHAFT BEARING INSTALLATION When the bearings need replacing select and install the proper bearing by the following procedure 1 Measure the crankshaft journal diameter and confirm its classification from the following Fig 20 In the case of a bearing supplied as a service part its identification color is painted at the position show in Fig 21 NOTE Service Replacement p...

Page 798: ...se vehicle on hoist 2 Remove thru bolt at rear mount and remove bolts attaching module to crossmember 3 Remove upper attaching bolt from rear support strut bracket Fig 25 4 Remove front attaching bolts from support module to lower radiator support 5 Support cooling module 6 Remove lower radiator support bolts and remove support 7 Remove thru bolt at front mount and remove support module INSTALLATI...

Page 799: ...ine support bracket to the cylinder block NOTE If centering or adjusting the engine trans mission assembly is needed refer to Adjustments in this section 8 Reverse removal procedure for installation Refer to Fig 28 for bolt tightening specifications LEFT SIDE MOUNT NOTE If centering or adjusting the engine trans mission assembly is needed refer to Adjustments in this section The left side engine m...

Page 800: ... rear engine mount brackets from the body 17 Lower vehicle Remove air cleaner assembly 18 Remove power steering pump and reservoir Set them aside 19 Remove A C compressor 20 Remove ground straps to body 21 Mount the bracket Special Tool 6973 to the right side of the cylinder block Fig 30 Align the front adjustable post with the hole in the bracket 22 Raise vehicle enough to allow engine dolly and ...

Page 801: ...automatic transmission cooler lines shifter and kickdown linkage Refer to Group 21 Transmission for procedures 13 Connect fuel line and heater hoses 14 Install ground straps Connect engine and throttle body connections and harnesses Refer to Group 8 Electrical for procedure 15 Connect throttle body linkage Refer to Group 14 Fuel System for procedure 16 Install radiator and shroud assembly Install ...

Page 802: ...ube to seal the cylinder head cover to spark plug tube If these seals show signs of hardness and or cracks they should be replaced CYLINDER HEAD REMOVAL 1 Refer to Timing Belt removal outlined in this section for disassembly and remove camshaft sprock ets 2 Remove rocker arm assemblies Refer to proce dure outline in this section Fig 32 Cylinder Head Components CYLINDER HEAD COVER BREATHER HOSE GAS...

Page 803: ...ies from cylinder head 5 Mark rocker arm hydraulic lash adjuster assemblies for reassembly in their original position Remove rocker arm hydraulic lash adjuster assembly Lash adjusters are serviced as an assembly with the rocker arm Fig 36 NOTE The automatic lash adjusters are precision units installed in machined openings in the valve actuating ends of the rocker arms Do not disas semble the auto ...

Page 804: ...all thrust case and tighten fasteners to 13 N m 108 in lbs 3 Install camshaft seal Camshaft must be installed before the camshaft seal is installed Refer to procedure outlined in this section 4 Install camshaft sprocket and tighten to 88 N m 65 ft lbs 5 Install timing belt Refer to procedure outlined in this section 6 Install rocker arm assemblies in correct order as removed Tighten the rocker arm...

Page 805: ...eal Fig 43 as outlined in valve installation outlined in this section 2 Use Special Tool MD 998772A with Mounting Post 6886 Forcing Screw Arm 6887 Forcing Screw 6765 and adapter 6865 Fig 42 to compress valve springs only enough to install locks Correct align ment of tool is necessary to avoid nicking valve stems air pressure required piston at TDC 3 Install rocker arm and lash adjuster assemblies ...

Page 806: ...sult from misalignment of the valve spring compressor CAUTION When depressing the valve spring retainers with valve spring compressor the locks can become dislocated Check to make sure both locks are in their correct location after removing tool CRANKSHAFT DAMPER 1 Remove drive belt splash shield Fig 49 2 Remove accessory drive belts Refer to Group 7 Cooling System for procedure Fig 45 Valve Stem ...

Page 807: ... mount bracket the lower timing belt cover must be removed first 5 Remove the engine mount bracket Fig 51 6 Remove the timing belt covers Fig 51 Remove covers in this order a The upper left cover b The lower cover c The upper right cover NOTE To remove right rear timing belt cover the power steering pump bracket must be removed 7 To install reverse previous procedures Fig 50 Crankshaft Damper CRAN...

Page 808: ...3 Compress plunger into the tensioner body Install a pin through the body to retain the plunger Timing Belt System UPPER RIGHT TIMING BELT COVER UPPER LEFT TIMING BELT COVER LOWER TIMING BELT COVER CRANKSHAFT DAMPER SPACER IDLER PUL LEY CRANKSHAFT SPROCKET TENSIONER ARM ENGINE MOUNT BRACKETTENSIONER PULLEY TENSIONER CAMSHAFT SPROCKET BOLT 88 N m 65 ft lbs CAMSHAFT SPROCKET TIMING BELT 182 N m 134 ...

Page 809: ... the crankshaft sprocket to the tensioner pulley 5 Apply rotating force to the crankshaft sprocket in the clockwise direction to tension belt check that all timing marks are aligned 6 Using Special Tool MD 998767 and a torque wrench on the tensioner pulley Apply 4 4 N m 38 9 in lbs of torque to tensioner Fig 58 Tighten ten sioner pulley bolt to 48 N n 35 ft lbs 7 With torque being applied to the t...

Page 810: ...ling System for the procedure 15 Raise vehicle on hoist and install right inner splash shield CAMSHAFT SPROCKETS REMOVAL 1 Hold camshaft sprocket with Special Tool 6847 loosen and remove bolt and washer Fig 59 2 Remove camshaft sprocket from camshaft INSTALLATION 1 Place camshaft sprocket on camshaft 2 Install bolt and washer to camshaft Using Spe cial Tool 6847 hold camshaft sprocket and torque b...

Page 811: ...an INSTALLATION NOTE Oil pan to cylinder block sealing is provided with Mopar Silicone Rubber Adhesive Sealant or equivalent gasket material See Form In Place Gas kets in Standard Service Procedures 1 Apply sealant as shown in Fig 64 2 Install pan and tighten screws to 6 N m 50 in lbs 3 Reverse removal procedure for installation 4 Install correct amount of new oil Fig 62 Remote Battery CableNegati...

Page 812: ...CRANKSHAFT The crankshaft is supported in four main bearings All upper bearing shells in the crankcase have oil grooves All lower bearing shells in stalled in the monoblock main bearing cap are plain Crankshaft end play is controlled by thrust washers on the num ber three main bearing journal REMOVAL 1 Remove front mounted oil pump assembly and gasket Fig 66 and Fig 67 Fig 66 Crankshaft and Cylind...

Page 813: ... other is plain One pair of each thrust washers are installed into the block and one pair into the main bearing cap Fig 69 3 Apply a thin film of grease to plain side of thrust washers and position them on each side of number three main bearing Grooved surface towards crankshaft 4 Oil the bearings and journals and install crankshaft 5 Install lower main bearing shells without oil grooves in monobl...

Page 814: ...AR ING WITH TAB FRONT PLAIN MONOBLOCK MAIN BEARING CAP THRUST BEARING WITHOUT TAB Fig 70 Crankshaft Main Bearing Cap BEARING CAP BEARING CAP BOLT CYLINDER BLOCK TIMING BELT END CRANKSHAFT FRONT 9 78 2 5L ENGINE JX REMOVAL AND INSTALLATION Continued ...

Page 815: ...nd tighten bolts to 11 N m 96 in lbs OIL FILTER CAUTION When servicing the oil filter Fig 75 avoid deforming the filter can by installing the remove install tool band strap against the can to base lockseam The lockseam joining the can to the base is reinforced by the base plate 1 Turn counter clockwise to remove 2 To install lubricate new filter gasket Screw fil ter on until gasket contacts base T...

Page 816: ...e letter R and arrow toward the front of engine are to be installed in cyl inders 1 3 5 Pistons with the letter L and arrow toward the front of engine are to be installed in cyl inders 2 4 6 2 Mark connecting rod and cap with cylinder number Fig 79 3 Remove piston rings Fig 80 INSTALLING PISTON RINGS 1 The No 1 and No 2 piston rings have a differ ent cross section Install rings with manufacturers ...

Page 817: ...ll No 2 piston ring and then No 1 piston ring Fig 83 10 Position piston ring end gaps as shown in Fig 84 11 Position oil ring expander gap at least 45 from the side rail gaps but not on the piston pin cen ter or on the thrust direction Fig 80 Piston Ring Removal Fig 81 Piston Ring Installation NO 1 PISTON RING NO 2 PISTON RING SPACER EXTENDER OIL RING SIDE RAIL Fig 82 Side Rail Installation SIDE R...

Page 818: ...handle At the same time guide connecting rod into position on connecting rod journal Fig 85 8 Install rod caps Install nuts on cleaned and oiled rod bolts and tighten nuts to 51 N m 37 ft lb CAUTION Piston assemblies are not to be inter changed from bank to bank 9 Check alignment marks made during disassem bly and that bearing position notches new or used are on the same side as shown in Fig 86 DI...

Page 819: ...hey may be removed with 400 grit sand paper If deep scratches are present replace the camshaft and check the cylinder head for damage Replace the cyl inder head if worn or damaged Check the lobes for pitting and wear If the lobes show signs of wear check the corresponding rocker arm roller for wear or damage Replace rocker arm if worn or damaged If lobes show signs of pitting on the nose flank or ...

Page 820: ... Grinding Limit Maximum of 0 2 mm 008 inch is permitted CAUTION This is a combined total dimension of stock removal from cylinder head if any and block top surface is 0 2 mm 0 0079 in VALVE GUIDES 1 Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner 2 Using a small hole gauge and a micrometer measure valve guides in 3 places top middle and bot tom Fig 95 R...

Page 821: ... adjuster assembly for wear or damage Fig 98 Replace assembly as necessary OIL FILTER BRACKET 1 Check the oil filter mounting surface The sur face must be smooth flat and free of debris or old pieces of rubber Fig 99 2 Check bracket for cracks and oil leaks Fig 96 Valve Guide Specification Fig 97 Valve Guide Height Fig 98 Rocker Arm Hydraulic Lash AdjusterAssemblies SPECIAL TOOL MD998443 ROLLER RO...

Page 822: ...p as shown in Fig 100 Tighten cap to 41 N m 30 ft lbs TIMING BELT INSPECTION 1 Remove the upper left timing belt cover Fig 104 2 Inspect both sides of the timing belt drive back Replace belt if any of the following conditions exist Hardening of back rubber back side is glossy without resilience and leaves no indent when pressed with fingernail Cracks on rubber back Cracks or peeling of canvas Fig ...

Page 823: ...des valves or both 4 Check for even contact at face center with valve seat Point C 5 Check margin Replace valve if margin is out of specification Fig 109 6 Check valve guide height Fig 107 Fig 104 Timing Belt Covers UPPER RIGHT TIMING BELT COVER FASTENERS UPPER LEFT TIMING BELT COVER FASTENERS LOWER TIMING BELT COVER FASTENERS ENGINE BRACKET FAS TENERS Fig 105 Timing Belt Inspection PEELING TOOTH ...

Page 824: ...y length Check and reposition right and left engine support assemblies as required Adjust drive train position if required for the following conditions Drive shaft distress See Group 2 Suspension and Driveshaft Any front end structural damage after repair Support Assembly replacement ENGINE SUPPORT ADJUSTMENT 1 Remove the load on the engine motor mounts by carefully supporting the engine and trans...

Page 825: ...0 5 mm 0 019 in Exhaust 1 2 mm 0 047 in Service Limit 0 7 mm 0 028 in Valve Stem to Guide Clearance Intake 0 02 to 0 05 mm 0 0008 to 0 002 in Service Limit 0 10 mm 0 004 in Exhaust 0 04 to 0 07 mm 0 0016 to 0 0028 in Service Limit 0 15 mm 0 006 in Valve Face Angle 45 to 45 1 2 Valve Stem Diameter Intake and Exhaust 6 0 mm 0 236 in DESCRIPTION STANDARD DIMENSION AND SERVICE LIMIT Valve Guide Height...

Page 826: ...0 000 mm 2 362 inches Pin Diameter 50 000 mm 1 969 inches Bearing Surface Out of Round 0 03 mm Max 0 001 inch Max Bearing Surface Taper 0 005 mm Max 0 0002 inch Max Bearing Oil Clearance 0 02 to 0 04 mm 0 0008 to 0 0016 inch Undersize Service Bearing 0 25 to 0 50 0 75 mm 0 010 to 0 020 0 030 inch Cylinder Block I D Bore 83 50 to 83 53 mm 3 29 inches Flatness of Top Surface 0 05 mm 0 002 inch 0 1 m...

Page 827: ...r Pipe Assembly 19 N m 13 ft lbs Thermostat Housing Bolt 19 N m 13 ft lbs Water Inlet Pipe Bolt 14 N m 10 ft lbs Water Pump Bolt 24 N m 17 ft lbs Cylinder Head Cover Bolt 3 5 N m 2 5 ft lbs Rocker Arm and Rocker Arm Shaft Bolt 31 N m 23 ft lbs Thrust Case Bolt 13 N m 9 ft lbs Cylinder Head and Valve Cylinder Head Bolt 108 N m 80 ft lbs Oil Filter 14 N m 10 ft lbs Oil Filter Bracket Bolt 23 N m 17 ...

Page 828: ...SPECIAL TOOLS ENGINE 2 5L Remover C 4679 A Insert C 4685 C2 Installer MD 998717 Holders MD 998443 Installer MD 998713 Installer MD 998718 Compressor C 3422 B Adapter 6526 9 92 2 5L ENGINE JX ...

Page 829: ...Wrench MD 998767 Compressor MD 998772 A Installer MD 998774 Puller 1026 Installer 6052 Dolly 6135 Fixture Engine 6710 Screw 6765 JX 2 5L ENGINE 9 93 SPECIAL TOOLS Continued ...

Page 830: ...779 Support Bar Cradle 6710 3A Holder 6847 Engine Cradle Posts 6848 Bracket Cradle Post Support 6973 Adapter 6885 Posts 6886 Adapter 6887 Camshaft Seal Installer 6863 9 94 2 5L ENGINE JX SPECIAL TOOLS Continued ...

Page 831: ...LER 6 INTAKE MANIFOLD PLENUM 2 5L ENGINE 11 INTAKE MANIFOLD 2 4L ENGINE 7 CLEANING AND INSPECTION EXHAUST MANIFOLD INSPECTION 2 4L ENGINE 14 EXHAUST MANIFOLD 2 5L ENGINE 14 INTAKE MANIFOLD 2 5L ENGINE 14 SPECIFICATIONS TORQUE 14 GENERAL INFORMATION EXHAUST SYSTEM The exhaust system has a front mounted catalytic converter with flex joint center mounted resonator and rear muffler Fig 1 Band clamps a...

Page 832: ...anifold Refer to Section 25 for a complete description Diag nosis and Service Procedures on the exhaust gas recirculation system and components HEAT SHIELD Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed near the catalytic converters Fig 4 All engines are equipped with a heat shield crimped on the top of the convertor Refer to Group 23 B...

Page 833: ...ures GROUND STRAP All vehicles are equipped with a ground strap on the exhaust system The ground strap is attached from the rear muffler bracket to the body Fig 9 The ground strap is used to suppress radio frequency interference static EXHAUST FLEX JOINT COUPLING A exhaust flex joint coupling Fig 5 is used to secure the catalytic converter to the engine manifold This joint actually moves back and ...

Page 834: ...of ductile cast iron with the front bank and rear bank independent of each other The exhaust from the front bank exhaust manifold is fed through a exhaust crossover pipe to be combined with the rear bank exhaust at the exhaust outlet to the exhaust pipe Fig 6 Intake and Exhaust Manifolds 2 5L Engine LEFT SIDE MANIFOLD SUP PORT GASKET NUT 21 N m 16 ft lbs OIL DIPSTICK AND TUBE SPRING WASHER GASKET ...

Page 835: ...ce gasket e Exhaust flex joint e Replace catalytic converter assembly f Pipe and shell noise from front exhaust pipe f Characteristic of single wall pipe EXCESSIVE EXHAUST NOISE a Leak at pipe joints a Tighten clamps at leaking joints b Burned or rusted out muffler assembly or exhaust pipe b Replace muffler resonator tailpipe assembly or exhaust pipe with catalytic c Burned or rusted out resonator...

Page 836: ...catalytic converter to exhaust manifold attaching fasteners Fig 8 Remove catalytic con verter from vehicle 8 Clean ends of pipes and or muffler to assure mating of all parts Discard broken or worn insula tors rusted clamps supports and attaching parts NOTE When replacement is required on any com ponent of the exhaust system it is most important that original equipment parts or their equivalent be ...

Page 837: ...ARNING RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING SYSTEM COMPONENTS SER VICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES NEVER SMOKE WHILE SERVICING THE VEHICLE To release fuel pressure refer to Group 14 Fuel System for procedure REMOVAL 1 Perform fuel system pressure release procedure before attempting any repairs 2 Disconnect negative cable from auxiliary jumper terminal Fig ...

Page 838: ...on to throttle body support bracket fasteners at the throttle body and loosen the fastener at the transmission end Fig 9 Exhaust System Support Insulators JX REAR MUFFLER SUPPORT ISOLATORS RESONATOR SUPPORT ISO LATORS MUFFLER FRONT PIPE SUP PORT ISOLATOR FASTENER GROUND STRAP Fig 10 Band Clamp CLAMP SIZE TORQUE SPECI FICATION Fig 11 Auxiliary Jumper Terminal AUXILIARY JUMPER TERMINAL LEFT STRUT TO...

Page 839: ...tighten to 11 9 N m 105 in lbs at the throttle body first Next tighten the bracket at the transmission 6 Connect manifold absolute pressure MAP and intake air temperature sensor wiring connectors 7 Connect knock sensor electrical and starter relay connectors Connect wiring harness to intake manifold tab 8 Connect Idle Air Control IAC motor and Throttle Position Sensor TPS wiring connectors 9 Conne...

Page 840: ...haust system Refer to procedure outlined in this section 2 Remove exhaust manifold heat shield Fig 17 3 Remove 8 exhaust manifold retaining fasteners and remove exhaust manifold Fig 18 INSTALLATION 1 Install new manifold gasket DO NOT APPLY SEALER 2 Set exhaust manifold in place Tighten fasten ers starting at center and progressing outward in both directions to 23 N m 200 in lbs torque Repeat this...

Page 841: ...et hose clamp 8 Release snaps holding air cleaner housing cover to housing 9 Remove air cleaner cover and inlet hoses from engine 10 Unplug TPS and idle air control motor con nectors Fig 23 and Fig 24 11 Squeeze retainer tab on throttle cable and slide cable out of bracket Fig 25 Fig 19 Intake and Exhaust Manifolds 2 5L Engine LEFT SIDE MANIFOLD SUP PORT GASKET NUT 21 N m 16 ft lbs OIL DIPSTICK AN...

Page 842: ...d Left Manifold Support Bolt SUPPORT BRACKET BOLT MAP SENSOR INTAKE AIR TEM PERATURE SEN SOR Fig 23 Throttle Position Sensor THROTTLE BODY THROTTLE POSITION SENSOR Fig 24 Idle Air Control Motor Fig 25 Throttle Cable Attachment SPEED CONTROL CABLE THROTTLE CABLE RELEASE TANG Fig 26 EGR Tube and Right Manifold Support Bolt EGR TUBE BOLTS SUPPORT BRACKET BOLT EGR TUBE 11 12 EXHAUST SYSTEM AND INTAKE ...

Page 843: ...ten bolts to 18 N m 13 ft lbs 8 Install EGR tube to plenum Tighten EGR tube to intake manifold plenum screws to 11 N m 95 in lbs torque 9 Install throttle cables 10 Attach electrical connectors to sensors 11 Tighten air inlet tube clamps to 3 N m 61 25 in lbs 65 12 Connect negative terminal to auxiliary jumper terminal EXHAUST MANIFOLDS 2 5L ENGINE REMOVAL 1 Raise vehicle and disconnect exhaust pi...

Page 844: ...scard gasket and clean all gasket surfaces of manifold to cylinder heads 2 Check upper and lower manifold gasket sur faces for flatness with straight edge Surface must be flat within 0 15 mm per 300 mm 006 in per foot of manifold length 3 Inspect manifolds for cracks or distortion Replace manifold if necessary EXHAUST MANIFOLD 2 5L ENGINE Inspect exhaust manifolds for damage or cracks and check di...

Page 845: ...cle 8 Disengage fog lamp wire connectors from back of fog lamps if so equipped INSTALLATION 1 Ensure that energy management foam is prop erly installed in front fascia Fig 2 2 Engage fog lamp wire connectors to back of fog lamps if so equipped 3 Position fascia on vehicle and slide rearward being careful to ensure that the grille slides between hood latch handle and headlamp adapter assembly 4 Ins...

Page 846: ...to access nuts holding fascia to quarter pan els 8 Remove nuts holding rear fascia to quarter panels 9 Remove screw holding fascia to right rear quar ter panel 10 Slide fascia rearward and separate from vehi cle INSTALLATION 1 Ensure that the energy management foam is properly installed in rear fascia Fig 5 2 Position fascia on vehicle and slide forward to engage studs on quarter panel CAUTION Ens...

Page 847: ...n of nuts on frame rail to aid in installation 4 Remove nuts holding rear bumper reinforce ment to frame rail Fig 6 5 Separate bumper reinforcement from vehicle INSTALLATION 1 Position rear bumper reinforcement on vehicle 2 Install nuts holding bumper reinforcement to frame rail Use previously made marks to properly position bumper reinforcement 3 Install rear fascia Fig 5 Rear Bumper Energy Manag...

Page 848: ... holding engine support module to front suspension crossmember 4 Install bolts holding radiator support cross member to radiator closure panel 5 Install bolt holding engine support module to front engine mount isolator 6 Install bolt holding engine support module to rear engine mount isolator FRONT SUSPENSION CROSSMEMBER REMOVAL 1 Hoist and support vehicle on safety stands Refer to Group 0 Lubrica...

Page 849: ...uspension for proper procedure 9 Install engine support module SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION TORQUE Rear Bumper Reinforcement Attaching Nut 271 N m 200 ft lbs Front Suspension Crossmember Attaching Bolt 115 N m 85 ft lbs Radiator Support Crossmember Attaching Bolts 115 N m 85 ft lbs Headlamp Adapter Assembly Attaching Bolts 34 N m 25 ft lbs Engine Support Module Bolts Front Modu...

Page 850: ... surface Vertical dimensions can be taken from the work sur face to the locations indicated were applicable Fig 3 Fig 4 Fig 5 Fig 6 Fig 7 Fig 8 Fig 9 Fig 10 and Fig 11 Fig 3 Engine Compartment Top View A RADIATOR INSULATOR B FENDER FRONT BOLT C HOOD SLAM BUMPER D STRUT FORWARD NUT INBOARD E STRUT REARWARD NUT OUTBOARD 13 6 BUMPERS AND FRAME JX SPECIFICATIONS Continued ...

Page 851: ...OTTOM OF EXTENSION B BOTTOM OF RADIATOR C ENGINE COMPARTMENT REAR PLP D PLP Fig 5 Forward Frame Section Bottom View TO REAR MID PLP A FRONT PLP B ENGINE COMPARTMENT REAR PLP C FRONT MID PLP JX BUMPERS AND FRAME 13 7 SPECIFICATIONS Continued ...

Page 852: ...Fig 6 Rear Frame Section Side View ZERO PLANE A REAR MID PLP B CENTER OF TRACK BAR MOUNT C CENTER OF REAR CROSSMEMBER D REAR PLP 13 8 BUMPERS AND FRAME JX SPECIFICATIONS Continued ...

Page 853: ...TOR C CENTER OF TRACK BAR MOUNT D CENTER OF REAR CROSSMEMBER E REAR PLP Fig 8 Windshield Opening CENTER OF RADIUS AT TOP CORNER TO CENTER OF RADIUS AT BOTTOM COR NER Fig 9 Door Opening A 25mm SUNVISOR HOLE MASTER GAGE SLOT CENTER REAR HINGE HOLE JX BUMPERS AND FRAME 13 9 SPECIFICATIONS Continued ...

Page 854: ...LOT VIEW A A DOOR OPENING PLP TO TOP CORNER OF OPPOSITE B PILLAR B DOOR OPENING PLP TO OPPOSITE DOOR OPENING PLP C CENTER OF 25 mm SUN VISOR HOLE TO OPPOSITE DOOR OPENING PLP VIEW A Fig 11 Trunk Opening 13 10 BUMPERS AND FRAME JX SPECIFICATIONS Continued ...

Page 855: ...tain detergents corrosion and stability additives are recommended Using gasolines that have these additives will help improve fuel economy reduce emissions and main tain vehicle performance Poor quality gasoline can cause problems such as hard starting stalling and stumble If you experi ence these problems try another brand of gasoline before considering service for the vehicle GASOLINE OXYGENATE ...

Page 856: ...emissions and improve air quality Chrysler Corporation strongly supports the use of reformulated gasolines whenever available Although your vehicle was designed to provide optimum perfor mance and lowest emissions operating on high qual ity unleaded gasoline it will perform equally well and produce even lower emissions when operating on reformulated gasoline Materials Added to Fuel Indiscriminate ...

Page 857: ... as part of the fuel pump module Refer to Fuel Pump Module The fuel delivery system contains a replaceable in line filter The filter attaches to the frame above the rear of the fuel tank Refer to the Maintenance Schedules in the Introduction section of this manual for recommended fuel filter replacement intervals A returnless fuel system is used on all vehicles Fuel is returned through the fuel pu...

Page 858: ... rollover valve The valve is mounted on top of the fuel tank The valve functions as a tank pressure control valve while the vehicle is upright but contains a check valve that prevents fuel from escaping from the fuel tank when the vehicle is turned over The fuel filler cap acts as a pressure vacuum relief valve When air pressure inside the fuel tank gets too high or too low the fuel filler cap ope...

Page 859: ...s The fitting con tains non serviceable O ring seals Fig 4 CAUTION Quick connect fittings are not serviced separately Do not attempt to repair damaged quick connect fittings or fuel tubes Replace the complete fuel tube quick connect fitting assembly The quick connect fitting consists of the O rings retainer and casing Fig 4 When the fuel tube enters the fitting the retainer locks the shoulder of t...

Page 860: ...g is not required If pressure is not correct record the pressure If pressure is above specifications check for a kinked or restricted fuel return tube from filter to pump module If the fuel return tube is not pinched or restricted replace the fuel pressure regulator If fuel pressure is below specifications refer to the diagnosis chart for Fuel Pressure Below Specifi cations 14 6 FUEL SYSTEM JX DIA...

Page 861: ... SURIZE SYSTEM CHECK PRESSURE FUEL PRESSURE DOES NOT CHANGE STILL LOW RESTRICTION BETWEEN FUEL PUMP INLET AND FUEL SUPPLY NIP PLE ON TOP OF FUEL PUMP MODULE CHECK FOR PLUGGED FUEL PUMP INLET STRAINER INLET STRAINER PLUGGED REPLACE INLET STRAINER INLET STRAINER NOT PLUGGED REPLACE FUEL PUMP MOD ULE FUEL PRESSURE ABOVE OR AT SPECIFICATIONS RESTRICTION IN CHASSIS FUEL SUPPLY TUBE CHECK FOR KINKED OR ...

Page 862: ...ifications refer to Fuel Pressure Below Specifications chart FUEL LEVEL SENSOR This procedure tests the resistance of the level sensor itself It does not test the level sensor circuit Refer to Group 8W Wiring Diagrams for circuit identification The level sensor is a variable resistor Its resis tance changes with the amount of fuel in the tank The float arm attached to the sensor moves as the fuel ...

Page 863: ...TOR CONNECTOR REFER TO WIRING DIA GRAMS FOR COLOR CODES AND PIN TERMINAL NUM BERS CIRCUITS OK YES TEST THE ENGINE CON TROL SYSTEM WITH THE DRB SCAN TOOL YES CIRCUIT IS OK CHECK FOR FUEL DELIVERY AT SUS PECT INJECTOR BY REMOV ING THE INJECTOR FROM THE RAIL AND OBSERVING FOR FUEL AND OR RESTRICTIONS IN THE RAIL OR INJECTOR FUEL INLET REFER TO FUEL INJECTOR REMOVAL AND INSTALLA TION IN THE SERVICE PR...

Page 864: ... end of a jumper wire to the A142 circuit terminal of the fuel rail harness connector 3 Connect the other end of the jumper wire to a 12 volt power source 4 Connect one end of a jumper wire to a good ground source 5 Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector Repeat procedure for 2 to 3 injectors FUEL TANK ...

Page 865: ...LATION CAUTION Never install a quick connect fitting without the retainer being either on the fuel tube or already in the quick connect fitting In either case ensure the retainer locks securely into the quick connect fitting by firmly pulling on fuel tube and fit ting to ensure it is secured 1 Using a clean lint free cloth clean the fuel tube nipple and retainer 2 Prior to connecting the fitting t...

Page 866: ... component for damage Replace as necessary 7 Prior to connecting the quick connect fitting to component being serviced check condition of fitting and component Clean the parts with a lint free cloth Lubricate them with clean engine oil 8 Insert the quick connect fitting into the compo nent being serviced until a click is felt 9 Verify a locked condition by firmly pulling on fuel tube and fitting 1...

Page 867: ...URE BEFORE DISCONNECTING QUICK CONNECT FIT TINGS AT FUEL FILTER AND FUEL PUMP MODULE REFER TO THE FUEL PRESSURE RELEASE PRO CEDURE 1 Release fuel system pressure Refer to Fuel Pressure Release Procedure in this section 2 From inside trunk disconnect fuel pump mod ule wiring jumper from main body harness The 4 pin connector is located under the trunk mat on the left side of trunk near the base of t...

Page 868: ...dule harness grommet is installed in body as tank is raised into position 3 Lower vehicle and connect pump module con nector 4 Fill tank with fuel 5 Connect negative cable to auxiliary jumper ter minal FUEL PRESSURE REGULATOR The fuel pressure regulator is part of the fuel pump module Fig 18 Remove the fuel pump mod ule from the fuel tank to access the fuel pressure reg ulator WARNING FUEL SYSTEM ...

Page 869: ...abs on the reservoir body lock over the locking tangs on the strainer 4 Install fuel pump module Refer to Fuel Pump Module Installation in this section FUEL LEVEL SENSOR REMOVAL Remove fuel pump module Refer to Fuel Pump Module in this section 1 Depress retaining tab and remove the fuel pump level sensor connector from the BOTTOM of the fuel pump module electrical connector Fig 21 NOTE The pump mo...

Page 870: ... sensor locks in place 4 Install level sensor wires in connector Push the wires up through the connector and then pull them down until they lock in place Ensure signal and ground wires are installed in the correct position Fig 27 5 Install locking wedge on connector 6 Push connector up into bottom of fuel pump module electrical connector Fig 23 Loosening Level Sensor Fig 24 Level Sensor Removal In...

Page 871: ... fuel rail Refer to Quick Connect Fittings in the Fuel Delivery Section of this Group 5 Connect negative cable to auxiliary jumper ter minal FUEL RAIL 2 5L REMOVAL 1 Disconnect negative cable from auxiliary jumper terminal WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES NEVER SMOKE WHILE SERVICING THE...

Page 872: ...onnectors from fuel injectors 17 Remove 4 bolts holding fuel rail Fig 34 18 Lift fuel rail off engine There are spacers under each fuel rail bolt Fig 35 Fig 30 Throttle Position Sensor THROTTLE BODY THROTTLE POSITION SENSOR Fig 31 Idle Air Control Motor THROTTLEBODY IDLE AIR CONTROL MOTOR THROTTLE POSITION SEN SOR Fig 32 Throttle Cable Attachment SPEED CONTROL CABLE THROTTLE CABLE RELEASE TANG Fig...

Page 873: ... 37 3 Pull injector out of fuel rail Replace fuel injec tor O rings INSTALLATION 1 Reverse procedure for installation FUEL TANK WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES NEVER SMOKE WHILE SERVICING THE VEHICLE REMOVAL 1 Release fuel system pressure Refer to Fuel Pressure Release Procedure in thi...

Page 874: ...r valve 4 Connect chassis fuel tube to fuel filter Refer to Quick Connect Fittings in the Fuel Delivery section of this Group 5 Connect fuel fill tube to tank inlet Tighten hose clamp to 3 5 N m 31 in lbs torque 6 Install pump module harness grommet into body 7 Position fuel filter and fuel tank straps Install the front bolts first and then the rear bolts Tighten fuel tank strap bolts to 23 N m 25...

Page 875: ...1 Install rubber gromment in body housing Fig 43 Make sure chamfer is in the proper location Fig 44 2 Use a lubrication on fuel filler tube when inserting it in the rubber gromment 3 Install fuel tube onto the fuel tank neck 4 Tighten hose clamp to 3 5 N m 31 in lbs 5 Install fuel filler ground strap on to body lip Fig 41 Fuel Filler Cap Fig 42 Rubber Gromment and Body Housing Fig 43 Body Housing ...

Page 876: ...ig 47 2 Compress the retaining tabs on the cable and slide cable out of bracket Fig 47 3 From inside vehicle reach behind the top of the pedal shaft and push the retainer toward rear of vehicle It may be necessary to squeeze retainer ears together on dash side of pedal shaft 4 Lift cable up through slot in top of pedal shaft 5 From the engine compartment pull the throttle cable and grommet out of ...

Page 877: ...nto the dash panel 2 Install cable housing throttle body end into the cable mounting bracket on the engine 3 Place cable through slot in top of pedal shaft 4 Step on pedal and retainer will snap into place 5 From the engine compartment rotate the throttle lever forward to the wide open position and install cable clasp SPECIFICATIONS TORQUE DESCRIPTION TORQUE Accelerator Pedal to Dash Nuts 12 N m 1...

Page 878: ... SWITCH PCM INPUT 33 POWERTRAIN CONTROL MODULE 28 RADIATOR FAN RELAYS PCM OUTPUT 39 SCI RECEIVE PCM INPUT 34 SENSOR RETURN PCM INPUT 34 SPEED CONTROL RELAY PCM OUTPUT 39 SPEED CONTROL SERVOS PCM OUTPUT 39 SPEED CONTROL PCM INPUT 34 SYSTEM DIAGNOSIS 27 TACHOMETER PCM OUTPUT 39 THROTTLE BODY 39 THROTTLE POSITION SENSOR PCM INPUT 34 TRANSAXLE PARK NEUTRAL SWITCH PCM INPUT 34 VEHICLE SPEED AND DISTANC...

Page 879: ... for Wide Open Throttle WOT There are several differ ent modes of operation that determine how the PCM responds to the various input signals There are two different areas of operation OPEN LOOP and CLOSED LOOP During OPEN LOOP modes the PCM receives input signals and responds according to preset PCM programming Inputs from the upstream and down stream heated oxygen sensors are not monitored dur in...

Page 880: ...ved during the Ignition Switch On zero RPM mode If the PCM does not detect a minimum difference between the two values it sets a MAP diagnostic trouble code into memory Once the ASD and fuel pump relays have been energized the PCM determines injector pulse width based on the following Battery voltage Engine coolant temperature Engine RPM Intake air temperature IAT Throttle position The number of e...

Page 881: ...s in respones to MAP sensor feedback The PCM may receive a closed throttle input from the Throttle Position Sensor TPS when it senses an abrupt decrease in manifold pressure This indicates a hard deceleration In response the PCM may momentarily turn off the injectors This helps improve fuel economy emissions and engine braking If decel fuel shutoff is detected downstream oxy gen sensor diagnostics...

Page 882: ...Position Sensor Crankshaft Position Sensor Engine Coolant Temperature Sensor Fuel Level Sensor Ignition Switch Intake Air Temperature Sensor Knock Sensor 2 0 2 4L only Manifold Absolute Pressure MAP Sensor Oxygen Sensors Power Steering Pressure Switch SCI Receive Speed Control Switches Throttle Position Sensor Transmission Park Neutral Switch automatic transmission Vehicle Speed Sensor NOTE PCM Ou...

Page 883: ...D SENSE PCM INPUT The ASD sense circuit informs the PCM when the ASD relay energizes A 12 volt signal at this input indicates to the PCM that the ASD has been acti vated This input is used only to sense that the ASD relay is energized When energized the ASD relay supplies battery voltage to the fuel injectors ignition coils and the heating element in each oxygen sensor If the PCM does not receive ...

Page 884: ...he crankshaft position sensor mounts to the engine block behind the generator just above the oil filter Fig 5 2 5L ENGINE On a 2 5L engine this sensor is a hall effect device that detects notches in the flexplate The sensor is located in the transaxle housing above the vehicle speed sensor Fig 6 ENGINE COOLANT TEMPERATURE SENSOR PCM INPUT The coolant temperature sensor has one element The element ...

Page 885: ... uses the upstream heated oxygen sensor input when adjusting injector pulse width When the catalytic converter efficiency drops below emission standards the PCM stores a diagnostic trouble code and illuminates the malfunction indica tor lamp MIL The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors The oxygen sensors are equipped with a hea...

Page 886: ... match the upstream sensor input except for a slight time delay By com paring the downstream heated oxygen sensor input to the input from the upstream sensor the PCM cal culates catalytic convertor efficiency IGNITION SENSE PCM INPUT The ignition sense input informs the Powertrain Control Module PCM that the ignition switch is in the crank or run position INTAKE AIR TEMPERATURE SENSOR PCM INPUT Th...

Page 887: ...r pressure from the MAP sensor voltage While the engine operates the PCM determines intake manifold pressure from the MAP sensor voltage Based on MAP sensor voltage and inputs from other sensors the PCM adjusts spark advance and the air fuel mixture The MAP sensor mounts to the intake manifold POWER STEERING PRESSURE SWITCH PCM INPUT A pressure sensing switch is located on the power steering gear ...

Page 888: ...provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral This input is used to determine idle speed varying with gear selection and ignition tim ing advance The park neutral switch is sometimes referred to as the neutral safety switch THROTTLE POSITION SENSOR PCM INPUT The throttle position sensor mounts to the side of the throttle body Fig 18 or Fig 19 The Thr...

Page 889: ...y The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay The fuse also protects the power circuit for the fuel pump relay and pump The fuse is located in the PDC Refer to Group 8W Wiring Diagrams for circuit information The PCM controls the relay by switching the ground path for the solenoid side of the relay on and off The PCM turns the ground path off wh...

Page 890: ...w back pressure varies the strength of the vacuum signal applied to the EGR valve Varying the strength of the vacuum signal changes the amount of EGR supplied to the engine This provides the correct amount of exhaust gas recirculation for different operating conditions The solenoid transducer and EGR valve mount to the rear of the cylinder head Fig 23 or Fig 24 GENERATOR FIELD PCM OUTPUT The PCM r...

Page 891: ...e Powertrain Control Module PCM Refer to On Board Diagnostics in Group 25 Emission Control Systems The data link connector is located inside the vehicle under the instrument panel at the driver s kick panel Fig 27 FUEL INJECTORS PCM OUTPUT All engines use electrically operated top feed fuel injectors Fig 28 The Automatic Shutdown ASD relay supplies battery voltage to the fuel injectors The PCM con...

Page 892: ...MP PCM OUTPUT The PCM supplies the malfunction indicator check engine lamp on off signal to the instrument panel through the CCD Bus The CCD Bus is a communi cations port Various modules use the CCD Bus to exchange information The Check Engine lamp comes on each time the ignition key is turned ON and stays on for 3 seconds as a bulb test The Malfunction Indicator Lamp MIL stays on continuously whe...

Page 893: ...ontrol relay supplies also operated by the PCM supplies battery voltage to the servos When the PCM supplies a ground to the vacuum servo the speed con trol system opens the throttle plate to obtain or main tain the selected road speed When the PCM supplies a ground to the vent servo the speed control system releases the throttle plate The PCM balances the two servos to maintain the set speed Refer...

Page 894: ...d fuses are fully seated in the PDC Fig 33 A label on the underside of the PDC cover shows the locations of each relay and fuse 4 Inspect accelerator cable and cruise control cable if equipped connections Check their connec tions to the throttle arm of the throttle body for any binding or restrictions 5 Check the electrical connections at the idle air control motor and throttle position sensor Fig...

Page 895: ...2 and spark plug cables at distributor 9 Inspect the electrical and hose connections at the duty cycle purge solenoid Fig 43 10 Check electrical connection to the radiator fan Fig 36 PCV Valve 2 4L Engine INTAKE MANI FOLD PCVVALVE Fig 37 PCV Valve 2 5L Engine PCV VALVE FRONT VALVE COVER Fig 38 MAP Sensor and Intake Air Temperature Sensor 2 4L Engine INTAKE AIR TEMPERATURE SENSOR THROTTLE BODY MAP ...

Page 896: ... at the solenoid and transducer for leaks Fig 48 or Fig 49 17 Inspect electrical connections at the generator Check the generator belt for glazing or damage 18 Inspect electrical connector at the crankshaft position sensor Fig 50 or Fig 51 Fig 41 Ignition Coil and Spark Plugs IGNITION COILS SPARK PLUG CABLE SPARK PLUG INSULATOR Fig 42 Distributor Electrical Connectors Viewed From Rear of Distribut...

Page 897: ... COOLANT FILL NECK ENGINE COOLANT TEMPER ATURE SENSOR AIR INLET TUBE Fig 48 Electronic EGR Transducer 2 4L Engine Fig 49 Electronic EGR Transducer 2 5L Engine Fig 50 Crankshaft Position Sensor 2 4L Engines Typical Fig 51 Crankshaft Position Sensor 2 5L Engine DISTRIBUTOR HOLD DOWN BOLT CRANKSHAFT POSITION SENSOR JX FUEL SYSTEM 14 43 DIAGNOSIS AND TESTING Continued ...

Page 898: ...rol servo if equipped Refer to Group 8H Vehicle Speed Control ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown ASD and fuel pump relays The terminals on the bottom of each relay are numbered Fig 58 Fig 52 Output Speed Sensor Automatic Transmission MANUAL VALVE LEVER OUTPUT SPEED SENSOR Fig 53 Power Steering Pressure Switch POWER STEERIN...

Page 899: ...85 OR 86 DURING THIS TEST 7 Attach the other end of the jumper wire to relay terminal 86 This activates the relay The ohm meter should now show continuity between relay ter minals 87 and 30 The ohmmeter should not show continuity between relay terminals 87A and 30 8 Disconnect jumper wires 9 Replace the relay if it did not pass the continu ity and resistance tests If the relay passed the tests it ...

Page 900: ... PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition Repair as required 3 Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51 If OK go to next step If not OK repair as required 4 Test MAP sensor supply voltage between sen sor connector terminals 2 and 1 with the key ON The voltage should be approximately 5 volts 6 5...

Page 901: ...ER a Remove the throttle body from engine b While holding the throttle open spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner Only use Mopar Parts Cleaner to clean the throttle body c Using a soft scuff pad clean the top and bot tom of throttle body bore and the edges and mani fold side of the throttle blade The edges of the throttle blade and...

Page 902: ... the throttle bore that are closest to the throttle blade when it is closed must be free of deposits 4 Use compressed air to dry the throttle bodies 5 Inspect throttle body for foreign material 6 Install throttle body on manifold REMOVAL AND INSTALLATION THROTTLE BODY 2 4L ENGINES REMOVAL 1 Remove air inlet resonator as described in this section 2 Remove throttle shield Fig 63 3 Remove throttle ca...

Page 903: ... cable and slide cable out of bracket Fig 67 4 Slide speed control cable out of bracket if equipped Fig 67 5 Remove EVAP purge hose from nipple on throt tle body 6 Remove connectors from throttle position sen sor and idle air control motor 7 Remove bolts holding throttle body to intake manifold Remove throttle body INSTALLATION 1 Attach electrical connectors to idle air control motor and throttle ...

Page 904: ...in this section 4 Remove TPS mounting screws 5 Remove throttle position sensor INSTALLATION 1 The throttle shaft end of the throttle body slides into a socket in the TPS Fig 71 The socket has two tabs inside it The throttle shaft rests against the tabs When indexed correctly the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The...

Page 905: ...he intake manifold plenum Fig 75 REMOVAL 1 Remove air inlet resonator 2 Reaching through intake manifold from throttle body end disconnect sensor connector 3 Remove sensor INSTALLATION 1 Install sensor Tighten sensor to 28 N m 20 ft lbs torque 2 Attach electrical connector to sensor 3 Install air inlet resonator INTAKE AIR TEMPERATURE SENSOR 2 5L The intake air temperature sensor threads into the ...

Page 906: ...lbs MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 2 4L The MAP sensor attaches to the intake manifold plenum Fig 75 2 5L The MAP sensor attaches to the intake manifold plenum Fig 76 REMOVAL 1 Disconnect electrical connector from MAP sen sor 2 Remove sensor mounting screws 3 Remove sensor INSTALLATION 1 Insert sensor into intake manifold while mak ing sure not to damage O ring seal 2 Tighten mounting screw...

Page 907: ...vehicle UPSTREAM HEATED OXYGEN SENSOR 2 5L REMOVAL 1 Raise and support vehicle 2 Disconnect electrical connector from sensor 3 Remove sensor using an oxygen sensor crow foot wrench such as Snap On tool YA8875 or equiva lent Fig 80 INSTALLATION 1 After removing the sensor the exhaust mani fold threads must be cleaned with an 18 mm X 1 5 6E tap If reusing the original sensor coat the sensor threads ...

Page 908: ...r electrical harness to clips along body 3 Connect electrical connector to sensor 4 Lower vehicle AIR INLET RESONATOR 2 0L REMOVAL 1 Remove 2 bolts holding air inlet resonator to intake manifold Fig 82 2 Loosen screw holding resonator to throttle body Fig 83 3 Loosen clamp holding resonator to air inlet tube Remove resonator INSTALLATION 1 Install air inlet resonator to throttle body 2 Install air...

Page 909: ...hten to 56 5 N m 4565 in lbs torque AIR CLEANER The air cleaner housing attaches to the inner fender in front of the driver s side strut tower Fig 85 An ambient air duct supplies underhood air for the engine FILTER ELEMENT REPLACEMENT REMOVAL 1 Unfasten clasps on rear of air cleaner housing cover Lift cover off air cleaner housing Fig 86 2 Remove filter element Fig 87 3 If necessary clean the insi...

Page 910: ...2 Remove the sensor mounting bolt 3 Lift the sensor out of the transaxle extension housing Ensure the O ring was removed with the sensor INSTALLATION The speed sensor gear meshes with a gear on the output shaft 1 With O ring in place install sensor 2 Install mounting bolt 3 Connect electrical connector to sensor KNOCK SENSOR For removal installation procedures refer to Group 8D Ignition System Ser...

Page 911: ...s IAC Motor To Throttle Body Bolts 3 N m 25 in lbs MAP Sensor Mounting Screws 3 N m 25 in lbs Oxygen Sensor 28 N m 20 ft lbs Powertrain Control Module PCM Mounting Screws 4 N m 35 in lbs Throttle Body Mounting Bolts 26 N m 19 ft lbs Throttle Position Sensor 3 N m 25 in lbs Throttle Shield Bolt 4 5 N m 40 in lbs Fig 90 Vehicle Speed Sensor TRANSAXLE SPEED SENSOR SPEED SENSOR RETAINING BOLT JX FUEL ...

Page 912: ...SPECIAL TOOLS FUEL Extractor C 4334 Pressure Gauge Assembly C 4799 B Fuel Pressure Test Adapter 6539 Spanner Wrench 6856 Metering Orifice Fuel Line Tool Fuel Line Adapter 14 58 FUEL SYSTEM JX ...

Page 913: ...Fuel Line Adapter 1 4 JX FUEL SYSTEM 14 59 SPECIAL TOOLS Continued ...

Page 914: ......

Page 915: ... Power Steering Supply and Pressure Hoses and Power Steering Fluid Return Hose Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth Power assist steering is provided by an open center rotary type control valve It is used to direct oil from the power steering pump to either side of the integral steering rack piston Road fe...

Page 916: ...nting bolts Tighten to specified torque if found to be loose 2 Front suspension crossmember to frame bolts or studs loose 2 Tighten the front suspension crossmember attaching bolts or studs to the specified torque 3 Tie rod is loose outer or inner 3 Check tie rod pivot points for wear Replace worn loose parts as required 4 Loose lower control arm to front suspension crossmember bolts 4 Tighten con...

Page 917: ...replace O Ring as required 3 Low power steering fluid level 3 Fill power steering fluid reser voir to proper level and perform leakage diagnosis 4 Air leak between power steer ing fluid reservoir and power steering pump 4 Inspect and or replace power steering fluid reservoir or supply hose as required SQUEAK OR RUBBING SOUND 1 Sound coming from steering column 1 Check for squeak in steering column...

Page 918: ... steering column or intermediate shaft 8 Correct condition See Steering Column Service Procedure 9 Steering column coupler binding 9 Realign the steering column to eliminate the binding condition 10 Binding upper or lower ball joint 10 Replace the upper or the lower control arm as required 11 Excessive friction in steering gear 11 Replace steering gear assembly CONDITION POSSIBLE CAUSES CORRECTION...

Page 919: ...dure Replace the power steering pump if necessary 7 High internal leak in steering gear assembly 7 Check steering system using the Power Steering System Test Procedure If steering gear is defective replace steering gear CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL DOES NOT RETURN TO CENTER POSITION 1 Tires not inflated to specified pressure 1 Inflate tires to specified pressure 2 Improper f...

Page 920: ... or replace with new parts as necessary 8 Loose outer tie rod ends 8 Check free play of outer tie rod ends and replace if required 9 Loose inner tie rod ends 9 Replace steering gear assembly 10 Defective steering gear rotary valve 10 Replace steering gear assembly CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL DOES NOT WANT RETURN TO CENTER POSITION 1 Radial tire lead 1 Rotate tires as recomm...

Page 921: ...repair or replace the component as required Refer to Power Steering Pump and or Power Steering Gear in this group of the service manual for required procedures CONDITION POSSIBLE CAUSES CORRECTION AERATION AND OVERFLOW OF FLUID 1 Air leaks 1 Check for air leaking into the power steering system as described under Sucking Air Diagnosis and correct condition 2 Low fluid level 2 Extremely cold tempera...

Page 922: ...ssure for operation of the power steer ing gear is provided by a belt driven power steering pump Fig 1 The TTA power steering pump used on this vehicle is a droop flow rate and constant dis placement vane type pump In the event of a power steering pump drive belt failure manual steering control of the vehicle can still be maintained However under these conditions steering effort will be significan...

Page 923: ... its seat and allows oil to flow through a trigger orifice located in the outlet fitting This reduces pressure on the spring end of the flow control valve which then opens and allows the oil to return to the intake side of the pump This action limits maximum pressure output of the pump to a safe level Under normal power steering pump operating con ditions pressure requirements of the pump are belo...

Page 924: ...esting power steering pump maximum pressure output and flow control valve operation Do not leave valve closed for more than 5 seconds as the pump could be damaged 8 Close valve fully three times and record high est pressure indicated each time All three read ings must be above specifications and within 345 kPa 50 psi of each other NOTE Power steering pump maximum relief pres sure is 8240 to 8920 k...

Page 925: ...NTROL VALVE O RING SEAL DISASSEMBLE The power steering pump does not require removal from the engine for removal and replacement of the flow control valve fitting O Ring 1 Remove the power steering fluid pressure hose from power steering pump pressure fitting Fig 5 2 Remove the power steering pump discharge flow control valve fitting Fig 6 from the power steering pump housing Use care to prevent t...

Page 926: ...tion shown in step 1 below Over tightening may result in strip ping the threads out of the pressure switch port on the steering gear 1 Install power steering pressure switch into power steering gear by hand until fully seated Then using a crow foot and extension tighten power steer ing pressure switch to a torque of 16 N m 12 ft lbs 2 Install vehicle wiring harness connector onto power steering pr...

Page 927: ... low pressure ports on the steering gear 3 Disconnect the power steering pressure hose Fig 9 at the power steering gear Drain power steering fluid from power steering pump and hose through open end of hose 4 If the vehicle is equipped with a 2 4 liter engine remove the power steering pressure hose routing bracket from the power steering return hose bracket on rear of engine Fig 10 Then remove the ...

Page 928: ... both O rings using fresh clean power steering fluid 6 Install the Banjo Bolt into the power steering pressure hose banjo fitting Fig 15 7 Attach the power steering pressure hose to the outlet fitting on the power steering pump Fig 13 Do not tighten the pressure fitting banjo bolt at this time CAUTION Hoses must remain away from exhaust system vehicle components and unfriendly sur faces causing po...

Page 929: ...ning the engine 16 Raise front wheels of vehicle off the ground 17 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops Then turn the engine off 18 Add power steering fluid if necessary 19 Lower the vehicle and turn the steering wheel slowly from lock to lock 20 Stop the engine Check the fluid level and refill as required 21 If the fluid is extremely fo...

Page 930: ... Fig 20 Then remove the bolt Fig 20 attaching the power steering pressure hose routing bracket to the cylinder head 7 If vehicle is equipped with a 2 5 liter engine remove the 2 routing brackets Fig 21 attaching the power steering return hose to the power steering pressure hose routing brackets 8 Remove the power steering return hose from the vehicle The power steering return hose is removed from ...

Page 931: ...ehicle CAUTION Care must be used when installing power steering fluid return hose on power steering fluid reservoir If excessive force is used when try ing to install hose on nipple of power steering fluid reservoir nipple can be broken off the reservoir 11 Install power steering return hose on power steering fluid reservoir fitting Install hose clamp on power steering return hose at power steerin...

Page 932: ... the power steering pres sure hose CAUTION Do not use automatic transmission fluid in power steering system Only use MoparT Power Steering Fluid or equivalent 5 Fill power steering fluid reservoir 6 Start the engine and let run for a few seconds Then turn the engine off 7 Add fluid if necessary Repeat the above proce dure until the fluid level remains constant after run ning the engine 8 Raise fro...

Page 933: ... wheel stops Then turn the engine off 9 Add power steering fluid if necessary 10 Lower the vehicle and turn the steering wheel slowly from lock to lock 11 Stop the engine Check the fluid level and refill as required 12 If the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure 13 After hose is installed check for leaks at all hose connections POWER ST...

Page 934: ...or wheel speed sensor cable grommet Fig 29 from right inner fender Fig 25 Accessory Drive Splash Shield SPLASH SHIELD Fig 26 Power Steering Fluid Pressure Hose Attachment To Pump POWER STEERING PUMP POWER STEERING FLUID SUPPLY HOSE FLOW CONTROL VALVE FIT TING ABS HYDRAULIC CONTROL UNIT HEAT SHIELD POWER STEERING PRES SURE HOSE Fig 27 Power Steering Pump Front Bracket Attachment POWER STEERING PUMP...

Page 935: ...accessory drive bracket 3 Loosely install the bolt mounting the power steering pump to its rear mounting bracket Fig 28 4 Loosely install bolt attaching top of power steering pump front bracket to the cast aluminum accessory drive bracket Access to install the bolt is through the wheel speed sensor cable routing hole Fig 31 5 Using a lint free towel wipe clean all open power steering hose ends and...

Page 936: ...met in routing hole Install retainer for wheel speed sensor cable grommet Fig 30 on right inner fender 17 Install accessory drive slash shield in right front inner fender 18 Install tire back on vehicle Tighten the wheel lug nuts in proper sequence until all lug nuts are torqued to half specification Then repeat tightening sequence to full specified torque of 135 N m 100 ft lbs 19 Lower vehicle CA...

Page 937: ...luid pressure hose After power steering fluid has drained out of pump and hose install a cap on the power steering pressure hose and a plug in the power steering pump pressure fitting 8 Remove the antilock brakes hydraulic control unit heat shield Fig 37 from the hydraulic control unit mounting bracket 9 Remove bolt at adjusting slot in accessory drive mounting bracket Fig 38 attaching back of pow...

Page 938: ...ting Fig 40 6 Install a new O ring on the power steering pressure hose banjo fitting bolt Fig 41 7 Lubricate both O rings using fresh clean power steering fluid NOTE When installing the pressure hose it must be installed between the front bracket of the power steering pump and power steering pump pulley 8 Install the power steering pressure hose on the power steering pump pressure fitting and loos...

Page 939: ...er the vehicle Start engine again and turn the steering wheel slowly from lock to lock 25 Stop the engine Check the fluid level and refill as required 26 If the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure 27 After power steering pump is installed check for leaks at all hose connections and power steering pump fittings POWER STEERING OIL COOLER...

Page 940: ...eering gear shaft 2 Siphon as much power steering fluid as possi ble from the power steering fluid reservoir 3 Raise the vehicle using a frame contact type hoist or supported as required using jack stands See Hoisting in the Lubrication and Maintenance group of this service manual for the required hoisting or jacking procedure to be used for this vehicle 4 Remove the left front wheel tire 5 Remove...

Page 941: ...Clamp Special Tool C 4124 properly crimp the clamps on the power steering fluid hoses at the power steering oil cooler line 6 Install the power steering fluid return hose on the steering gear Then using a crow foot and torque wrench Fig 50 tighten the tube nut to a torque of 31 N m 275 in lbs 7 Install the clip Fig 48 holding the 2 power steering fluid cooler lines together 8 Install the front sus...

Page 942: ...seconds Then turn the engine off 19 Add fluid if necessary Repeat the above pro cedure until the fluid level remains constant after running the engine 20 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops 21 Add power steering fluid if necessary 22 Stop the engine Check the fluid level and refill as required 23 If the fluid is extremely foamy allow th...

Page 943: ... stand a few minutes and repeat the above pro cedure DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP DRIVE PULLEY The power steering pump must be removed from the vehicle for removal of the power steering pump pulley Refer to Power Steering Pump Removal in the Power Steering Pump Service Procedures section in this group of the service manual DISASSEMBLE 1 Remove power steering pump from engine Refer ...

Page 944: ...oval in the Power Steering Pump Service Procedures section in this group of the service manual for required procedure CAUTION Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley This will damage the pulley and the power steering pump 2 Mount Puller Special Tool C 4333 or C 4068 on power steering pump pulley Mount power steering pump and puller in a vise Fig 57...

Page 945: ... pump 7 Install power steering pump and bracket assembly back on engine Refer to Power Steering Pump Installation in the Power Steering Pump Ser vice Procedures section in this group of the service manual for required procedure SPECIFICATIONS POWER STEERING PUMP FLOW SPECIFICATIONS Flow At 1500 RPM And Minimum Pressure 5 7 to 7 6 Liters Min 1 5 to 2 0 GPM Control Valve Pressure Relief 8240 to 8920...

Page 946: ...n lbs Pressure Hose Banjo Bolt 34 N m 25 ft lbs Return Hose Bracket To Head 2 4L 28 N m 21 ft lbs Pressure Hose To Return Hose Bracket 9 N m 75 in lbs Pressure Hose To Cylinder Head 2 5L 54 N m 40 ft lbs Return Hose To Pressure Hose Bracket 2 5L 9 N m 75 in lbs POWER STEERING FLUID RESERVOIR Reservoir To Mounting Bracket Or Engine 28 N m 21 ft lbs Reservoir Bracket To Engine 28 N m 21 ft lbs SPECI...

Page 947: ...eration of the power steering system on this vehi cle This test will provide the flow rate of the power steering pump along with the maximum relief pres sure This test is to be performed any time a power steering system problem is present to determine if the power steering pump or power steering gear is not functioning properly The following pressure and flow test is performed using Pressure Flow ...

Page 948: ...against the stops for more than 5 seconds at a time because pump damage will result 9 Open test valve Turn steering wheel to the extreme left and right positions until against the stops recording the highest indicated pressure at each position Compare pressure gauge readings to power steering pump specifications If the highest output pressures are not the same against either stop the steering gear...

Page 949: ...ting procedure to be used for this vehicle 5 Remove both front wheel and tire assemblies from the vehicle 6 Remove nuts attaching both outer tie rod ends to the steering knuckles Fig 7 Nuts are to be removed from tie rod ends using the following procedure hold tie rod end stud with an 11 32 socket while loosening and removing nut with wrench Fig 7 7 Remove both tie rod end studs from the steer ing...

Page 950: ...e front suspension crossmember to the body of the vehicle 8 Using an awl scribe a line on the body Fig 9 and Fig 10 marking the front to back installed location where the front suspension crossmember is mounted against the body of the vehicle The line should be scribed at both the front and back of where the crossmember is mounted to the vehicle and on each side of the vehicle In Fig 9 and Fig 10 ...

Page 951: ...ion crossmember Transmission jack is used to lower support and raise front suspen sion crossmember when removing steering gear assembly 18 From each side of the vehicle remove the 2 bolts attaching the front and rear of the front sus pension crossmember to the frame rails of vehicle Fig 17 19 Using transmission jack lower front suspen sion crossmember enough to allow steering gear to be removed fr...

Page 952: ...r assembly on front suspen sion crossmember Install the 2 long steering gear assembly to front crossmember mounting bolts Fig Fig 15 Rear Support Bracket Attachment To Crossmember REAR SUPPORT BRACKET STABILIZER BAR CROSS MEMBER ATTACHING BOLTS Fig 16 Engine Support Bracket To Transaxle Bracket Bolt TRANSAXLE MOUNTING BRACKET BOLT STEERING GEAR FRONT SUSPENSION CROSSMEMBER ENGINE SUPPORT BRACKET F...

Page 953: ...member attaching bolts and tighten to a torque of 75 N m 55 ft lbs 6 Install bolt Fig 16 attaching engine support bracket to transaxle mounting bracket Tighten bolt to a torque of 75 N m 55 ft lbs 7 Install the 2 bolts attaching the rear support bracket for the under engine support bracket Fig 15 to the rear of the front suspension crossmember Tighten bolts to a torque of 75 N m 55 ft lbs 8 Instal...

Page 954: ...reservoir to correct level with Mopart Power Steering Fluid or equivalent See Checking Fluid Level 23 Lower front wheels of vehicle back on the ground CAUTION During this procedure do not allow the steering gear inner tie rod boots to become twisted See Wheel Alignment in the suspension section of this service manual 24 Check front alignment and adjust the front Toe setting on the vehicle Refer to...

Page 955: ...his group of the service man ual for the required procedure 4 Securely mount the steering gear in a vise or other appropriate holding fixture 5 Loosen the inner to outer tie rod jam nut Fig 27 Remove the outer tie rod from inner tie rod 6 Remove jam nut Fig 27 from inner tie rod 7 Using pliers expand tie rod boot clamp Fig 28 and remove from tie rod boot 8 Remove the tie rod boot to steering gear ...

Page 956: ...ring gear boot to become twisted See Wheel Alignment in the suspension section of this service manual 7 Make toe adjustment by turning inner tie rod 8 Tighten the inner to outer tie rod jam nut to 75 N m 55 ft lbs torque Lubricate tie rod boot groove with silicone type lubricant before installing outer boot clamp making sure boot is not twisted OUTER TIE ROD END DISASSEMBLE 1 Loosen inner tie rod ...

Page 957: ...rvice manual 5 Adjust the front Toe setting on the vehicle Refer to the Toe Setting Procedure in Front Suspen sion Service Procedures in this group of the service manual Refer to the Specifications Section at the end of this group for the desired front Toe specifica tion 6 Tighten tie rod jam nut Fig 31 to 75 N m 55 ft lbs torque 7 Adjust the steering gear to inner tie rod boots at inner tie rod i...

Page 958: ...SPECIAL TOOLS POWER STEERING GEAR Remover Tie Rod End MB 990635 P S System Analyzer 6815 Installer Boot Clamp C 4975A 19 44 STEERING JX ...

Page 959: ...ing column coupler MUST be inspected whenever a vehicle is involved in an impact or when ever any of the following conditions exist 1 The steering column coupler must be inspected whenever a vehicle is involved in a collision which deploys the air bag regardless of the extent of dam age done to the vehicle 2 If a vehicle is involved in an impact of the vehi cles front suspension or under carriage ...

Page 960: ... Safety goggles should be worn at all times when working on steering columns CAUTION Disconnect negative ground cable from the battery before servicing any column com ponent CAUTION Do not attempt to remove the pivot pins to disassemble the tilting mechanism Damage will occur REMOVAL AND INSTALLATION STEERING COLUMN ASSEMBLY WARNING SAFETY GOGGLES SHOULD BE WORN AT ALL TIMES WHEN WORKING ON STEERI...

Page 961: ...el Fig 5 6 Remove the 3 screws attaching the top cover to the dash panel Fig 6 7 Remove the top cover from the dash panel Removal of the top cover is required to gain access to the screws Fig 7 attaching the top of the knee bol ster to the dash panel 8 Remove screws attaching the knee bolster to the instrument panel Fig 7 Fig 2 Remote Ground Cable At Shock Tower SPEED CONTROL SERVO LEFT STRUT TOWE...

Page 962: ...FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOYMENT 11 Remove the 2 bolts 1 on each side of the steering wheel attaching the airbag module to the steering wheel Fig 9 12 Remove the airbag module from the center of the steering wheel 13 Remove the locking tab from clockspring air bag electrical lead connector Fig 10 Locking tab is removed by pulling it straight out of the airbag con necto...

Page 963: ...r hammer on steering wheel or steering column shaft when removing steering wheel from steering column 20 Remove steering wheel assembly from steer ing column shaft using Puller Snap On CJ2001P or an equivalent 21 Remove the 2 screws attaching the upper and lower shrouds to the steering column Fig 15 First remove upper shroud from steering column then release tilt lever and tilt steering column to ...

Page 964: ...d to coupler and is not remov able Then separate steering coupler from steering gear Fig 15 Steering Column Shroud Attaching Screws CLOCKSPRING ATTACHINGSCREWSSTEERING COLUMN SHROUDS TILT LEVER Fig 16 Wiring Harness Connection To Clock Spring And Halo Light CLOCKSPRING HALO LIGHT WIRING HARNESS CONNEC TOR WIRING HARNESS CON NECTORS Fig 17 Wiring Harness Connections To Ignition And Multi Function S...

Page 965: ...umn in place Be sure both breakaway capsules are still fully seated in the slots of the upper steering column mounting bracket and the mounting studs are cen tered for and aft in the plastic capsules Fig 23 Then equally tighten both steering column upper mounting nuts Fig 22 until upper steering column mounting bracket is seated against support bracket Tighten the 4 steering column bracket to supp...

Page 966: ...eel on shaft of steering column assembly making sure to fit flats on hub of steering wheel with formations on inside of clockspring 12 Install steering wheel to steering column shaft retaining nut and tighten until steering wheel is fully installed on shaft Tighten steering wheel retaining nut to a torque of 61 N m 45 ft lbs 13 Turn the key cylinder to the unlock position unlocking the steering co...

Page 967: ... lamp fails to light blinks on and off or goes on and stays on there is an airbag system malfunction Refer to the Passive Restraint Diagnostic Test Manual to diag nose the system malfunction 26 Test the operation of the horn lights and any other functions that are steering column operated If applicable reset the radio and the clock 27 Road test vehicle to ensure proper operation of the steering sy...

Page 968: ... roll pin into the coupler until spring pin is fully installed through both sides of the coupler assembly SPECIFICATIONS STEERING COLUMN FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE STEERING WHEEL Retaining Nut 61 N m 45 ft lbs STEERING COLUMN ASSEMBLY Mounting Bracket Attaching Nuts 12 N m 105 in lbs Flex Coupler Pinch Bolt 27 N m 240 in lbs Airbag Module Attaching Nuts 10 N m 90 in lbs SPEC...

Page 969: ... 14 INTERLOCK MECHANISM 17 MANUAL VALVE LEVER SHIFT LEVER 17 OIL PUMP SEAL 25 SHIFTER IGNITION INTERLOCK CABLE 14 SOLENOID ASSEMBLY REPLACE 17 SPEED SENSOR INPUT 19 SPEED SENSOR OUTPUT 19 TRANSAXLE 21 TRANSMISSION CONTROL MODULE 19 TRANSMISSION RANGE SENSOR 18 VALVE BODY 20 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL REPAIR 57 INPUT CLUTCHES RECONDITION 46 TRANSAXLE RECONDITION 28 VALVE BODY RECONDITION...

Page 970: ...id should be at normal operating temperature approximately 82 C or 180 F The fluid level is correct if it is in the HOT region cross hatched area on the oil level indi cator Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and build up slowly ...

Page 971: ...operate the valves directly without any intermediate element Direct operation means that these units must have very high output They must close against the size able flow areas and high line pressures Fast response is also required to meet the control require ments Two of the solenoids are normally venting and two are normally applying this was done to provide a default mode of operation With no e...

Page 972: ...m called OBDII The powertrain control module communicates with the Transmission Control Module Whenever the transaxle sets a fault in the Transmission Con trol Module dependent on which fault is set the powertrain control module will turn on a MIL Mal function Indicator Lamp on the instrument cluster By reading the code in the powertrain control module it will tell you where the fault occurred If ...

Page 973: ...d or 3rd gear while in the Autostick mode The speed control is operable in 3rd and 4th gear Auto stick mode Speed control will be deactivated if the transaxle is shifted to 2nd gear Shifting into OD position cancels the Autostick mode and the tran saxle resumes the OD shift schedule AUTOMATIC OVERRIDES For safety durability and driveability some shifts are executed automatically or prevented SHIFT...

Page 974: ...e tests be certain that fluid level and condition and shift cable adjustments have been checked and approved Fluid must be at operating temperature 150 to 200 degrees F Install an engine tachometer raise vehicle on hoist which allows front wheels to turn and position tachometer so it can be read Attach 150 psi gauges to ports required for test being conducted A 300 psi gauge C 3293 is required for...

Page 975: ... Torque converter clutch off pressure should be less than 5 psi 5 This test checks the torque converter clutch hydraulic circuit TEST SIX SELECTOR IN REVERSE 1 Attach gauge to the reverse and LR clutch tap 2 Move selector lever to the reverse position 3 Read reverse clutch pressure with output sta tionary foot on brake and throttle opened to achieve 1500 rpm Shift Lever Position Start Safety Park ...

Page 976: ...W REVERSE CLUTCH Apply air pressure to the low reverse clutch feed hole rear of case between 2 bolt holes Then look in the area where the low reverse piston contacts the first separator plate Watch carefully for the piston to move forward The piston should return to its origi nal position after the air pressure is removed UNDERDRIVE CLUTCH Because this clutch piston cannot be seen its oper ation i...

Page 977: ...d not be possible when the igni tion switch is in the LOCK or ACCESSORY position 3 If the Interlock System operates in any way other than as described above repair of the Interlock System is required See Adjustment and Repair pro cedures in this section for the required procedures SHIFT POSITION INDICATOR The transmission range sensor on the valve body sends a signal to the TCM on the position of ...

Page 978: ...76 should be used A filter change should be made at the time of the oil change Also the magnet on the inside of the oil pan should be cleaned with a clean dry cloth If the transaxle is disassembled for any reason the fluid and filter should be changed FLUID DRAIN REFILL AND LEVEL CHECK DRAIN AND REFILL 1 Raise vehicle on a hoist See Group 0 Lubrica tion Place a drain container with a large opening...

Page 979: ...ontaminated the fluid the oil cooler s must be flushed The cooler bypass valve in the transaxle must be replaced also The torque converter must also be replaced with an exchange unit This will insure that metal particles or sludged oil are not later transferred back into the reconditioned or replaced transaxle There are two different procedures for flushing coolers and lines The recommended proced...

Page 980: ...ion line into a one quart container of Mopart type 7176 automatic transmis sion fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from cooler...

Page 981: ...ed sensor The TCM must be calibrated to the different combinations of equip ment available A procedure has been developed called Pinion Factor It allows the technician to set the Transmission Control Module initial setting so that the speedometer readings will be correct Failure to perform this procedure will cause a No Speedometer Operation condition This procedure must be performed if the Transm...

Page 982: ...n 5 Pry the cable retaining clip up and off of the gearshift mechanism Remove the gearshift cable from the gearshift mechanism 6 Pry up the adjuster lock on the shifter ignition interlock cable Unsnap the shifter ignition interlock cable end fitting from the groove in the gearshift mechanism Remove the cable core end from the plastic cam of the shifter mechanism 7 Remove the nuts at the base of th...

Page 983: ...lever down and slide lower shroud forward to remove it from column Fig 18 15 Tilt wheel to full down position and remove upper steering column shroud 16 Verify vehicle ignition is on Grasp the inter lock cable clip and connector Remove the cable from the interlock housing Fig 19 17 Unclip the cable retaining clip located along the cable housing Fig 12 Instrument Panel Top Cover Left Side FUSE PANE...

Page 984: ...em See Interlock System Adjustment in this section of service manual 8 Perform the Shifter Ignition Interlock System operation check as described in the beginning of this section 9 Install console assembly Refer to Group 23 Body 10 Install the gearshift knob set screw and knob 11 Tilt wheel to full down position and install upper steering column shroud 12 Hold tilt wheel lever down and slide lower...

Page 985: ...terlock mechanism to steering column attaching screws Torque screws to 3 N m 21 in lbs 2 Snap the interlock cable into the housing 3 Install the lower column covers shrouds and knee bolster Refer to Interlock Cable Replacement MANUAL VALVE LEVER SHIFT LEVER REMOVAL 1 Remove shift cable from lever 2 Loosen the lever mounting bolt Do not remove bolt not necessary 3 Pull up on lever and remove INSTAL...

Page 986: ...rom guide bracket and remove valve body from transaxle 11 Place valve body on workbench Fig 27 12 Remove TRS retaining screw Fig 28 13 Remove manual shaft seal Fig 29 14 Slide Transmission Range Sensor up the man ual shaft and remove Fig 30 Fig 25 Attaching Screws SOCKET WRENCH SOLENOID ASSEMBLY SOUND COVER ATTACHING PLATE ATTACHING SCREWS 8 WAY CON NECTOR Fig 26 Solenoid Assembly SOLENOID ASSEMBL...

Page 987: ...mission control module is next to the bat tery on the left side of vehicle in the engine compart ment It is held in place by three mounting screws NOTE If the transmission control module has been replaced the following procedures must be per formed Quick Learn Procedure This procedure will allow the transmission control module to learn the characteristics of the vehicle Electronic Pinion Factor Pr...

Page 988: ...re CAUTION The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped When installing valve body assembly onto tran saxle observe Fig 38 Guide park rod rollers into Fig 33 Transmission Control Module Fig 34 Oil Pan Bolts OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 35 Oil Pan Fig 36 Oil Filter O RING OIL FIL TER Fig 37 Valve Body Attaching Bolt...

Page 989: ...ht of the transaxle should be allowed to rest on the drive plate during removal 1 Disconnect battery negative cable at left strut tower Fig 41 2 Remove air cleaner duct 3 Remove transmission control module TCM and wiring Fig 42 Fig 38 Push Park Rod Rollers from Guide Bracket PARK SPRAG GUIDE BRACKET PARK SPRAG ROLLERS SCREWDRIVER Fig 39 Remove Valve Body VALVE BODY Fig 40 Valve Body Removed VALVE ...

Page 990: ...right side lower splash shields Fig 49 CAUTION The exhaust flex joint must be discon nected from the exhaust manifold anytime the engine is lowered If the engine is lowered while the flex pipe is attached damage will occur 12 Remove bolts securing exhaust flex joint to exhaust manifold Disconnect exhaust pipe from manifold Fig 43 Solenoid Pack Connector SOLENOID PACK CON NECTOR Fig 44 Transaxle Co...

Page 991: ...e engine clockwise to line up converter bolts Fig 52 Remove converter bolts Fig 53 Mark converter for reassembly ease 24 Remove crank position sensor if equipped 25 Remove transaxle wiring 26 Loosen right side steering gear bolts Loosen right side K frame bolts 27 Remove left side steering gear bolts Remove left side K frame bolts Fig 54 28 Remove sway bar mounts Fig 55 29 Position transmission ja...

Page 992: ...rocedure may cause transaxle shutter 2 Check and or adjust gear shift cable 3 Refill transaxle with MOPARt ATF PLUS Automatic Transmission Fluid Type 7176 Fig 52 Rotate Engine Clockwise TURN CLOCKWISE LOWER ENGINE PULLEY Fig 53 Converter Bolts DRIVE PLATE DRIVE PLATE BOLT Fig 54 Steering Gear and K frame Bolts K FRAME MOUNT STEERING RACK MOUNT Fig 55 Sway Bar Mounts SWAY BAR MOUNT Fig 56 Transmiss...

Page 993: ...B OIL PUMP SEAL Fig 58 Install Oil Pump Seal TOOL C 4193 HANDLE TOOL C 4171 Fig 59 Transmission Range Sensor Screw Fig 60 Transmission Range Sensor Removed Fig 61 Manual Shaft and Rooster Comb MANUAL SHAFT VALVE BODY TRANSMISSION RANGE SENSOR RETAINING SCREW ROOSTER COMB JX TRANSAXLE 21 25 REMOVAL AND INSTALLATION Continued ...

Page 994: ... PLATE ROOSTER COMB Fig 64 Valve Body Screws VALVE BODY SCREWS VALVE BODY SCREWS VALVE BODY SCREWS VALVE BODY SCREWS Fig 65 Valve Body and Transfer Plate OVERDRIVE CLUTCH 5 BALL CHECK SEPARATOR PLATE TRANSFER PLATE VALVE BODY Fig 66 Transfer Plate and Separator Plate OVERDRIVE CLUTCH 5 BALL CHECK THERMAL VALVE SEPARATOR PLATE FILTER TRANSFER PLATE 21 26 TRANSAXLE JX DISASSEMBLY AND ASSEMBLY Contin...

Page 995: ...SE SWITCH VALVE T C LIMIT VALVE Fig 68 Springs and Valves Location 2 4 ACCUMULATOR REGULATOR VALVE SOLENOID SWITCH VALVE MANUAL VALVE TORQUE CONVERTER CON TROL VALVE TORQUE CONVERTER CLUTCH VALVE Fig 69 Remove or Install Dual Retainer Plate SPECIAL TOOL 6301 JX TRANSAXLE 21 27 DISASSEMBLY AND ASSEMBLY Continued ...

Page 996: ...nge is required The 4 thrust plate is located behind the overdrive clutch hub Fig 70 Remove or Install Retainer Plate REGULATOR VALVE SPRING RETAINER VALVE BODY TOOL 6302 REGULATOR VALVE SPRING Fig 71 Oil Pan Bolts OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 72 Oil Pan OIL PAN 1 8 INCH BEAD OF RTV SEALANT OIL FILTER Fig 73 Oil Filter O RING OIL FIL TER Fig 74 Valve Body Attaching Bolts VALVE BODY V...

Page 997: ...DY TRANSMISSION RANGE SENSOR Fig 78 Accumulators UNDERDRIVE CLUTCH ACCUMU LATOR RETURNSPRING SEAL RING 2 OVERDRIVE CLUTCH ACCUMU LATOR Fig 79 Accumulator Underdrive ACCUMULATOR PISTON UNDERDRIVE RETURN SPRINGS SEAL RING SEAL RING Fig 80 Accumulator Overdrive ACCUMULATOR PISTON OVERDRIVE RETURN SPRING SEAL RING SEAL RING JX TRANSAXLE 21 29 DISASSEMBLY AND ASSEMBLY Continued ...

Page 998: ...nch Fig 81 Low Reverse Accumulator Snap Ring SNAP RING PLUG Fig 82 Low Reverse Accumulator Plug Cover ADJUSTABLE PLIERS PLUG Fig 83 Low Reverse Accumulator Piston SUITABLE TOOL SEAL RINGS PETROLATUM PISTON PISTON Fig 84 Low Reverse Accumulator ACCUMULATOR PIS TON NOTE NOTCH RETURN SPRINGS SEAL RINGS Fig 85 Measure Input Shaft End Play DIAL INDICATOR INPUT SHAFT 21 30 TRANSAXLE JX DISASSEMBLY AND A...

Page 999: ... Pump Attaching Bolts PUMP HOUS ING PUMP ATTACHING BOLTS Fig 87 Install Tool C 3752 PULLERS TOOL C 3752 PUMP Fig 88 Remove Oil Pump PUSH IN ON INPUT SHAFT WHILE REMOVING PUMP Fig 89 Oil Pump Removed OIL PUMP GASKET Fig 90 Oil Pump Gasket PUMP GAS KET Fig 91 Remove Bypass Valve COOLER BYPASS VALVE JX TRANSAXLE 21 31 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1000: ...mbly INPUT CLUTCHES ASSEMBLY 4 THRUST WASHER Fig 94 Front Sun Gear Assembly FRONT SUN GEAR ASSEMBLY 4 THRUST WASHER Fig 95 Front Carrier and Rear Annulus Assembly 6 NEEDLE BEAR ING FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO REMOVE OR INSTALL Fig 96 Rear Sun Gear 7 NEEDLE BEARING REAR SUN GEAR Fig 97 2 4 Clutch Retainer Snap Ring COMPRESS JUST ENOUGH TO REMOVE OR INSTALL SNAP...

Page 1001: ...ING Fig 100 2 4 Clutch Return Spring 24 CLUTCH RETURNSPRING Fig 101 2 4 Retainer and Spring Indexed NOTE POSITION RETURN SPRING 24 CLUTCH RETAINER Fig 102 2 4 Clutch Pack CLUTCH PLATE 4 CLUTCH DISC 4 CAUTION TAG AND IDENTIFY CLUTCH PACKS TO ASSURE ORIGINAL PLACEMENT JX TRANSAXLE 21 33 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1002: ...P RING FLAT SNAP RING END BETWEEN 2 00 3 00 LOW REVERSE REACTION PLATE START HERE TO PRESS INTO GROOVE INSTALLATION SEQUENCE A THRU H DO NOT REUSE SNAP RING TRANSAXLE CASE OIL PAN FACE Fig 105 Snap Ring Installed Fig 106 Low Reverse Reaction Plate LOW REVERSE REACTION PLATE FLAT SIDE UP Fig 107 Remove One Disc ONE DISC FROM LOW REVERSE CLUCTH 21 34 TRANSAXLE JX DISASSEMBLY AND ASSEMBLY Continued ...

Page 1003: ...LUTCH DISCS 5 CAUTION TAG AND IDEN TIFY PACKS TO ASSURE ORIGINAL PLACEMENT Fig 110 Rear Cover Bolts REAR COVER BOLTS REAR COVER Fig 111 Rear Cover REAR COVER 1 8 INCH BEAD OF MOPAR SILI CONE RUBBER ADHESIVE SEAL ANT AS SHOWN Fig 112 Remove Transfer Shaft Gear Nut TRANSFER SHAFT GEAR OUTPUT GEAR SPECIAL TOOL 6259 Fig 113 Transfer Shaft Gear Nut and Washer TRANSFER SHAFT LOCK WASHER NUT JX TRANSAXLE...

Page 1004: ... Ft lbs TRANSFER SHAFT GEAR 200 FT LBS TORQUE WRENCH SPECIAL TOOL 6259 Fig 117 Transfer Shaft Gear and Select Shim TRANSFER SHAFT GEAR BEARING CUP RETAINER SHIM SELECT Fig 118 Bearing Cup Retainer ALIGN INDEXING TAB TO SLOT BEARING CUP RETAINER Fig 119 Remove Transfer Shaft Bearing Cone WRENCHES TOOL 5048 WITH JAWS TOOL 5048 4 AND BUTTON TOOL L 4539 2 TRANSFER SHAFT GEAR 21 36 TRANSAXLE JX DISASSE...

Page 1005: ...OR PRESS RAM HANDLE C 4171 TOOL 6061 TRANSFER SHAFT BEARING CUP RETAINER USE REMOVED BEARING CUP TO SUPPORT RETAINER Fig 123 Transfer Shaft Bearing Snap Ring SNAP RING PLIERS TOOL 6051 TRANSFER SHAFT BEARING SNAP RING TRANSFER SHAFT Fig 124 Transfer Shaft SPECIAL TOOL 5049 A TRANSFER SHAFT OUTPUT GEAR Fig 125 Remove Transfer Shaft Bearing Cone ARBOR PRESS RAM TRANSFER SHAFT TOOL P 334 BEARING CONE...

Page 1006: ...one ARBOR PRESS RAM TOOL 6052 NEW BEARING CONE TRANSFER SHAFT Fig 127 Bearing Cup Removed BEARING CUP BEARING CONE O RING TRANSFER SHAFT OIL BAF FLE Fig 128 Remove Output Gear Bolt OUTPUT GEAR TOOL 6259 Fig 129 Output Gear Retaining Bolt Stirrup Serration Side Out OUTPUT GEAR RETAINING BOLT STIRRUP Fig 130 Stirrup Strap Align Strap Holes With Tapped Gear Holes OUTPUT GEAR BOLT RETAINING STRAP STIR...

Page 1007: ...RAP STIRRUP Fig 134 Bend Tabs On Strap Up Against Flats Of Bolts RETAINING STRAP TABS RETAINING STRAP STIRRUP Fig 135 Output Gear Bolt and Washer CONED LOCK WASHER OUTPUT GEAR BOLT Fig 136 Remove Output Gear OUTPUT GEAR BUTTON TOOL 6055 WRENCHES BOLTS TOOL L 4407 6 TOOL L 4407 Fig 137 Install Output Gear WRENCHES TOOL 6261 WITH STUD OUTPUT GEAR JX TRANSAXLE 21 39 DISASSEMBLY AND ASSEMBLY Continued...

Page 1008: ...ng Cone TOOL 5048 WITH JAWS 5048 5 AND BUTTON L 4539 2 OUTPUT GEAR WRENCHES Fig 141 Install New Bearing Cone Fig 142 Rear Carrier Assembly Fig 143 Remove Rear Carrier Bearing Cone TOOL 5048 WITH JAWS 5048 3 AND BUTTON 6055 REAR CAR RIER ASSEMBLY WRENCHES 21 40 TRANSAXLE JX DISASSEMBLY AND ASSEMBLY Continued ...

Page 1009: ...RN SPRING SNAP RING INSTALL AS SHOWN TOOL 5058 3 TOOL 5059 TOOL 6057 Fig 147 Remove or Install Snap Ring SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN SNAP RING PLIERS TOOL 6057 Fig 148 Low Reverse Piston Return Spring LOW REVERSE PISTON RETURN SPRING PISTON Fig 149 Drive Out Anchor Shaft HAMMER ANTIRATCHET SPRING DRIFT PARK SPRAG GUIDE BRACKET ANCHOR SHAFT GUIDE BRACKET JX TRANSAXLE 21...

Page 1010: ...OT SHAFT PLIERS Fig 152 Pivot Shaft and Guide Bracket ANTIRATCHET SPRING GUIDE BRACKET PAWL PIVOT SHAFT Fig 153 Guide Bracket Assembled PAWL GUIDE BRACKET ANTIRATCHET SPRING MUST BE ASSEMBLED AS SHOWN Fig 154 Guide Bracket Disassembled GUIDE BRACKET PAWL SPLIT SLEEVE ANTIRATCHET SPRING STEPPED SPACER SPACER Fig 155 Low Reverse Clutch Piston LOW REVERSE CLUTCH PISTON LIP SEAL LIP SEAL 21 42 TRANSAX...

Page 1011: ...TON RETAINER GASKET Fig 158 Piston Retainer Gasket GASKET HOLES MUST LINE UP LOW REVERSE CLUTCH PIS TON RETAINER GASKET Fig 159 Remove Output Bearing Inner Cup OUTPUT BEARING CUPS REPLACE IN PAIRS HAMMER STEELDRIFT Fig 160 Remove Output Bearing Outer Cup TOOL 6062 Fig 161 Install Both Output Bearing Cups OUTPUT BEARING CUPS WRENCHES TOOL 5050 JX TRANSAXLE 21 43 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1012: ...ck clearance is 0 76 to 2 64mm 030 to 104 inch If not within specifica tions the clutch is not assembled properly There is no adjustment for the 2 4 clutch clearance Fig 162 Checking Output Gear Bearings End Play TOOL L 4432 DIAL INDICATOR OUTPUT GEAR SPECIAL SCREWS TOOL 6260 Fig 163 Checking Output Gear Bearings Turning Torque INCH POUND TORQUE WRENCH OUTPUT GEAR Fig 164 Check Low Reverse Clutch ...

Page 1013: ...UTION Be sure to reinstall O ring on oil pump after selecting the proper No 4 thrust plate NOTE Input shaft end play must be 005 to 025 inch For example if end play reading is 055 inch select No 4 Thrust Plate which is 071 to 074 thick This should provide an input shaft end play reading of yes Fig 166 Select Thinnest No 4 Thrust Plate OVERDRIVE SHAFT ASSEM BLY THINNEST 4 THRUST PLATE SELECT 3 DABS...

Page 1014: ...R REVERSE CLUTCH SNAP RING SELECT Fig 172 Pry Reverse Clutch Reaction Plate REVERSE CLUTCH REACTION PLATE SCREW DRIVER SCREW DRIVER Fig 173 Reverse Clutch Reaction Plate REVERSE CLUTCH REACTION PLATE INSTALL FLAT SIDE DOWN Fig 174 Reverse Clutch Pack REVERSE CLUTCH PLATE REVERSE CLUTCH DISC CAUTION TAG AND IDENTIFY CLUTCH PACKS TO ASSURE ORIGINAL PLACE MENT 21 46 TRANSAXLE JX DISASSEMBLY AND ASSEM...

Page 1015: ...nap Ring OD REVERSE CLUTCH WAVED SNAP RING SCREWDRIVER OVERDRIVE SHAFT ASSEM BLY Fig 178 Remove OD Clutch Pack OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK 3 THRUST PLATE 3 THRUST WASHER UNDERDRIVE SHAFT ASSEMBLY Fig 179 Overdrive Clutch Pack OVERDRIVE CLUTCH PLATE CAUTION TAG AND IDEN TIFY CLUTCH PACKS TO ASSURE ORIGINAL PLACE MENT OVERDRIVE SHAFT ASSEM BLY OVERDRIVE CLUTCH DISC Fig 180 Overdrive ...

Page 1016: ...HAFT ASSEMBLY Fig 182 No 2 Needle Bearing 2 NEEDLE BEARING NOTE 3 TABS Fig 183 OD UD Reaction Plate Tapered Snap Ring OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING SCREWDRIVER DO NOT SCRATCH REAC TION PLATE CAUTION DO NOT REUSE TAPERED SNAP RING Fig 184 OD UD Reaction Plate Fig 185 Remove One UD Clutch Disc Fig 186 UD Clutch Flat Snap Ring UNDERDRIVE CLUTCH REACTION PLATE FLAT SNA...

Page 1017: ...DISC CAUTION TAG AND IDENTIFY CLUTCH PACKS TO ASSURE ORIGINAL REPLACEMENT Fig 188 UD Spring Retainer Snap Ring Fig 189 UD Return Spring and Retainer UNDERDRIVE SPRING RETAINER SNAP RING LIP SEAL PISTON RETURN SPRING Fig 190 Underdrive Clutch Piston Fig 191 Input Hub Tapered Snap Ring Fig 192 Tap on Input Hub INPUT SHAFT AND HUB ASSEMBLY PLASTIC HAMMER JX TRANSAXLE 21 49 DISASSEMBLY AND ASSEMBLY Co...

Page 1018: ...ING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING SCREW DRIVER SNAP RING RETURNSPRING SPECIAL TOOL 6057 OD RE VERSE PISTON Fig 196 Snap Ring and Return Spring OD REVERSE PIS TON RETURNSPRING SNAP RING O RING Fig 197 Remove Input Shaft Snap Ring INPUT SHAFT SHARP POINTED TOOL LIP SEALS SNAP RING O RINGS Fig 198 Remove Input Shaft ARBOR PRESS RAM SOCKET INPUT SHAFT LIP SEAL LIP SEAL O RINGS INPUT SHAFT...

Page 1019: ...ER DO NOT SCRATCH BEARING SURFACE SNAP RING LIP SEALS O RINGS Fig 201 Return Spring and Snap Ring OD REVERSE PIS TON RETURNSPRING SNAP RING O RING Fig 202 Install Snap Ring ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING SCREW DRIVER SNAP RING RETURNSPRING SPECIAL TOOL 6057 OD RE VERSE PISTON Fig 203 Install OD Reverse Piston PUSH DOWN TO INSTALL OVERDRIVE RE VERS...

Page 1020: ...ING SPECIAL TOOL 5067 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY Fig 208 UD Return Spring and Retainer UNDERDRIVE SPRING RETAINER SNAP RING LIP SEAL PISTON RETURN SPRING Fig 209 Install UD Spring Retainer and Snap Ring ARBOR PRESS RAM SNAP RING PLI ERS SNAP RING OD REVERSE PIS TON TOOL 5067 TOOL 5059A Fig 210 Underdrive Clutch Pack CLUTCHPLATE ONE UD CLUTCH DISC CLUTCH DISC CAUTION TAG AND IDENTIFY CL...

Page 1021: ...TE STEP SIDE DOWN Fig 214 Tapered Snap Ring OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING SCREWDRIVER DO NOT SCRATCH REAC TION PLATE CAUTION DO NOT REUSE TAPERED SNAP RING Fig 215 Seating Tapered Snap Ring OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING SCREW DRIVER USE CAUTION DO NOT SCRATCH REACTION PLATE Fig 216 Set Up Dial Indicator for Clutch Clearance SELECT R...

Page 1022: ...One Clutch Disc HOOK TOOL UNDERDRIVE REACTION PLATE CHART Fig 218 Install OD Clutch Pack OVERDRIVE CLUTCH PACK Fig 219 Install Waved Snap Ring OVERDRIVE REACTION PLATE WAVED SNAP RING SCREWDRIVER Fig 220 OD Reverse Pressure Plate OVERDRIVE REVERSE PRESSURE PLATE STEP SIDE DOWN Fig 221 Pressure Plate Installed 21 54 TRANSAXLE JX DISASSEMBLY AND ASSEMBLY Continued ...

Page 1023: ...arance HOOK TOOL OVERDRIVE REVERSE PRESSURE PLATE DIAL INDICA TOR KIT C 3339 Fig 224 Install Reverse Clutch Pack REVERSE CLUTCH PLATE REVERSE CLUTCH DISCS Fig 225 Install Reaction Plate REVERSE CLUTCH REAC TION PLATE FLAT SIDE DOWN Fig 226 Install Reverse Clutch Snap Ring REVERSE CLUTCH SNAP RING SELECT SCREW DRIVER REVERSE CLUTCH REAC TION PLATE Fig 227 Seating Snap Ring to Determine Reverse Clut...

Page 1024: ...rder Now proceed with the next phase of the assembly Fig 228 Check Reverse Clutch Pack Clearance COMPRESS CLUTCH PACK WITH FINGER TO ZERO INDICATOR HOOK TOOL REVERSE CLUTCH SNAP RING CHART Fig 229 Install No 2 Needle Bearing 2 NEEDLE BEARING NOTE 3 SMALL TABS TABS UP Fig 230 Install Underdrive Shaft Assembly UNDERDRIVE SHAFT ASSEMBLY 2 NEEDLE BEARING Fig 231 Install No 3 Thrust Washer 3 THRUST WAS...

Page 1025: ...erdrive Shaft Assembly OVERDRIVE SHAFT ASSEMBLY 3 THRUST PLATE 3 THRUST WASHER Fig 234 Input Clutch Assembly OVERDRIVE SHAFT ASSEMBLY Fig 235 Differential Cover Bolts DIFFERENTIAL COVER DIFFERENTIAL COVER BOLTS Fig 236 Remove or Install Differential Cover DIFFERENTIAL ASSEMBLY 1 8 INCH BEAD OF MOPAR SILICONE RUBBER ADHE SIVE SEALANT DIFFERENTIAL COVER Fig 237 Differential Retainer Bolts DIFFERENTI...

Page 1026: ...ig 240 Position Bearing Cone Onto Differential DIFFERENTIAL ASSEMBLY DIFFERENTIAL BEARING Fig 241 Install Differential Bearing Cone SPECIAL TOOL C 4171 SPECIAL TOOL 6536 DIFFERENTIAL ASSEMBLY Fig 242 Position Button and Collets Onto Differential and Bearing Ring Gear Side SPECIAL TOOL L 4539 2 SPECIAL TOOL 5048 SPECIAL TOOL 5048 4 Fig 243 Position Tool 5048 Over Button and Collets at Differential ...

Page 1027: ...AL TOOL C 4996 NOTE POSI TION DIAL INDICATOR SET DIFFERENTIAL ASSEMBLY SIDE GEAR MOVE SIDE GEAR UP AND DOWN Fig 246 Checking Side Gear End Play Typical SPECIAL TOOL C 4996 NOTE POSITION DIAL INDICATOR SET DIFFERENTIAL ASSEMBLY MOVE SIDE GEAR UP AND DOWN Fig 247 Differential Bearing Retainer DIFFERENTIAL BEARING CUP DIFFERENTIAL BEARING RETAINER Fig 248 Position Bearing Cup Remover Tool in Retainer...

Page 1028: ...toward the N Neutral position until lever is in the N position If the starter will also operate at this point the gearshift linkage is properly adjusted If the starter fails to operate in either position link age adjustment is required ADJUSTMENT 1 Set parking brake 2 Remove the gearshift knob set screw and knob 3 Remove gearshift selector bezel and lamp wir ing 4 Install the gearshift knob set sc...

Page 1029: ...e run position Move the shifter to the reverse position You should not be able to remove the ignition key from the lock cylinder If the key can be removed at this point re adjust the inter lock and tighten the adjustment nut Place the shifter in the PARK position Turn the ignition key to the OFF lock position You should be able to remove the ignition key from the lock cylin der If not re adjust th...

Page 1030: ... 04 mm 0016 inch thicker shim If the turning torque is too low install a 04 mm 0016 inch thinner shim Repeat until the proper turning torque is 3 to 8 inch pounds DIFFERENTIAL BEARING 1 Position the transaxle assembly vertically on the support stand differential bearing retainer side up 2 Install Tool L 4436A into the differential and onto the pinion mate shaft 3 Rotate the differential at least o...

Page 1031: ...ng shim and cup f Install the differential bearing retainer using Tool 5052 and C 4171 Seal the retainer to the housing with MOPARt Adhesive Sealant and torque bolts to 28 N m 250 in lbs 7 Using Tool L 4436A and an inch pound torque wrench recheck the turning torque of the differen tial The turning torque should be between 5 and 18 inch pounds DIFFERENTIAL BEARING SHIM CHART HIM THICKNESS MM INCH ...

Page 1032: ...59 to remove the retaining nut and washer Remove the transfer shaft gear using Tool L 4407 7 Remove the gauging shim and install the cor rect shim Install the transfer gear and bearing assembly CAUTION Original retaining nut may not be reused Always use a new retaining nut when reas sembling 8 Install the new retaining nut and washer and torque to 271 N m 200 ft lbs Measure transfer shaft end play...

Page 1033: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC JX TRANSAXLE 21 65 SCHEMATICS AND DIAGRAMS Continued ...

Page 1034: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 66 TRANSAXLE JX SCHEMATICS AND DIAGRAMS Continued ...

Page 1035: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC JX TRANSAXLE 21 67 SCHEMATICS AND DIAGRAMS Continued ...

Page 1036: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 68 TRANSAXLE JX SCHEMATICS AND DIAGRAMS Continued ...

Page 1037: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC JX TRANSAXLE 21 69 SCHEMATICS AND DIAGRAMS Continued ...

Page 1038: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 70 TRANSAXLE JX SCHEMATICS AND DIAGRAMS Continued ...

Page 1039: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC JX TRANSAXLE 21 71 SCHEMATICS AND DIAGRAMS Continued ...

Page 1040: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 72 TRANSAXLE JX SCHEMATICS AND DIAGRAMS Continued ...

Page 1041: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC JX TRANSAXLE 21 73 SCHEMATICS AND DIAGRAMS Continued ...

Page 1042: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 74 TRANSAXLE JX SCHEMATICS AND DIAGRAMS Continued ...

Page 1043: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC JX TRANSAXLE 21 75 SCHEMATICS AND DIAGRAMS Continued ...

Page 1044: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 76 TRANSAXLE JX SCHEMATICS AND DIAGRAMS Continued ...

Page 1045: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC JX TRANSAXLE 21 77 SCHEMATICS AND DIAGRAMS Continued ...

Page 1046: ...57 Direct 1 00 Overdrive 0 69 Reverse 2 21 Final Drive Ratio 2 5 3 91 FDR 2 4 3 91 FDR Pump Clearances Millimeter Inch Outer Gear to Pocket 045 141 0018 0056 Outer Gear Side Clearance 020 046 0008 0018 Inner Gear Side Clearance 020 046 0008 0018 Tapered Roller Bearing Settings Millimeter Inch Output Gear 02 05 Preload 0008 002 Preload Transfer Shaft 05 10 End Play 002 004 End Play Differential 15 ...

Page 1047: ...m 165 in lbs Output Gear Bolt 271 N m 200 ft lbs Output Gear Stirrup Ret 23 N m 17 ft lbs Output Speed Sensor 27 N m 20 ft lbs Pressure Taps 5 N m 45 in lbs Pump To Case Bolts 22 N m 16 ft lbs Reaction Shaft Bolts 22 N m 16 ft lbs Rear End Cover 19 N m 14 ft lbs Sixty Way Connector 4 N m 35 in lbs Solenoid Assembly To Case 12 N m 105 in lbs Transmission Range Sensor 5 N m 45 in lbs Transfer Gear N...

Page 1048: ...uge Low C 3292 Pressure Gauge High C 3293SP Dial Indicator C 3339 Sleeve C 3717 Oil Pump Puller C 3752 Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A 21 80 TRANSAXLE JX SPECIAL TOOLS Continued ...

Page 1049: ...ler C 4628 Adapter C 4996 Remover Kit L 4406 Gear Puller L 4407A Bearing Installer L 4410 Gear Checking Plate L 4432 Bearing Puller L 4435 Differential Tool L 4436A JX TRANSAXLE 21 81 SPECIAL TOOLS Continued ...

Page 1050: ...Special Jaw Set L 4518 Installer L 4520 Adapter MD 998343 Bearing Splitter P 334 Puller Set 5048 Remover Installer 5049 A Installer 5050A Installer 5052 21 82 TRANSAXLE JX SPECIAL TOOLS Continued ...

Page 1051: ...Compressor 5058A Compressor 5059 A Installer 5067 Pliers 6051 Installer 6052 Installer 6053 Button 6055 Plate 6056 JX TRANSAXLE 21 83 SPECIAL TOOLS Continued ...

Page 1052: ...Disk 6057 Installer 6061 Bearing Cup Remover 6062 A Holder 6259 Bolt 6260 Installer 6261 Tip 6268 Remover Installer 6301 21 84 TRANSAXLE JX SPECIAL TOOLS Continued ...

Page 1053: ...Remover Installer 6302 Installer 6342 Installer 6536 A Remover 6787 Cooling System Tester 7700 Seal Remover 7794 a JX TRANSAXLE 21 85 SPECIAL TOOLS Continued ...

Page 1054: ......

Page 1055: ...horten the life of any tire are Rapid acceleration Severe application of brakes High speed driving Taking turns at excessive speeds Striking curbs and other obstacles Radial ply tires are more prone to irregular tread wear It is important to follow the tire rotation inter val shown in the section on Tire Rotation This will help to achieve a greater tread life potential TIRE IDENTIFICATION Tire typ...

Page 1056: ...t provided with the vehicle SPARE TIRE TEMPORARY The temporary spare tire is designed for emer gency use only The original tire should be repaired and reinstalled at the first opportunity or a new tire purchased Do not exceed speeds of 50 MPH Refer to Owner s Manual for complete details TIRE INFLATION PRESSURES WARNING OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING THE TIRE CAN FAIL SUDD...

Page 1057: ... 120 km h For emergency vehicles that are driven at speeds over 90 mph 144 km h special high speed tires must be used Consult tire manufacturer for correct inflation pressure recommendations REPLACEMENT TIRES The original equipment tires provide a proper bal ance of many characteristics such as Ride Noise Handling Durability Tread life Traction Rolling resistance Speed capability It is recommend t...

Page 1058: ...hile tire noise will usually remain constant LEAD CORRECTION CHART Use the following chart to correct a vehicle leading or drifting problem Fig 5 Tire Wear Patterns CONDITION RAPID WEAR AT SHOULDERS RAPID WEAR AT CENTER CRACKED TREADS WEAR ON ONE SIDE FEATHERED EDGE BALD SPOTS SCALLOPED WEAR EFFECT CAUSE UNDER INFLATION OR LACK OF ROTA TION OVER INFLATION OR LACK OF ROTA TION UNDER INFLATION OR EX...

Page 1059: ...UFACTURER NOTE VERIFY THAT LEAD IS NOT RELATED TO STEER ING WHEEL NOT CENTERED SEE ALIGNMENT SECTION IN GROUP 2 SUSPENSION OF THIS SERVICE MANUAL FOR THE SERVICE AND PREFERRED ALIGNMENT SPECIFICATIONS AND THE VEHICLE FENDER LIP TO GROUND HEIGHTS REMOVE FRONT SHOCK SPRING UPPER CONTROL ARM ASSEMBLY PER INSTRUCTIONS IN FRONT SUSPENSION SECTION REMOVE BOTH BRACKET TO BODY PLASTIC LOCA TOR PINS FROM U...

Page 1060: ...ta tion is maintained Refer to Owner s Manual for rotation schedule REPAIRING TIRE LEAKS For proper repairing a radial tire must be removed from the wheel Repairs should only be made if the defect or puncture is in the tread area Fig 7 The tire should be replaced if the puncture is located in the sidewall Deflate tire completely before dismounting tire from the wheel Use lubrication such as a mild...

Page 1061: ... If the high spot is NOT within 102 mm 4 0 in of either high spot draw an arrow on the tread from second high spot to first Break down the tire and remount it 90 degrees on rim in that direction Fig 10 This procedure will normally reduce the runout to an acceptable amount CLEANING AND INSPECTION CLEANING OF TIRES Remove protective coating on tires before delivery of vehicle The coating could cause...

Page 1062: ...enger car tire or T for temporary use tire 185 Nominal width of tire in millimeters 70 Tire height to width ratio R Radial ply tire or D for bias ply tire 14 Nominal rim diameter in inches Do not install smaller than minimum size tires shown on the tire inflation placard on the vehicle 22 8 TIRES AND WHEELS JX ...

Page 1063: ...ial wheel clamps for the alignment equipment The wheel studs and nuts are designed for the spe cific wheel applications used on a vehicle and must be replaced with equivalent parts Do not use replacement parts of lesser quality or of a substitute design from the original equipment part All aluminum and steel wheels have wheel stud nuts with an enlarged nose This enlarged nose is necessary to ensur...

Page 1064: ...HE SERVICE HISTORY OF THE RIM MAY HAVE INCLUDED SEVERE TREAT MENT OR VERY HIGH MILEAGE THE RIM COULD FAIL WITHOUT WARNING TIRE AND WHEEL RUNOUT NOTE Runout should always be measured off the vehicle and on a suitable balance machine Radial run out is the difference between the high and low points on the outer edge of the tire or wheel Lateral run out is the total side to side wobble of the tire or ...

Page 1065: ...uld be used only when a two plane balancer is not available Off vehicle tire and wheel balancing is recom mended to be used on this vehicle NOTE If on vehicle equipment is being used to bal ance the tire wheel assemblies remove the oppo site tire wheel from the vehicle For static balancing find the location of heavy spot on tire wheel causing the imbalance Counter balance wheel directly opposite t...

Page 1066: ... WEIGHT LOCATION TIRE OR WHEEL TRAMP OR WHEEL HOP Fig 10 Dynamic Unbalance Balance OF SPINDLE ADD BALANCE WEIGHTS HERE PER DIRECTION OF DYNAMIC BALANCING EQUIPMENT CORRECTIVE WEIGHT LOCATION HEAVY SPOT WHEEL SHIMMY AND VIBRATION 22 12 TIRES AND WHEELS JX REMOVAL AND INSTALLATION Continued ...

Page 1067: ...void rattling of the wheel cover be sure all five retaining nuts are correctly tightened WHEEL AND TIRE CAST ALUMINUM WHEEL To install the wheel first position it properly on the mounting surface using the hub pilot as a guide All wheel nuts should be lightly tightened before pro gressively tightening them in the proper sequence Fig 12 Then tighten wheel nuts in the proper sequence to a torque of ...

Page 1068: ...etaining nut to a point just prior to this occur ring To avoid rattling of the wheel cover be sure all five retaining nuts are correctly tightened WHEEL COVER RETAINING NUT If a retaining nut for the lock on wheel is damaged it can be replaced as a separate part of the wheel cover Use the following procedure for replacing a wheel cover retaining nut REMOVE 1 If required remove the wheel cover from...

Page 1069: ...ge past the 2 small retaining tabs in wheel cover SPECIFICATIONS WHEEL SPECIFICATIONS Wheel Mounting Stud Size M12 x 1 5mm Mounting Stud Lug Nut Hex Size 19mm Mounting Lug Nut Tightening Torque 135 N m 100 ft lbs Fig 16 Wheel Cover Retaining Nut Retention WHEEL COVER WHEEL COVER RETAINING NUT SMALL RETAINING TABS LARGE RETAINING TAB JX TIRES AND WHEELS 22 15 REMOVAL AND INSTALLATION Continued ...

Page 1070: ......

Page 1071: ... result Always have a fire extinguisher ready for use when welding Disconnect the negative cable clamp from the battery when servicing electrical components that are live when the ignition is OFF Damage to electri cal system can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol vents on painted or upholste...

Page 1072: ...ear coat for durability PAINTED SURFACE TOUCH UP When a painted metal surface has been scratched or chipped it should be touched up as soon as possi ble to avoid corrosion For best results use Mopart Scratch Filler Primer Touch Up Paints and Clear Top Coat Refer to Introduction group of this manual for Body Code Plate information TOUCH UP PROCEDURE 1 Scrape loose paint and corrosion from inside sc...

Page 1073: ...ear Coat GW7 4037 18238 B8833 37298 CHA88 GW7 1997 MOLDING COLORS MOLDING COLOR CHRY CODE PPG BASF DUPONT S W ACME M S AKZO NOBEL SIKKENS Candy Apple Red RH2 4974 26098 B9616 51063 CHA95 RH2 5025 51064 Lt Gold SYL 83539 26097 B9618 51076 CHA96 SYL Orchid RMK 74085 25038 B9522 50272 CHA95 RMK Medium Fern RJP 47320 25040 B9524 50270 CHA95 RJP Forest Green SG8 47439 26078 B9609 5106 CHA95 SG8 Lt Iris...

Page 1074: ...t or clean from any surface If the moldings are set in urethane it would also be unlikely they could be salvaged Before removing the windshield check the availability of the windshield and moldings from the parts supplier REMOVAL AND INSTALLATION WINDSHIELD The urethane adhesive holding the windshield to the opening pinch weld fence can be cut using a sharp cold knife from the exterior of the vehi...

Page 1075: ...ssary so that the distance from the center of the dowel pin hole to the top of the windshield is 91 61 mm 3 61 in 5 Place a piece of tape over the ratcheting por tion of the support spacer to prevent them from mov ing 6 Repeat Step 3 through Step 5 for the opposite side of the windshield 7 Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a ...

Page 1076: ...d wipers 23 Install inside rear view mirror 24 After urethane has cured remove tape strips and water test windshield to verify repair Fig 2 Center Windshield and Mark at Support Spacers A PILLAR WINDSHIELD MARKS SUPPORT SPACER COWL Fig 3 Work Surface Set up and Molding Installation Fig 4 Position Urethane Compression Spacers Typical A PILLAR ROOF PANEL SPACERS WINDSHIELD OPEN ING Fig 5 Lower Winds...

Page 1077: ...SHION ASSEMBLY 8 FRONT SEAT CUSHION COVER 8 FRONT SEAT SIDE SHIELD 8 MANUAL SEAT ADJUSTERS 14 POWER SEAT ADJUSTER 14 REAR SEAT BACK COVER 15 REAR SEAT CUSHION COVER 14 SEAT RECLINER 14 REMOVAL AND INSTALLATION FRONT AND REAR SEAT DIAGRAMS Refer to Fig 1 and Fig 2 for more information while servicing the front or rear seat JX BODY 23 7 ...

Page 1078: ...BAR ROD ASSEMBLY LUMBAR BACKREST SEAT SUSPENSION CARPET SHIELD FRONT SEAT BELT BUCKLE POWER SEAT WIRING HAR NESS POWER SEAT ADJUSTER ASSEMBLY POWER SEAT SWITCH SEAT SIDE SHIELD MANUAL SEAT ADJUSTER ASSEMBLY CUSHION FRAME ASSEM BLY MEMORY DUMP CAM LOWER RECLINER HANDLE RECLINER ASSEMBLY UPPER RECLINER HANDLE 23 8 BODY JX REMOVAL AND INSTALLATION Continued ...

Page 1079: ...Fig 2 Rear Seat Covers VINYL LEATHER CLOTH CLOTH VINYL LEATHER JX BODY 23 9 REMOVAL AND INSTALLATION Continued ...

Page 1080: ...ame 3 Peel seat cushion cover back from seat cushion foam to access hog rings holding seat cushion cover to seat cushion foam 4 Remove hog rings holding seat cushion cover to seat cushion foam 5 Separate seat cushion cover from seat cushion foam INSTALLATION 1 Position seat cushion foam to seat cushion frame 2 Wrap fabric flap on bottom of cushion foam behind and under rear rail of cushion frame P...

Page 1081: ...recliner lead screw to seat frame 16 Separate seat back from seat frame 17 Unscrew lead screw from recliner mechanism Fig 6 INSTALLATION 1 Screw recliner lead screw into recliner mecha nism Fig 6 WARNING Do not pull on upper recliner handle or recliner cable end at any point during the following steps The recliner lead screw is spring loaded and will eject if either the handle or cable is pulled 2...

Page 1082: ... secure the lower seat belt anchor is not re usable Verify avail ability prior to proceeding 3 Remove nut holding lower seat belt anchor to seat frame Fig 5 4 Remove upper recliner handle and lumber adjustment handle if so equipped 5 Remove headrest Fig 7 6 Separate plastic retainer strip at bottom of seat back Fig 8 7 Remove hog rings holding seat cover seam cords to wires in seat back foam Fig 9...

Page 1083: ...g snaps on outboard portion of seat belt bezel inside seat back cover and seat belt retrac tor cover 18 Using a suitable hook style tool inserted through opening in seat belt bezel support the inside of the seat belt retractor cover while snapping the inboard portion of the bezel into the cover 19 Install upper recliner handle and lumbar adjustment handle if so equipped 20 Attach lower seat belt a...

Page 1084: ...e in this section REAR SEAT CUSHION COVER REMOVAL 1 Remove rear seat cushion from vehicle Refer to procedures found in this section 2 Place seat cushion on a suitable work surface in inverted position 3 Remove hog rings around perimeter of seat cushion holding seat cushion cover to seat cushion frame 4 Pull seat cover from seat cushion frame and seat cushion foam 5 Remove hog rings holding seat co...

Page 1085: ...e lower horizontal seam 5 If vehicle is equipped with cloth seats a Install hog rings at each hog ring locator center first to attach ends of vertical portions of U shaped wires to vertical foam wires b Align notch in center of upper horizontal seat cover seam to center hog ring location c Install a hog ring at each hog ring locator to hold upper horizontal seam wire to wire in seat back foam 6 In...

Page 1086: ...sec tions 5 Remove nuts holding tack strip to deck panel 6 Separate tack strip from deck panel CAUTION Cover all painted and upholstered sur faces to avoid damage while performing the follow ing operations 7 Reposition tack strip above rear deck and quar ter panels 8 Using a grease pencil mark location of outer top cover on rear tack strip to aid installation 9 Remove staples holding top cover to ...

Page 1087: ...window 6 Remove nuts holding beltline tack strips to vehicle NOTE Support top 12 above windshield header 7 Remove the 5 piece beltline tack strips and save plastic centering bushings for reinstallation NOTE Be sure to note the locations of the plastic centering bushings for installation 8 Disengage elastic strap from the third roof bow if equipped 9 Remove antenna mast 10 Place protective padding ...

Page 1088: ...6 for left side of the vehicle 9 Install sail panel springs to front of cover assem bly 10 Install antenna mast 11 Engage backlite elastic strap to number three roof bow 12 Install plastic centering bushings to the belt line tack strips 13 Using the nuts install the beltline tacking strips starting with the center tack strip and work ing outboard 14 Feed heated rear window wire harness thru sleeve...

Page 1089: ... rear seat back HYDRAULIC CYLINDER REMOVAL 1 Disconnect battery negative cable 2 Remove rear seat cushion and rear seat back 3 Remove quarter trim panel 4 Remove cylinder mounting bracket and nut Fig 6 5 Remove pivot bolt holding cylinder shaft to top linkage 6 Disconnect hydraulic lines from the cylinder 7 Remove cylinder from vehicle INSTALLATION Reverse the preceding operation Fill hydraulic sy...

Page 1090: ...t NOTE Refer to Cam Adjustment or Balance Link Adjustment paragraphs of this section to adjust for ward or rearward position of the top header LATCH HOOK ADJUSTMENT If the convertible top latching effort is excessive it can be reduced by lengthening the latch hook Fig 8 The top header weatherstrip requires enough compression to prevent air and water leaks Adjust latch hook to achieve reasonable la...

Page 1091: ...am high side is indicated by a arrow on the cam threaded end TO ADJUST CAM SETTING 1 Lower top to half down position to remove all possible strain from the cam 2 Remove torx head screw 3 Using appropriate torx bit rotate cam as nec essary and secure set screw BALANCE LINK ADJUSTMENT WARNING DO NOT PLACE HANDS OVER GAPS IN MOVABLE CONVERTIBLE TOP COMPONENTS DUR ING SERVICING PERSONAL INJURY CAN RES...

Page 1092: ...ELEASE CABLE 25 HOOD LATCH 25 HOOD PROP ROD 26 HOOD 26 INSIDE REAR VIEW MIRROR 40 LEFT FRONT WHEELHOUSE SPLASH SHIELD 27 LOCK BUTTON BELL CRANK 33 MANUAL FRONT SEAT 42 OUTER DOOR BELT WEATHERSTRIP 36 OUTSIDE DOOR HANDLE 36 POWER FRONT SEAT 42 QUARTER GLASS 47 QUARTER PANEL OUTER BELT WEATHERSTRIP MOLDING 49 QUARTER PANEL WEATHERSTRIP 38 QUARTER TRIM PANEL 46 QUARTER WINDOW MODULE 48 RADIATOR SUPPO...

Page 1093: ...t turns hoist the right side of the vehi cle For hoisting recommendations refer to Group 0 Lubrication and Maintenance General Information section WATER LEAK DETECTION To detect a water leak point of entry do a water test and watch for water tracks or droplets forming on the inside of the vehicle If necessary remove inte rior trim covers or panels to gain visual access to the leak area If the hose...

Page 1094: ...body surface can catch wind and whistle Gaps in sealed areas behind overhanging body flanges can cause wind rushing sounds Misaligned movable components Missing or improperly installed plugs in pillars Weld burn through holes UNIVERSAL TRANSMITTER NOTE The universal transmitter is disabled when the vehicle theft security system VTSS is activated Universal Transmitter will operate most Garage door ...

Page 1095: ...2 Remove left front cowl trim panel 3 Remove screws holding hood release handle to inner cowl panel Fig 4 4 Release clips holding hood release cable to left inner frame rail Fig 5 5 Disengage rubber grommet at lower dash panel 6 Disengage push in fastener holding hood release cable to dash panel 7 Separate hood release cable from vehicle INSTALLATION 1 Route hood release cable through hole in lowe...

Page 1096: ... HINGE REMOVAL 1 Support hood on the side that requires hinge replacement 2 Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to aid installation 3 Remove cowl cover 4 Remove bolts holding hood to hinge 5 Remove bolts holding hood hinge to front fender flange and separate hinge from vehicle INSTALLATION 1 If necessary paint new hinge before installa tion 2 ...

Page 1097: ...clips holding cowl cover to cowl plenum under hood to cowl bulb seal 3 Install screws holding cowl cover to cowl 4 Install windshield wiper arms Refer to Group 8K Windshield Wipers and Washers BATTERY SPLASH SHIELD REMOVAL 1 Remove screws holding battery splash shield to front bumper fascia Fig 9 2 Rotate half turn retainers holding battery splash shield to wheelhouse splash shield counter clockwi...

Page 1098: ...o be re used Verify availability prior to proceeding 1 Open and support door on a suitable lifting device 2 Disengage wire connector at hinge pillar 3 Remove bolts holding door check strap to hinge pillar 4 Remove clip holding hinge pin in lower door hinge 5 Remove pin from lower hinge Fig 11 6 Remove clip holding hinge pin in upper hinge 7 Remove pin from upper hinge Fig 11 8 Separate door from v...

Page 1099: ...ge to marks made previously and tighten all bolts 6 Install bolts holding door check strap to lower A pillar if removed previously 7 Verify door fit and operation Adjust door hinge for proper door alignment if necessary DOOR GLASS REMOVAL 1 Remove door trim panel and watershield 2 Remove inner door belt weatherstrip 3 Loosen inner belt stabilizer Fig 13 4 Remove door speaker if so equipped 5 Lower...

Page 1100: ...einforcement 10 Separate bolt heads from key hole slots in inner door panel 11 Remove window regulator through large hole in inner door panel Fig 19 12 Remove power window motor from regulator Refer to Group 8S Power Windows for motor proce dure INSTALLATION 1 Install power window motor on regulator Refer to group 8S Power Windows for motor procedures 2 Move window regulator into position in door ...

Page 1101: ...OVAL 1 Remove door trim panel and watershield 2 Remove nut holding top of guide bar to inner door panel 3 Using a suitable allen wrench hold jack screw stationary while removing nut holding bottom of guide bar to inner door panel 4 Separate guide bar from vehicle and remove through access hole in inner door panel Fig 21 INSTALLATION 1 If a new guide bar is being installed preset bottom jack screw ...

Page 1102: ... channel 5 Engage clips holding perimeter of trim panel to door 6 Install screws holding trim panel to door 7 Engage clips holding speaker grille to door trim panel DOOR WATERSHIELD REMOVAL 1 Remove door trim panel 2 Remove door speaker if equipped 3 Remove door trim pull cup mount bracket 4 Disengage clip holding lock linkage to lock but ton bell crank 5 Peel watershield away from adhesive around...

Page 1103: ...Fig 27 6 Separate side view mirror from vehicle INSTALLATION 1 Feed power mirror wire harness through hole in mirror flag and seat grommet Do not pull on wire harness to seat grommet 2 Position side view mirror to vehicle 3 Install nuts holding side view mirror to mirror flag 4 Engage push in fastener holding power mirror wire connector to inner door panel if so equipped 5 Engage power mirror moto...

Page 1104: ...weatherstrip 7 Install door glass 8 Install side view mirror 9 Verify glass fit and operation Adjust door glass as necessary 10 Install door trim panel DOOR CHECK STRAP REMOVAL 1 Remove door trim panel 2 Remove watershield as necessary to gain access 3 Remove bolts holding check strap to lower A pillar 4 Remove bolts holding check strap to door end frame Fig 29 5 Separate door check strap from veh...

Page 1105: ...g lock cylinder to outside door panel Fig 33 3 Disengage clip holding link to key cylinder 4 Separate lock cylinder from outer door panel INSTALLATION 1 Position lock cylinder and gasket in door outer panel 2 Install clip holding lock cylinder to outside door panel 3 Engage link to key cylinder 4 Install outside door handle DOOR LATCH STRIKER REMOVAL 1 Mark outline of door latch striker on B pilla...

Page 1106: ... Install nuts holding door handle to outer door panel 3 Connect latch rod at door latch 4 Install watershield 5 Install door trim panel 6 Verify door handle operation Adjust door latch as necessary DOOR INNER BELT WEATHERSTRIP REMOVAL 1 Remove door trim panel 2 Pull upward on rear edge of inner belt weath erstrip Fig 36 3 Separate weatherstrip from vehicle INSTALLATION 1 Start leading edge of weat...

Page 1107: ...R MOLDING REMOVAL 1 Partially raise convertible top 2 Remove header and A pillar weatherstrip as necessary to gain access 3 Remove screws holding A pillar weatherstrip retainer to header weatherstrip retainer 4 Remove screws holding header weatherstrip retainer to header panel Fig 39 5 Separate retainer from vehicle INSTALLATION 1 Clean any residual seal material from header panel 2 Position heade...

Page 1108: ... holding weatherstrip to B pillar 3 Remove weatherstrip from door opening flange 4 Separate quarter panel weatherstrip from vehi cle Fig 42 INSTALLATION 1 Position panel weatherstrip onto vehicle 2 Install weatherstrip to door opening flange 3 Install push in fasteners holding weatherstrip to B pillar 4 Install door sill trim panel SIDE RAIL WEATHERSTRIPS FRONT REMOVAL 1 Partially raise convertibl...

Page 1109: ... on vehicle 2 Push weatherstrip into retainer channel align ing embossment on backside of weatherstrip to cor ner of retainer 3 Lower convertible top 4 Adjust position of weatherstrip so that weath erstrip is butted tightly against quarter panel and center side rail weatherstrip 5 Secure convertible top SUN VISOR REMOVAL 1 Disengage sun visor from sun visor support 2 Remove screws holding sun viso...

Page 1110: ...near A pillar 2 Align locating pins on back side of trim panel to holes in A pillar 3 Press clips on A pillar trim panel into slots in A pillar HEADER TRIM PANEL RIGHT OR LEFT REMOVAL 1 Remove sun visor 2 Remove inside rear view mirror right side only 3 Disengage clip holding header trim panel to header panel 4 Separate header trim panel from vehicle Fig 49 INSTALLATION 1 Position header trim pane...

Page 1111: ...ng tool disengage clips holding door sill trim panel to door sill Fig 52 2 Starting at one end of sill trim panel pull upward on sill trim panel in order to disengage clips holding sill trim panel to door opening flange 3 Separate door sill trim panel from vehicle INSTALLATION 1 Position door sill trim panel on vehicle 2 Align locating rib to net against cowl trim panel 3 Engage clips on sill trim...

Page 1112: ...fully seated to floor pan crossmember 9 Install and tighten rear outboard bolt holding seat to side sill pylon 10 Install and tighten forward rear outboard bolt holding seat to side sill pylon 11 Install and tighten rear inboard bolt holding seat to floor pan 12 Move seat to full rearward position Push rearward slightly on seat to ensure that the adjuster latches are engaged on both seat tracks 13...

Page 1113: ...belt retractor to seat frame NOTE The torque specification on the retractor bolts is 16 2 N M 12 ft lbs 4 Install seat belt retractor cover Fig 54 5 Install seat cover Refer to procedure found in this section 6 Attach lower seat belt anchor to bolt on seat adjuster 7 Verify that seat belt is routed such that it will not be twisted when engaged to the seat belt buckle 8 Install new nut holding lowe...

Page 1114: ...ets on floor pan 5 Connect PRNDL bezel wire connector on shifter mechanism 6 Install lighted PRNDL letter bezel 7 Install plastic plunger rod to shifter lever 8 Install shift lever knob and tighten set screw on front of shifter knob FORWARD INSTRUMENT PANEL CONSOLE REMOVAL 1 Remove floor console 2 Remove instrument panel cluster hood Refer to Group 8E Instrument Panel and Gauges for proper procedu...

Page 1115: ... on top of seat cushion 3 Push seat cushion rearward and align wire loops to retainers in floor pan 4 Push rear seat cushion firmly downward and engage wire loops to retainers in floor pan REAR SEAT BACK REMOVAL 1 Remove rear seat cushion 2 Remove rear inner seat belt assembly Fig 58 3 Pull bottom of rear seat back forward until seat back brackets clear studs on floor pan Fig 59 4 Push upward on r...

Page 1116: ...h in fasteners holding quarter trim panel to inner quarter panel at front of trim panel 10 Pull trim panel from inner quarter panel and disconnect speaker wiring connector 11 Separate quarter trim panel from vehicle INSTALLATION 1 Position quarter trim panel on vehicle 2 Connect speaker wiring connector 3 Install push in fasteners holding quarter trim panel to inner quarter panel at front of trim ...

Page 1117: ...n 3 Remove rear inner seat belt assembly Fig 63 INSTALLATION 1 Position rear inner seat belt assembly onto studs on floor pan 2 Install nuts holding seat belt assembly to floor pan 3 Install rear seat cushion NOTE Torque specification for rear inner seat belt assembly is 40 N m 350 in lbs QUARTER GLASS NOTE No access is provided to glass fasteners except if glass is in the full up position If this...

Page 1118: ...ter glass adjustment procedure in this section 9 Install quarter trim panel CARPET REMOVAL 1 Lower convertible top to full down position 2 Remove front seats 3 Remove rear seat cushion 4 Remove floor console and forward instrument panel console 5 Remove door sill trim panels 6 Remove cowl trim panels 7 Remove quarter trim panels 8 Remove amplifier on passenger side of floor pan if so equipped 9 Re...

Page 1119: ...ing down ward until weatherstrip molding is fully seated 3 Install screws holding outer belt weather strip to outer quarter panel 4 Tighten fasteners for upper belt molding 5 Install quarter trim panel 6 Raise and secure convertible top UPPER DECK MOLDING REMOVAL 1 Lower convertible top to midway position 2 Remove screws holding upper deck molding to rear deck panel above convertible top rear atta...

Page 1120: ...fastener in rear of side piece 4 Disengage slots in right left convertible top storage area from studs along jackscrew Fig 69 5 Separate right left storage area from vehicle INSTALLATION 1 Position right left convertible top storage area in vehicle 2 Engage slot in right left storage area to studs along tack strip 3 Install tack strip trim piece 4 Install push in fasteners to hold center and side ...

Page 1121: ...inge by prying cylinder from ball stud on hinge Fig 71 7 With aid of a helper remove bolts holding trunk hinge to trunk lid 8 Remove bolts holding trunk hinge to quarter panel 9 Separate trunk hinge from vehicle INSTALLATION 1 Position trunk hinge to vehicle 2 Loosely install bolts holding trunk hinge to quarter panel 3 Loosely install bolts holding trunk hinge to trunk lid 4 Align trunk hinge to ...

Page 1122: ...uipped 5 Remove clip holding trunk lock cylinder to trunk lid 6 Separate trunk lock cylinder from vehicle INSTALLATION 1 Position trunk lock cylinder on vehicle 2 Install clip holding trunk lock cylinder to trunk lid 3 Install security alarm switch if so equipped 4 Install clip holding trunk lock cylinder to secu rity alarm switch if so equipped 5 Install trunk latch TRUNK OPENING WEATHERSTRIP REM...

Page 1123: ... using a suitable heat lamp or heat gun 6 Firmly press body side molding to body surface to insure adhesion ADJUSTMENTS FRONT DOOR GLASS ADJUSTMENT NOTE Verify that the door is properly adjusted to the body prior to adjusting the door glass NOTE Lower quarter glass to the full down posi tion while making door glass adjustments unless otherwise instructed UP STOP ADJUSTMENTS 1 Remove door trim pane...

Page 1124: ...itable allen wrench rotate jack screws to achieve the proper gap between the door glass weatherstrip retainer strip Fig 77 ADJUSTMENT SPECIFICATIONS MEASUREMENT LOCATIONS AND THEIR VALUES SECTION A A SECTION B B SEQUENCE ADJUSTMENT IN OUT FORWARD REARWARD UP DOWN NOTE Forward Rearward and Up Down adjustment are to be made at the same time Fig 77 Fig 78 Forward Up Stop Adjustment FORWARD UPSTOP ADJ...

Page 1125: ...en the remaining glass fastener 7 Raise glass to top of travel and verify position ing Fig 77 and Fig 81 8 To verify proper fit of the door glass to the header A pillar weatherstrip a Lower door glass slightly b Place a paper strip between the glass and weatherstrip near mirror flag and another near the front upper corner of the door glass c Raise glass to full up position d Pull the strip from be...

Page 1126: ...rim panel 2 Remove center and rear side rail weatherstrips from side rail weatherstrip retainer channels 3 Loosen up stop nuts 4 Raise quarter glass 5 Slide up stop to achieve proper glass to weath erstrip retainer gap Fig 82 6 Tighten all fasteners 7 Install center and rear side rail weatherstrips to side rail weatherstrip retainer channels 8 Cycle quarter glass between full up and full down posi...

Page 1127: ...ss b Adjust the door glass as necessary to cure the condition DOOR LATCH ADJUSTMENT 1 Insert a suitable allen wrench through elon gated slot in door end frame and loosen bolt 1 2 to one full turn Fig 83 2 Cycle outside door handle twice 3 Tighten adjusting screw to 30 in lbs 4 Verify latch operation SPECIFICATIONS BODY LUBRICATION SPECIFICATIONS LUBRICATION REQUIREMENTS Body mechanisms and linkage...

Page 1128: ...ver Parking Brake Mechanism Sliding Seat Tracks Trunk Latch MOPART MULTI PURPOSE GREASE OR EQUIVALENT All Other Hood Mechanisms Door Hinges Hinge Pin and Pivot Contact Areas MOPART LOCK CYLINDER LUBRICANT OR EQUIVALENT Door Lock Cylinders Trunk Lock Cylinder SPECIAL TOOLS BODY REMOVER MOLDINGS C 4829 STICK TRIM C4755 23 58 BODY JX SPECIFICATIONS Continued ...

Page 1129: ... WHEEL ASSEMBLY 13 BLOWER MOTOR RESISTOR 13 BLOWER MOTOR WHEEL 14 COMPRESSOR CLUTCH COIL ASSEMBLY 15 COMPRESSOR 14 CONDENSER 16 CONTROL MODULE 17 DISCHARGE LINE 18 EVAPORATOR PROBE 20 EVAPORATOR 19 EXPANSION VALVE 21 FILTER DRIER 22 HEATER CORE 23 HEATER HOSES 24 LIQUID LINE 25 MODE DOOR ACTUATOR MOTOR 12 RECIRCULATION DOOR CABLE 26 SUCTION LINE 27 TEMPERATURE DOOR CABLE 27 THERMAL LIMITER SWITCH ...

Page 1130: ...he pressure transducer functions as the refrigerant system pressure sensor It supports the condenser radiator fans and compressor func tions CLUTCH PULLEY AND COIL They are mounted on the compressor providing a way to drive the compressor The compressor clutch and coil are the only serviced parts on the compres sor When the compressor is not in operation the pulley free wheels on the clutch hub be...

Page 1131: ...be empty All quick connects use two O rings to seal the con nection The O rings are made from a special type of rubber that is not affected by R 134a refrigerant O ring replacement is required whenever lines are removed and installed Use only O rings specified for this vehicle Failure to use the correct type of O ring will cause the connection to leak within a short period of time When it is neces...

Page 1132: ...by debris in the refrigerant system If debris is believed to be the cause recycle the refrigerant and replace the expansion valve and receiver drier HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system High pressures are pro duced in the system when it is operating Extreme care must be exerci...

Page 1133: ...ting verify that the valve of the coupling is fully closed This will reduce the amount of effort required to make the connection 1 Connect a tachometer and manifold gauge set Attach a thermal couple to the evaporator line 2 Set control to A C RECIRC and PANEL tem perature lever on full cool and blower on high 3 Start engine and hold at 1000 rpm with A C clutch engaged 4 Engine should be warmed up ...

Page 1134: ...ach position shown on chart below The resis tance reading should be within the specifications shown If not OK replace the control module If OK check Blown fuse Cut wire Poor ground Poor connection Defective BCM Bulkhead connector inoperative Refer to Group 8W Wiring Diagrams HEATER PERFORMANCE TEST PRE DIAGNOSTIC PREPARATIONS Review Safety Precautions and Warnings in this group before performing t...

Page 1135: ...er the system has been charged with R 134a refrigerant and operated the oil in the com pressor is dispersed through the lines and compo nents The evaporator condenser and receiver drier will retain a significant amount of oil Refer to the A C Component Refrigerant Oil Capacities chart below When a component is replaced the specified amount of refrigerant oil must be added When the compressor is re...

Page 1136: ...refrigerant system If the refrigerant system has been open to the atmosphere it must be evacuated before the system can be filled Moisture and air mixed with the refrig erant will raise the compressor head pressure above acceptable operating levels This will reduce the per formance of the air conditioner and damage the com pressor Moisture will boil at near room temperature when exposed to vacuum ...

Page 1137: ...R 134a system Refer to the label under the hood for proper oil and refrigerant charge levels Fig 7 Due to the different characteristics of R 134a it requires all new service procedures WARNING AVOID BREATHING A C REFRIGERANT AND LUBRICANT VAPOR OR MIST EXPOSURE MAY IRRITATE EYES NOSE AND THROAT USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO RECLAIM R 134a SYSTEMS IF ACCIDENTAL SYS...

Page 1138: ...blocking off the airflow to the front grill area This will maintain a constant pressure and stop the cooling fans from alternating between high and low speeds 6 Observe Discharge pressure and Liquid line temperature Using the Charge Determination Graph determine where the system is currently operating Fig 8 If the system is in the undercharged region ADD 0 057 Kg 2 oz to the system and recheck rea...

Page 1139: ...n a R 134a refrig erant system 4 Shut off the vehicle and wait 2 to 7 minutes Then use an Electronic Leak Detector that is designed to detect R 134a type refrigerant and search for leaks Fittings lines or components that appear to be oily usually indicates a refrigerant leak To inspect the evaporator core for leaks insert the leak detector probe into the drain tube opening or a heat duct A R 134a ...

Page 1140: ...se Electrical power should be re established after 60 seconds which will auto matically initiate the software calibration procedure If this procedure fails it will be necessary to replace the mode door actuator motor The mode door actua tor motor is not serviceable and must be replaced if found to be defective The mode door actuator is located on the upper left side of the A C Heater housing Fig 9...

Page 1141: ...se retaining screws 5 Lower blower motor case from housing Fig 14 6 Remove fan scroll from motor shaft 7 Remove motor from motor case INSTALLATION For installation reverse the above procedures BLOWER MOTOR RESISTOR The blower motor resistor is located on the lower right side of the heater housing REMOVAL 1 Remove lower right underpanel silencer duct 2 Disconnect wiring connectors on blower motor r...

Page 1142: ...m with R 134a recov ery unit 5 Remove refrigerant lines from compressor Fig 17 6 Remove compressor attaching bolts Fig 18 and Fig 19 7 Remove compressor Fig 20 INSTALLATION 1 Position the compressor on the mount 2 Install the compressor attaching bolts Tighten bolts to 41 N m 30 ft lbs torque 3 Install drive belt refer to Group 7 Cooling System Fig 15 Blower Motor Resistor A C HOUSING BLOWER MOTOR...

Page 1143: ...THAT THE SNAP RING DOES NOT FLY OUT FROM THE GROOVE INSPECTION Examine frictional faces of the rotor pulley and armature plate for wear The pulley and plate should be replaced if there is excessive wear or scoring If the friction surfaces are oily inspect the shaft nose area of the compressor for excess oil If excess oil is present the shaft seal is leaking and the compressor must be replaced Chec...

Page 1144: ...il core check for cor rect voltage amperage Cycle the A C clutch approxi mately 20 times 5 seconds on and 5 seconds off For this procedure run engine at 1 500 to 2 000 rpm and set the system to MAX A C mode This procedure will seat the opposing friction surfaces and provide a higher clutch torque capability CONDENSER The condenser is located between the radiator and the front bumper The condenser ...

Page 1145: ...ONTROL MODULE The control module is located below the radio REMOVAL 1 Place the ignition key in the OFF position before removing control module 2 Remove trim bezel Fig 29 Fig 25 Grille Retainers GRILLE RETAINERS Fig 26 Radiator Support Crossmember UPPER RADIATOR CROSS MEMBER Fig 27 Condenser Mounting CONDENSER MOUNT ING CONDENSER Fig 28 Condenser Removal CONDENSER Fig 29 Control Module TRIM BEZEL ...

Page 1146: ...d for proper function of the control module To adjust the cable attach the cable to the lever arm of the control module Turn the knob fully counterclockwise Pull the cable jacket away from the cable end until taut Clip the cable jacket to the control module The knob should travel a full 180 if the cable is properly adjusted DISCHARGE LINE REMOVAL 1 Remove refrigerant from the A C system using a re...

Page 1147: ...over 4 Remove evaporator temperature probe 5 Remove clips retaining evaporator housing to heater distribution housing Fig 36 6 Separate evaporator housing from heater distri bution housing Fig 37 and Fig 38 7 Remove seal around evaporator tube inlet 8 Remove evaporator housing upper cover Fig 39 9 Lift evaporator out of lower housing Fig 40 10 Remove styrofoam seal around evaporator 11 Transfer ev...

Page 1148: ...This plate must be pushed inside the A C unit and orien tated in such a way that the plate can be removed Fig 38 Housings EVAPORATOR HOUSING HEATER DISTRIBUTION HOUSING Fig 39 Evaporator Housing Upper Cover EVAPORATOR HOUSING COVER EVAPORATOR HOUSING Fig 40 Remove Evaporator From Housing EVAPORATOR Fig 41 Evaporator Probe Wiring PROBE CONNECTOR EVAPORATOR PROBE Fig 42 Evaporator Probe EVAPORATOR P...

Page 1149: ... VEHICLE A C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR SOME MIXTURES OF AIR R 134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES THESE MIXTURES ARE POTENTIALLY DANGER OUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE REMOVAL 1 Remove refrigerant from the A C system using a refrigerant recovery machine 2 Disconnect clips from expansion...

Page 1150: ...sture and filter the refrigerant as it passes through the filter drier The filter drier is located left of the coolant bottle Fig 51 The A C refrigerant must be removed from the system before removing the filter drier Always use a refrigerant recovery machine Replace the filter drier if an A C system is left open for an extended period of time Fig 48 Lines At Expansion Valve A C LINES EXPANSION VA...

Page 1151: ...oval and Installation in this section REMOVAL 1 Disconnect battery negative remote cable 2 Remove radio control module bezel Fig 29 3 Remove right instrument panel side trim 4 Remove two screws at lower right side support beam 5 Remove bolt for instrument panel support at A pillar 6 Remove left instrument panel side trim 7 Remove upper instrument panel bezel 8 Remove lower knee bolster 9 Remove co...

Page 1152: ... core may become damaged and leak engine coolant into heater unit INSTALLATION For installation reverse the above procedures HEATER HOSES 2 5L REMOVAL The heater hoses for the 2 5L engine are preformed hoses with quick connect fittings at the engine These hoses are not serviceable and must be replaced using OEM parts The hoses are attached at the heater core using spring tension clamps NOTE Review...

Page 1153: ...er drier Fig 60 5 Remove the liquid line from the vehicle INSTALLATION For installation reverse the above procedu8res TO CONDENSER REMOVAL 1 Remove refrigerant from the A C system using a refrigerant recovery machine 2 Remove A C quick connect clip at condenser Fig 61 3 Disconnect quick connector at condenser Remove liquid line from condenser Use special tool kit 7193 to disconnect quick connector...

Page 1154: ...trol module retaining screws 7 Drop the A C control module into the cigar lighter cubby bin bezel opening Fig 68 Then dis connect the wiring on the rear of the control module 8 Release the recirculation cable retaining clip from the top of the control module Retain the clip for future use Then disconnect the recirculation control cable Fig 61 Clip Removal DISCHARGELINE LIQUID LINE LIQUID LINE CLIP...

Page 1155: ... LINE REMOVAL 1 Remove refrigerant from the A C system using a refrigerant recovery machine 2 Remove suction line clip at right strut tower Fig 70 3 Remove quick connect clip Fig 71 Disconnect quick connect at expansion valve end using Special Tool Kit 7193 CAUTION Cap all lines that are not being replaced and cap the expansion valve tubes 4 Disconnect line at compressor end Fig 72 5 Remove suctio...

Page 1156: ... cable 9 Disconnect cable at A C housing Fig 73 10 Remove cable core end from temperature actuator lever INSTALLATION For installation reverse the above procedures THERMAL LIMITER SWITCH There is no serviceability of the thermal limiter switch If the thermal limiter switch fails the com pressor must be replaced To replace the compressor refer to Compressor Replacement in this section UNIT HOUSING ...

Page 1157: ...ood bezel a few inches to expose the cubby bin cigar lighter bezel screws 10 Remove the cubby bin cigar lighter bezel and wiring 11 Remove the control module retaining screws 12 Drop the A C control module into the cigar lighter cubby bin bezel opening Fig 68 Then dis connect the wiring on the rear of the control module 13 Release the cable clips from the top of the control module Retain the clips...

Page 1158: ...r Fig 79 5 Remove rear Y cam actuator lever Fig 80 6 Turn front toggle lever until it lines up with slots on housing Fig 74 Heater A C Unit HVAC UNIT Fig 75 Mode Motor Linkage MODE MOTOR HVACUNIT Fig 76 Mode Motor DEFROST DOOR LEVER MODE CAM FLOOR DOOR LEVER FLOOR DOOR LEVER LINK DEFROST DOOR LINK LEVER PANEL DOOR PANEL DOOR LEVER PANEL DOOR LEVER LINK MODE MOTOR Fig 77 Recirculation Air Inlet REC...

Page 1159: ...on tab at evaporator probe cover Fig 84 Turn evaporator probe cover clockwise 90 15 Remove evaporator probe cover Pull evapora tor needle from evaporator Fig 85 Fig 79 Rear Y Cam Release Y CAM ACTUATOR LEVER REAR DOOR FLAT BLADE PRY TOOL Fig 80 Rear Y Cam Actuator REAR Y CAM ACTUATOR LEVER REAR LEVER AIR INLET FRONT TOGGLE LEVER FRONT ACTUATOR LEVER Fig 81 Rear Air Inlet Door RECIRC HOUSING REAR D...

Page 1160: ...inlet Fig 89 20 Remove evaporator housing upper cover Fig 90 21 Lift evaporator out of lower housing Fig 91 Fig 84 Evaporator Probe EVAPORATOR PROBE Fig 85 Evaporator Probe Needle EVAPORATOR PROBE NEE DLE Fig 86 Blower Motor Resistor BLOWER RESISTOR Fig 87 Housing Clips MOUNTING CLIPS Fig 88 Separate Housings HEATER DISTRIBUTION HOUSING A C EVAPORATOR HOUSING 24 32 HEATING AND AIR CONDITIONING JX ...

Page 1161: ... door air opening using a long thin screwdriver push in clip for floor door gear Remove floor door gear Fig 98 Fig 89 Evaporator Tube Inlet Seal EVAPORATOR CORE SEAL Fig 90 Evaporator Housing Upper Cover EVAPORATOR HOUSING COVER EVAPORATOR HOUSING Fig 91 Remove Evaporator From Housing EVAPORATOR Fig 92 Lower Floor Distribution Housing FLOOR DISTRIBUTION HOUSING HEATER DISTRIBUTION HOUSING Fig 93 H...

Page 1162: ... panel door gear from housing 33 Line up slots on panel door lever link Remove panel door lever link from housing Fig 104 Fig 94 Heater Core Cover Removal HEATER CORE COVER Fig 95 Slide Out Core HEATER CORE Fig 96 Temperature Door Lever Link TEMPERATURE DOOR LEVER LINK MOUNTING SCREW Fig 97 Temperature Door Lever Link Removal TEMPERATURE DOOR LEVER LINK Fig 98 Floor Door Gear FLAT BLADE PRY TOOL F...

Page 1163: ...m DEFROST DOOR LEVER LINK PANEL DOOR LEVER PANEL DOOR LEVER LINK MODE CAM DEFROST DOOR LEVER Fig 102 Mode Motor Cam Removal MODE CAM Fig 103 Panel Door Gear Release FLAT BLADE PRY TOOL PANEL DOOR Fig 104 Panel Door Lever Link PANEL DOOR LEVER LINK JX HEATING AND AIR CONDITIONING 24 35 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1164: ...ig 108 39 Unsnap panel door from rear half of housing Remove door from housing 40 Unsnap floor door from front half of housing Remove door from housing Fig 109 Fig 105 Defrost Door Lever Link Fig 106 Front And Rear Housing Halves REAR COVER FRONT COVER Fig 107 Defrost Door Removal DEFROST DOOR Fig 108 Temperature Control Door Removal FLAT BLADE PRY TOOL TEMPERATURE CONTROL DOOR Fig 109 Floor Door ...

Page 1165: ... 17 Install blower motor and resistor 18 Install air inlet housing to evaporator hous ing 19 Install evaporator housing to heat distribution housing 20 Install mode motor SPECIFICATIONS COMPRESSOR DESCRIPTION Displacement per Revolution 85 7 cc rev 5 2 cu in rev Maximum Allowable rpm 12000 rpm Maximum Allowable Continuous rpm 10000 rpm Refrigerant R 134A Oil SP15PAG 150cc 5 08 fl oz Weight 39 2 N ...

Page 1166: ......

Page 1167: ...IL Refer to Malfunction Indicator Lamp in this section Certain criteria must be met before the PCM stores a DTC in memory The criteria may be a spe cific range of engine RPM engine temperature and or input voltage to the PCM The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred This may happen because one of the DTC criteria for the circuit has not been met F...

Page 1168: ...ws the change from HIGH to LOW or LOW to HIGH assume the entire switch circuit to the PCM functions properly From the state display screen access either State Display Inputs and Outputs or State Display Sensors CIRCUIT ACTUATION TEST MODE The Circuit Actuation Test Mode checks for proper operation of output circuits or devices the Powertrain Control Module PCM may not internally recognize The PCM ...

Page 1169: ...JX EMISSION CONTROL SYSTEMS 25 3 DESCRIPTION AND OPERATION Continued ...

Page 1170: ...N OF DIAGNOSTIC TROUBLE CODE 12 Battery Disconnect Direct battery input to PCM was disconnected within the last 50 Key on cycles 55 Completion of fault code display on Check Engine lamp 01 54 P0340 No Cam Signal at PCM No camshaft signal detected during engine cranking 02 53 P0601 Internal Controller Failure PCM Internal fault condition detected 05 47 Charging System Voltage Too Low Battery voltag...

Page 1171: ...rich or lean condition detected from the oxygen sensor 21 17 Engine Is Cold Too Long Engine did not reach operating temperature within acceptable limits 23 15 P0500 No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load conditions 24 14 P0107 MAP Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage or 25 P0108 MAP Sensor Voltage Too High MAP sen...

Page 1172: ...maintained above the normal operating range 44 53 P0600 PCM Failure SPI Communications PCM Internal fault condition detected 45 27 P0205 Injector 5 Control Circuit Injector 5 output driver does not respond properly to the control signal or 46 P0206 Injector 6 Control Circuit Injector 6 output driver does not respond properly to the control signal 52 77 SPD CTRL PWR RLY or S C 12v Driver CKT Malfun...

Page 1173: ...d in cylinder 3 or 6E P0304 Cylinder 4 Mis fire Misfire detected in cylinder 4 70 72 P0420 Right Rear or just Catalyst Efficency Failure Catalyst efficiency below required level 71 31 P0441 Evap Purge Flow Monitor Failure Insufficient or excessive vapor flow detected during evaporative emission system operation 72 37 P1899 P N Switch Stuck in Park or in Gear Incorrect input state detected for the ...

Page 1174: ...unit or 96 Fuel Level Sending Unit Volts Too High Circuit shorted to voltage between PCM and fuel gauge sending unit or 97 Fuel Level Unit No Change Over Miles No movement of fuel level sender detected 98 65 P0703 Brake Switch Stuck Pressed or Released No release of brake switch seen after too many accelerations 99 44 P1493 Ambient Batt Temp Sen VoltsToo Low Battery temperature sensor input voltag...

Page 1175: ...pecific problem must be diagnosed If any of these monitors detect a problem affecting vehicle emissions the Malfunction Indicator Check Engine Lamp will be illuminated These monitors generate Diagnostic Trouble Codes that can be dis played with the check engine lamp or a scan tool The following is a list of the system monitors EGR Monitor Misfire Monitor Fuel System Monitor Oxygen Sensor Monitor O...

Page 1176: ...he O2S compensation control is mon itored Turning off the EGR shifts the air fuel A F ratio in the lean direction The O2S data should indi cate an increase in the O2 concentration in the com bustion chamber when the exhaust gases are no longer recirculated While this test does not directly measure the operation of the EGR system it can be inferred from the shift in the O2S data whether the EGR sys...

Page 1177: ...een predeter mined temperature thresholds limits the three port solenoid is briefly energized This initializes the pump by drawing air into the pump cavity and also closes the vent seal During non test conditions the vent seal is held open by the pump diaphragm assembly which pushes it open at the full travel posi tion The vent seal will remain closed while the pump is cycling due to the reed swit...

Page 1178: ...e of these conditions occurred a DTC was set Now there is a check to ensure that the component is working This is done by watching for a TPS indication of a greater or lesser throttle opening than MAP and engine rpm indicate In the case of the TPS if engine vacuum is high and engine rpm is 1600 or greater and the TPS indicates a large throttle opening a DTC will be set The same applies to low vacu...

Page 1179: ...o the body at all times also during diagnostic PCM CONNECTOR ENGAGEMENT The PCM may not be able to determine spread or damaged connector pins However it might store diagnostic trouble codes as a result of spread connec tor pins HIGH AND LOW LIMITS The PCM compares input signal voltages from each input device with established high and low limits for the device If the input voltage is not within lim...

Page 1180: ... vent valve hoses should the vehicle rollover All vehicles pass a 360 rollover The pressure relief valve opens at a certain pres sure When fuel tank pressure increases above the calibrated pressure the valve opens to release fuel tank vapors pressure The charcoal filled evaporative canister stores the vapors For pressure relief rollover valve service refer to the Fuel Tank section of Group 14 EVAP...

Page 1181: ...ube breaks when the cap is removed and relieves fuel tank pressure If the filler cap needs replacement only use the correct part POSITIVE CRANKCASE VENTILATION PCV SYSTEMS Intake manifold vacuum removes crankcase vapors and piston blow by from the engine The emissions pass through the PCV valve into the intake manifold where they become part of the calibrated air fuel mixture They are burned and e...

Page 1182: ...ck from the inlet This results in maximum vapor flow through the valve Fig 9 VEHICLE EMISSION CONTROL INFORMATION LABEL All models have a Vehicle Emission Control Infor mation VECI Label Chrysler permanently attaches the label in the engine compartment It cannot be removed without defacing information and destroying the label The label contains the vehicle s emission specifica tions and vacuum hos...

Page 1183: ... strong vacuum felt when placing a finger over the valve inlet Fig 10 With the engine off shake the valve The valve should rattle when shaken Replace the valve if it does not operate properly Do not attempt to clean the PCV valve VACUUM SCHEMATIC If any difference exists between the diagram on the Vehicle Emission Control Information VECI label and this illustration refer to the label on the vehic...

Page 1184: ...ENGINE VACUUM SCHEMATIC 2 0L 25 18 EMISSION CONTROL SYSTEMS JX DIAGNOSIS AND TESTING Continued ...

Page 1185: ...ENGINE VACUUM SCHEMATIC 2 4L ATX JX EMISSION CONTROL SYSTEMS 25 19 DIAGNOSIS AND TESTING Continued ...

Page 1186: ...ENGINE VACUUM SCHEMATIC 2 5L ATX 25 20 EMISSION CONTROL SYSTEMS JX DIAGNOSIS AND TESTING Continued ...

Page 1187: ...cle 5 Disconnect vacuum line from Leak Detection Pump LDP 6 Remove hoses from evaporative canister 7 Remove 3 nuts retaining evaporative canister to pump bracket Fig 11 Headlamp Attachment HEADLAMP ATTACHING BOLTS Fig 12 Headlamp Electrical Connector Removal Installation HEADLAMP ASSEMBLY Fig 13 Vacuum Line On LDP SERVICE VAC UUM SUPPLY LEAK DETECTION PUMP Fig 14 Evaporative Canister Attachment Nu...

Page 1188: ...d tighten 2 screws 7 Use the DRB to test the LDP and system ROLLOVER VALVES All vehicles have 2 rollover valves on top of the fuel tank The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover The rollover valves on the fuel tank are not ser viceable Fig 15 LDP Bracket Mounting Holes LDP BRACKET MOUNTING HOLES Fig 16 Front Upper Mounting Bolt FRONT UPPER MOUN...

Page 1189: ...ilute the incoming air fuel mixture The diluted air fuel mix ture reduces peak flame temperature during combus tion The EGR system consists of Fig 1 Fig 2 and Fig 3 EGR tube EGR valve Electric EGR Transducer Connecting hoses The electric EGR transducer contains an electri cally operated solenoid and a back pressure trans ducer Fig 4 The Powertrain Control Module PCM operates the solenoid The PCM d...

Page 1190: ...OARD DIAGNOSTICS The PCM performs an on board diagnostic check of the EGR system The diagnostic system uses the electronic EGR transducer for the system tests The diagnostic check activates only during selected engine driving conditions When the conditions are met the PCM energizes the transducer solenoid to disable the EGR The PCM checks for a change in the heated oxygen sensor signal If the air ...

Page 1191: ...armed to operating temperature for this test 1 All engines are equipped with two fittings located on the EGR valve Fig 6 The upper fitting located on the vacuum motor supplies engine vac uum to a diaphragm within the EGR valve for valve operation The lower fitting located on the base of the EGR valve is used to supply exhaust back pres sure to the EGR valve control 2 Disconnect the rubber hose at ...

Page 1192: ...r cleaner housing from the throt tle body 5 Using compressed air and using an air nozzle with a rubber tip apply approximately 50 psi of reg ulated shop air to the metal back pressure fitting on the EGR valve 6 By hand open the throttle to the wide open position Air SHOULD NOT BE HEARD emitting from the intake manifold while applying air pressure at the back pressure fitting 7 If air CAN BE HEARD ...

Page 1193: ...ectly replace the entire EGR valve and transducer together The EGR valve and electrical transducer are calibrated together REMOVAL The EGR valve and EGR transducer attach to the rear of the cylinder head Fig 7 1 Disconnect vacuum supply tube from EGR transducer solenoid 2 Disconnect electrical connector from solenoid 3 Remove EGR tube to EGR valve screws 4 Remove EGR valve mounting screws Remove E...

Page 1194: ...d 7 Attach electrical connector to solenoid EGR TUBE 2 0L The EGR tube attaches to the intake manifold ple num below the throttle body and EGR valve REMOVAL 1 Remove screws attaching EGR tube to intake manifold Fig 10 2 Remove EGR tube to EGR valve screws 3 Remove EGR tube Clean gasket surface on the EGR valve Wipe clean the grommet on the intake manifold INSTALLATION The rubber grommet that seals...

Page 1195: ... EGR valve REMOVAL 1 Remove screws attaching EGR tube to intake manifold Fig 12 2 Remove EGR tube to EGR valve screws Fig 13 3 Remove EGR tube Clean gasket surface on the EGR valve Wipe clean the grommet on the intake manifold INSTALLATION Use new gaskets on both ends of the EGR tube 1 Loosely install the EGR tube and fasteners 2 Tighten the EGR tube to intake manifold ple num screws to 11 N m 95 ...

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