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Chrysler 1998 Viper GTS, Owner'S Manual

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Chrysler 1998 Viper GTS Owner'S Manual Download Page 880

Summary of Contents for 1998 Viper GTS

Page 1: ...OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obli gations upon itself to install them on its products previously manufactured Litho in U S A Copyright 1997 Chrysler Co...

Page 2: ...group The first page of the group has a contents section that lists major topics within the group I f you are not sure which Group contains the infor mation you need look up the Component System i n the alphabetical index located i n the rear of this manual A Service Manual Comment form is included at the rear of this manual Use the form to provide Chrysler Corporation with your comments and sugge...

Page 3: ...N Electrically Heated Systems Power Door Locks 8 Q Vehicle Theft Security System 8 S Power Windows 8 0 Chime Buzzer Warning System 8 W Wiring Diagrams 9 Engine SiC Windshield Wipers and Washers 8 L Lamps 811 Passive Restraint Systems 1 j Exhaust System and Intake Manifold i 3 Frame and Bumpers j 4 Fuel System 1 9 Steering Transmission 2 2 Tires and Wheels 2 3 Body 2 4 Heating and Air Conditioning ...

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Page 5: ...Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta tion The formula to use the check digit is not released to the general public VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label is attached to the rear facing of the driver ...

Page 6: ...s and displays that are located on the instrument panel FASTENER IDENTIFICATION FASTENER IDENTIFICATION THREAD IDENTIFICATION SAE and metric bolt nut threads are not the same The difference is described i n the Thread Notation chart Fig 1 INCH METRIC GRADE CLASS IDENTIFICATION The SAE bolt strength grades range from grade 2 to grade 8 The higher the grade number the greater the bolt strength Ident...

Page 7: ...stomary SAE Grade Number 5 Bolt Head Markings 5 3 line These are a 1 SAE Grade 5 3 line Bolt Torque Grade 5 Bolt Bolt Torque Grade 8 Bolt Body Size Cast Iron Aluminum Cast Iron Aluminum N m ft lb N m ft lb N m Mb N m ft lb 1 4 20 9 7 8 6 15 11 12 9 28 12 9 9 7 18 13 14 10 5 16 18 20 15 16 12 30 22 24 18 24 23 17 19 14 33 24 25 19 3 8 16 40 30 25 20 55 40 40 30 24 40 30 35 25 60 45 45 35 7 16 14 60...

Page 8: ... bolt w washer hexagon bolt Hexagon head bolt Hexagon flange bolt w washer hexagon bolt Hexagon head bolt Hexagon head bolt 4 5 Bolt 6 head No 7 8 9 10 11 No mark No mark Two protruding lines Two protruding lines Three protruding Four l n l j P r o t r u d i n 9 lines 4T 51 61 71 8T 9T 10T 1 IT 4T 4T 51 61 71 81 Stud bolt Welded bolt No mark 4T Grooved 61 41 95IN 4 ...

Page 9: ...t 0 03 Cubic Meter 1 Yard 0 9 Meter 1 Cubic Yard 0 8 Cubic Meter 1 Mile 1 6 Kilometers J91IN 1 i E T i i C S Y S I E i W A R N I N G U S E MAY RESULT IN S O N A L INJURY O F A N I N C O R R E C T F A S T E N E R C O M P O N E N T D A M A G E O R P E R Figure art specifications and torque references i n this Service Manual are identified i n metric and SAE format During any maintenance or repair pr...

Page 10: ... 63 4333 7 9 4907 27 36 6071 47 63 7234 67 90 8398 87 117 9562 7 5 1629 27 19 9142 47 34 6654 67 49 4167 87 64 1679 8 10 8465 28 37 9629 48 65 0793 68 92 1956 88 119 3120 8 5 9005 28 20 6517 48 35 4030 68 50 1542 88 64 9545 9 12 2024 29 39 3187 49 66 4351 69 93 5514 89 120 6678 9 6 6381 29 21 3893 49 36 1405 69 50 8918 89 65 6430 10 13 5582 30 40 6745 50 67 7909 70 94 9073 90 122 0236 10 7 3756 30...

Page 11: ...5 160 12 17 5 175 13 5T 10 1 25 32 330 24 36 360 26 12 1 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 n o 8 12 120 9 8 1 25 25 260 19 28 290 21 71 10 1 25 52 530 38 58 590 43 12 1 25 95 97...

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Page 13: ...r any of the following conditions i t is considered severe service Extremely dusty areas 50 or more of vehicle operation in 32 C 90 F or higher temperatures Prolonged idling such as vehicle operation i n stop and go traffic Frequent short running periods Not allowing engine to warm to operating temperatures Police or taxi usage FUEL USAGE Viper engines require the use of unleaded fuel to reduce ex...

Page 14: ...AE ratings also apply to multiple grade gear lubricants I n addition A P I classification defines the lubricants usage LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI A l l approved products have the NLGI symbol Fig 3 on the label A t the bottom NLGI symbol is the usage and quality identification letters Wheel bearing lubricant is identified by the letter G Cha...

Page 15: ...re time and mileage are listed follow the interval that occurs first EMISSION CONTROL SYSTEM MAINTENANCE The scheduled emission maintenance listed i n b o l d type in the Maintenance Schedules must be done at the specified mileage to assure the continued proper operation of the emission control system These and all other maintenance services included i n the man ual should be done to provide the b...

Page 16: ... 144 000 KM OR AT 72 MONTHS Change engine oil and filter Lubricate front and rear ball joints and tie rod ends Change brake and clutch fluid Change rear axle fluid Inspect the brake linings Replace spark plugs Replace air cleaner elements Check and replace if necessary the P C V valve SR 97 500 MILES 156 000 KM OR AT 78 MONTHS Change engine oil and filter SCHEDULE B 3 000 MILES 5 000 KM Change eng...

Page 17: ...00 KM Change engine oil and filter Inspect the brake linings Change rear axle fluid 75 000 MILES 120 000 KM Change engine oil and filter Inspect the auto tensioning drive belt and replace i f necessary Lubricate front and rear ball joints and tie rod ends Inspect engine a i r cleaner elements and replace i f necessary 78 000 MILES 125 000 KM Change engine oil and filter 81 000 MILES 130 000 KM Cha...

Page 18: ...dicator i f equipped Low battery fluid level Generator drive belt condition and tension Fuel fumes or leakage correct i f necessary CAUTION If the c a u s e of starting problem on dis abled vehicle is severe damage to booster vehicle charging s y s t e m c a n result 2 When using another vehicle as a booster source turn off all accessories place gear selector i n park or neutral set park brake and...

Page 19: ... L E A K C A N R E S U L T DO NOT LIFT O R T O W V E H I C L E B Y F R O N T O R R E A R B U M P E R O R B U M P E R E N E R G Y A B S O R B E R UNITS D O NOT V E N T U R E U N D E R A L I F T E D V E H I C L E IF NOT S U P P O R T E D P R O P E R L Y ON S A F E T Y S T A N D S DO NOT A L L O W P A S S E N G E R S T O RIDE IN A T O W E D VEHI C L E CAUTION Do not damage brake lines exhaust system ...

Page 20: ...isture from the air inside of the vehicle Clean leather upholstery with Mopar Total Clean or equivalent and allow to dry overnight before closing vehicle I f desired dress the vinyl and leather interior components with Mopar Leather and Vinyl Protec tor or equivalent For deep cleaning and restoring oils to leather upholstery use a leather balm that is available at most leather goods retailers 10DY...

Page 21: ...oup 6 Manual Transmission and Clutch Start engine and verify that oil pressure gener ator charging rate and engine coolant temperature are i n the normal operating range Inspect engine and driveline for fluid leaks and abnormal noises correct any defects that are apparent Pump brake pedal several times to verify proper operation ...

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Page 23: ...n the knuckle is forward of the front wheel centerline The front steering knuckles are attached to the vehicle s steering rack by outer tie rod ends Fig 1 On the Viper rear suspension a knuckle similar to the front steering knuckle is used The rear knuckle is also attached to the upper and lower control arms using conventional style ball joints as i n the front The rear knuckle remains stationary ...

Page 24: ...1 Wiper Front Suspension TOE LINK SHOCK ROTOR A B S O R B E R STABILIZER BAR UPPER TOE STABILIZER CONTROL L I N K LOWER STABILIZER CONTROL BAR LINK PROPELLER K N U C K L E A R U SHAFT A X L E Fig 2 Wiper Rear Suspension LOWER CONTROL A R M KNUCKLE SHOCK A B S O R B E R ...

Page 25: ...s too high i t can be lowered by installing a reduced height upper spring seat on the shock absorber The required procedure to be used for checking and setting the vehicle curb height can be found under Service Procedures in this section of the service manual page C U R B HEIGHT CHECKING A N D SETTING 3 DESIGN HEIGHT SETTING 7 DESIGN HEIGHT During factory production the height the vehicle is at wh...

Page 26: ...front and rear wheels Fig 4 5 Check the distance from each of the front frame rails to the top surface of the Vehicle Height Checking Fixture Special Tool 6914 at front edge Fig 5 See Alignment Specifications at the end of this group for vehicle front curb height specification Fig 4 Height Checking Fixture Installation On Wheel M E A S U R E T H I S D I S T A N C E Fig 5 Measuring Vehicle Front Cu...

Page 27: ... removal and installation procedure N O T E After s h o c k a b s o r b e r s p r i n g s h a v e b e e n s h i m m e d o r r e d u c e d height s p r i n g seats h a v e been installed a n d s h o c k a b s o r b e r s have been installed b a c k o n t h e vehicle vehicle m u s t b e ballasted o r j a c k e d t o t h e specified vehicle d e s i g n height before t i g h t e n i n g a n d t o r q ...

Page 28: ...he rear shock absorber can be held i n the vise by clamping the shock absorber clevis i n the jaws of the vise Fig 9 80a38351 Fig 8 Front Shock Absorber Mounted In Vise 3 Compress shock absorber coil spring using Professional Services Equipment Spring Compressor GP 2020 C3 5 or an equivalent Fig 10 The spring compressor is to be equipped with an A 20 spring shoe on the top and bottom 4 Compress th...

Page 29: ... preferred infla tion pressure and adjust as necessary i f they are not N O T E When loosening the lower control arm mounting bolts be sure the alignment adjustment c a m s do not turn T h e c a m s must stay in their orig inal position s o the alignment of the vehicle is not affected 3 Loosen the mounting bolts for the following suspension components The mounting bolts must be loosened enough to ...

Page 30: ...ger compartment of the vehicle Fig 17 to lower the front of the vehicle to the specified design height D o not over ballast the vehicle I f vehicle is over ballasted the design h e i g h t w i l l be i n c o r r e c t a n d the special tool can be bent Fig 17 Correctly Ballasted Passenger Compartment 8 Add ballast weight as required to the trunk of the vehicle Fig 18 to lower the rear of the vehic...

Page 31: ...e vehicle must be released at the bottom of the jounce cycle This will ensure the vehicle s suspension will raise the vehicle to the correct curb height at the top of the jounce cycle 14 Check the vehicle s front curb height by mea suring the distance from the center of the front frame rail crossmember to top surface of Vehicle Height Checking Fixture at front edge Fig 19 See Alignment Specificati...

Page 32: ...e vehicle c h a n g e s height For this reason it is extremely important that all s u s pension specifications be c h e c k e d and adjusted with the vehicle at the correct height Alignment page W H E E L ALIGNMENT CHECK AND ADJUSTMENT 13 SPECIFICATIONS ALIGNMENT SPECIFICATIONS WITH VEHICLE AT CURB HEIGHT 19 specifications are required to be c h e c k e d with a vehicle at curb height the fuel tan...

Page 33: ...e Fig 1 CASTER Caster is the number of degrees of forward or rear ward tilt of the steering knuckles Forward tilt pro vides a negative caster angle Rearward tilt provides a positive caster angle Fig 1 Positive caster angle promotes directional stability This angle enables the front wheels to more easily return to the straight ahead position after turns WHEEL TOE POSITION Wheel toe position is the ...

Page 34: ... Replace If Required Replace Tires Replace Tie Rod End Replace Control Arm Bushing Replace Upper Control Arm Assembly Or Lower Ball Joint Tighten Upper Control Arm Pivot Bar Mounting Nuts To Specified Torque Verify Vehicle Alignment And Adjust To Preferred Specifications As Required Vehicle Instability Low Or Uneven Tire Air Pressure Loose Front Or Rear Wheel Bearings Broken Or Weak Coil Springs S...

Page 35: ...ts for wear and noise Check components for correct torque Refer to this group and group 19 Steering for additional informa tion 7 Inspect front and rear shock absorber assem blies for leaks or any sign of damage Jounce front and rear of vehicle to determine i f the shock absorb ers dampen vehicle motion properly 8 Inspect front and rear coil springs on shock absorbers for any signs of damage S E R...

Page 36: ...gle adjust ments CAMBER AND CASTER ANGLE ADJUSTMENT The camber and caster angles on the Viper are adjustable using cams located on the lower control arm bushing pivot bolts Correct camber and caster specifications are obtained by simultaneously rotat ing front and rear adjustment cams until lower con trol arm is correctly positioned C A U T I O N Prior t o a n y c a m b o l t r o t a t i o n l o c...

Page 37: ... inclinometers i n the other direc tion The inclinometers are now ready to be installed on the vehicle 10 Mount inclinometers to either both rear or both front Caster Angle Fixtures Special Tool 6916 Fig 7 or 6915 Fig 8 Make sure the inclinometer from the left side of the switch box is mounted to the left fixture and the inclinometer from the right side of the switch box is mounted to the right fi...

Page 38: ...TION The static wheel toe position should be the final adjustment made to the vehicle during the alignment procedure N O T E When setting front and rear wheel static toe position it is recommended to leave the engine running during the front wheel toe setting proce dure 1 Start the engine and turn wheels both ways before straightening and centering steering wheel Center steering wheel and retain w...

Page 39: ...n Adjustment 9 Remove caster angle inclinometers from front or rear knuckles DYNAMIC TOE PATTERN Dynamic toe pattern is the steering of the road wheels when there is vertical movement of the sus pension with no rotation of the steering wheel Dynamic toe pattern has been set at the factory when the vehicle was built I t will come into specifi cation when the specified camber caster and static toe s...

Page 40: ...t to production specifications This can be done using a trammel bar and does not require using an alignment rack When sport shims are replaced front wheel static toe must again be reset to production specifications This can also be done using a trammel bar and does not require using an alignment rack A l l other align ment settings will not be changed from production specifications N O T E T h e i...

Page 41: ...EHICLE T H E FOLLOWING ITEMS MUST BE CHECKED VEHICLE M U S T HAVE A FULL TANK O F FUEL ALL FLUIDS FILLED T O T H E PROPER LEVEL A L L ORIGINAL FACTORY SUPPLIED EQUIPMENT MUST ALSO BE IN T H E VEHICLE T H E VEHICLE MUST NOT HAVE A N Y LUGGAGE PASSENGERS OR ADDITIONAL WEIGHT TOE PER WHEEL SPECIFICATION WITH THE VEHICLE AT T H E SPECIFIED CURB H E I G H T 0 05 O R 0 04 0 10 OR 0 04 W H E N PERFORMING...

Page 42: ...omponents are not to be removed from the vehicle by striking them with a hammer or heating them page BALL JOINT SEAL BOOT UPPER 30 CONTROL ARM LOWER 32 CONTROL ARM UPPER 28 HUB BEARING 40 SHOCK ABSORBER 27 STABILIZER BAR 42 STABILIZER BAR ATTACHING LINK 43 STABILIZER BAR BUSHINGS 4 4 STEERING KNUCKLE 38 W H E E L MOUNTING STUD 4 4 D I S A S S E M B L Y AND A S S E M B L Y ISOLATOR BUSHINGS C O N T...

Page 43: ...l arm is mounted to the pivot bar using 2 rubber isolator bushings The lower control arm is mounted to the front lower frame rail of the vehicle using attaching brackets The lower control arm is mounted to the attaching brackets using rubber isolator bushings and 2 thru bolts SHOCK ABSORBER The Viper uses a combined shock absorber coil spring assembly Fig 2 on the front suspension The shock absorb...

Page 44: ...icle Attachment to the front steering knuckle is through a tapered stud which is part of the upper ball joint The upper control arm is mounted to the frame using a pivot bar which is isolated from the upper control arm by 2 rubber bushings Sport shims are located between the upper control arm pivot and the frame of the vehicle This shim is removable i f the vehicle is to be used for a vehicle spor...

Page 45: ...asket is used between the ball joint and the lower control arm Fig 7 STEERING KNUCKLE The steering knuckle Fig 8 used on the Viper is a one piece aluminum casting The steering knuckle has machined legs for attachment to upper control arm ball joint steering linkage and machined bosses for mounting the front brake calipers The steering knuckle includes the front hub and bearing assembly which is bo...

Page 46: ... isolator bushings Fig 11 3 Check for a broken or damaged coil spring lower seat on the shock absorber Fig 11 4 Check for a broken or damaged coil spring retainer Fig 11 5 Check to be sure the jounce bumper is on the shock absorber rod Also inspect the jounce bumper for signs of damage or deterioration 6 Check shock absorber for evidence of fluid run ning from the upper end of the fluid reservoir ...

Page 47: ...st the top of the tire While the force is being applied against the tire look for any movement between the u p p e r b a l l j o i n t and the steering knuckle 3 I f any lateral movement is evident at the upper ball joint the upper control arm will need to be replaced BALL JOINT WEAR INSPECTION LOWER All suspension ball joints used on the Viper operate with no free play Ball joint replacement is n...

Page 48: ...otation may indicate dirt intrusion or a failed hub bearing I f the hub bearing exhibits any of these conditions during diagnosis the hub bearing will require replacement the bearing is not service able Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement Moderate grease weapage from the hub bearing is considered normal and should not require replace m...

Page 49: ...pecifications This is required to maintain the vehicles correct curb height 1 Install shock absorber coil spring assembly on vehicle through center of upper control arm Fig 16 2 Install the shock absorber in mounting bracket on lower control arm Install the shock absorber attaching bolt Fig 14 D O N O T T I G H T E N B O L T A T T H I S T I M E 3 Using a pry bar carefully push down on the upper co...

Page 50: ...op of the shock absorber from the frame bracket 6 Remove shock absorber coil spring assembly from vehicle out through center of upper front control arm Fig 19 Fig 19 Remove install Shock Absorber 7 Remove the attaching bolt for the hub bearing mounting the brake flex hose bracket to the steer ing knuckle Fig 20 Fig 20 Brake Flex Hose Bracket 8 Remove the 2 bolts Fig 21 mounting the disc brake cali...

Page 51: ...cial Tool C 4150A to apply pressure against the upper ball joint stud This will separate the ball joint stud from the steering knuckle 14 Remove the 2 nuts attaching the upper con trol arm pivot bar to the upper frame rail Fig 25 Remove the upper control arm from the vehicle Fig 25 Upper Control Arm Mounting To Frame Rail INSTALL N O T E When installing the upper control arm be sure the sport s h ...

Page 52: ...er to frame bracket bolt Fig 18 D O N O T T I G H T E N B O L T A T T H I S T I M E 10 Install the wheel and tire 11 Tighten the wheel mounting stud nuts i n proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 122 N m 90 ft lbs 12 Lower the vehicle to ground from jack stands or hoist 13 Position vehicle on an alignmen...

Page 53: ...t on Remover Special Tool C 4150A to apply pressure against the upper ball joint stud This will separate the ball joint stud from the steer ing knuckle 10 Using a screw driver or other suitable tool pry the seal boot off of the ball joint Fig 31 11 Install NEW ball joint sealing boot on ball joint Install sealing boot as far as possible on the ball joint assembly 12 Position Receiving Cup Special ...

Page 54: ...repeat the tightening sequence to the full specified torque of 122 N m 90 ft lbs 20 Lower the vehicle to ground from jack stands or hoist CONTROL ARM LOWER R E M O V E 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting i n the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the front wheel...

Page 55: ...the ball joint grease seal and the bottom of the steering knuckle Fig 39 O C O T T E R L2ms PIN L O W E R C O N T R O L A R M B A L L J O I N T Fig 38 Bail Joint Attachment To Steering Knuckle TIE R O D E N D S P E C I A L T O O L 7X6983 B A L L JOINT S T A B I L I Z E R B A R ATTACHING LINK G R E A S E S E A L V L O W E R C O N T R O L A R M Fig 39 Special Tool 6983 Installed C A U T I O N Do not...

Page 56: ...trol arm Install the shock absorber to mounting bracket bolt and nut Fig 37 B U T DO N O T T I G H T E N A T T H I S T I M E 5 Install the stabilizer bar attaching link into mounting hole on the lower control arm Install the stabilizer bar attaching link nut Fig 35 Tighten the stabilizer bar attaching link nut to a torque of 17 N m 150 in lbs 6 Install brake rotor on hub bearing 7 Install the brak...

Page 57: ... K E CALIPER B R A K E FLEX Fig 43 Shock Absorber Lower Mounting Bolt And Nut 4 Remove the front hub bearing assembly attach ing bolt which mounts the brake hose bracket to the steering knuckle Fig 44 5 Remove the 2 bolts attaching the brake caliper to the steering knuckle Fig 45 Remove the brake caliper from the steering knuckle B R A K E N FLEX H O S E w B R A C K E T STEERING K N U C K L E LOWE...

Page 58: ...ACHING LINK G R E A S E SEAL V SPECIAL T O O L T 6 9 8 3 a T B A L L JOINT L O W E R C O N T R O L ARM 80a3834e Fig 49 Special Tool 6983 Installed CAUTION Do not strike the steering knuckle or apply heat to the steering knuckle when separating the ball joint stud from the steering knuckle 12 Install Puller Special Tool C 4150A on steer ing knuckle Fig 50 T h e ball bearing i n bolt of Special Tool...

Page 59: ...A T T H I S TIME 19 Install the stabilizer bar link into its mount ing holes on B O T H of the lower control arms Install the stabilizer bar link attaching nuts Fig 46 Tighten the stabilizer bar attaching link nuts to a torque of 17 N m 150 in lbs 20 Install brake rotor back on front hub bearing assembly 21 Install the disc brake caliper on the steering knuckle 22 Install the brake caliper attachi...

Page 60: ...2 bolts attaching the brake caliper to the steering knuckle Fig 55 Remove the brake caliper from the steering knuckle Fig 55 Brake Caliper Mounting Bolts 5 Support brake caliper by hanging i t from the upper control arm with mechanics wire Fig 56 Do not let brake caliper hang by brake flex hose 6 Remove the brake rotor from the hub bearing 7 Remove the cotter pin and attaching nut Fig 57 from the ...

Page 61: ... stud of the lower ball joint Also the Spacer Special Tool 6983 must be installed between the steering knuckle and Special Tool O4150 A as shown Fig 61 Fig 61 Tools Installed For Removing Ball Joint Fig 62 Special Tool C 4150A And Spacer Special Tool 6983 Correctly Positioned 12 Remove the cotter pin and nut Fig 63 attaching the upper ball joint stud to the steering knuckle CAUTION Do not strike t...

Page 62: ...en the hub bearing mounting bolt to a torque of 61 N m 45 ft lbs 12 Install the wheel and tire Tighten the wheel mounting stud nuts i n proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 122 N m 90 ft lbs 13 Lower the vehicle 14 Install the front and rear Vehicle Height Checking Fixtures Special Tools 6914 on the fro...

Page 63: ...and the steering knuckle T h e gasket is required to prevent galvanic corrosion between the hub bearing and the steering Fig 68 Hub Bearing Attaching Bolts knuckle T h e corrosion prevention gasket must be used when installing a hub bearing in the steering knuckle 1 Install a N E W corrosion prevention gasket Fig 69 on the hub bearing before installing i t i n the steering knuckle 2 Install the fr...

Page 64: ...k Mounting To Stabilizer Bar C A U T I O N U s e only Puller Special Tool MB991113 to remove the attaching link Fig 71 from the sta bilizer bar U s e of a pickle fork or other alternate tool will damage the seal and ball joints on attach ing link 4 Remove the stabilizer bar from the attaching link using Puller Special Tool MB991113 Fig 71 U P P E R C O N T R O L A R M STABILIZER BART ATTACHING LIN...

Page 65: ...HING LINK NOTE T h e s w a y bar links u s e d o n front s w a y bar of t h e Viper c a n be replaced w i t h o u t h a v i n g t o r e m o v e s w a y bar assembly from vehicle 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 vehicle 2 Remove...

Page 66: ...nut to a torque of 22 N m 200 in lbs 3 Install the wheel and tire assembly Tighten the wheel mounting stud nuts i n proper sequence until all nuts are torqued to half specification Repeat the tightening sequence to the full specified torque of 122 N m 90 ft lbs 4 Lower vehicle STABILIZER BAR f R E T A I N E R S T A B I L I Z E R BAR STABILIZER BAR RETAINER Fig 77 Stabilizer Bar Attachment To Frame...

Page 67: ...liper to the steering knuckle Fig 79 Remove the brake caliper from the steering knuckle Fig 79 Brake Caliper Mounting Bolts 5 Support the brake caliper by hanging i t from the upper control arm using mechanics wire Fig 80 Do not let brake caliper hang by brake flex hose 6 Remove the brake rotor from the hub bearing Fig 80 Stored Brake Caliper 7 Install a standard style wheel mounting nut on the wh...

Page 68: ...of t h e s h o c k absorber T h e s h o c k a b s o r b e r m u s t be c l a m p e d in t h e wise u s i n g t h e lower mounting e y e of t h e s h o c k absorber 1 Install the shock absorber vertically i n a vise using the lower isolator bushing of the shock absorb er Fig 83 2 Mark coil spring and shock absorber assembly right or left according to which side of the vehicle 80a38351 Fig 83 Shock ...

Page 69: ... of the spring must be installed down s o it fits the lower spring seat while the flat coil e n d of the spring points up s o it will properly fit against the spring upper seat 2 Install the coil spring on the shock absorber Be sure the end of the bottom coil is seated correctly on the spring seat of the shock absorber Fig 87 80a3cad8 Fig 87 Coil Spring Installation On Spring Seat W A R N I N G W ...

Page 70: ... control arm securely i n a vise Fig 89 U P P E R C O N T R O L A R M 80a3b14d Fig 89 Control Arm Mounted In Vise 3 Remove the nut and washer Fig 90 from each end of the upper control arm pivot bar 4 Install Remover Special Tool 6969 5 i n the mounting hole of the upper control arm pivot bar U P P E R C O N T R O L ARM Fig 90 Control Arm To Pivot Bar Mounting Nuts Fig 91 Special Tool 6969 5 is to ...

Page 71: ...the bolt of Remover Special Tool 6969 2 from turning while rotating the nut Fig 95 This will pull the pivot bar and the second isolator bushing out of the upper con trol arm at the same time SPECIAL U P P E R TOOL CONTROL A R M Fig 95 Tools Installed For Removal Of Second Bushing ASSEMBLY 1 Start the isolator bushing into the control arm by hand Be sure the bushing is installed straight 2 Position...

Page 72: ... 8 Install the nut and washer Fig 90 on each end of the upper control arm pivot bar Tighten the nuts just enough to hold the pivot bar in place Do not tighten or torque at this time This is to be done once the arm is back on the vehicle and the vehicle is set at design height 9 Install the upper control arm on the vehicle See Control A r m Upper i n the Removal And Installa tion section in this gr...

Page 73: ... 2 from turning while rotating the nut Fig 103 This will pull the isolator bushing out of the control arm 6 Transfer Remover s Special Tool 6969 1 and 6969 2 and Nut Special Tool 6969 4 to the remain ing isolator bushing in the lower control arm Fig 104 SPECIAL T O O L 6969 4 BOLT T H R U S T LOWER X J WASHER C O N T R O L A R M VISE J A W PROTECTIVE C A P S 80a3b1e4 Fig 104 Tool Installed For Sec...

Page 74: ...es The four wheel independent suspension alignment must be correct to assure proper road handling The frame and suspension components are calibrated at the assembly plant and should not require adjustment unless the vehicle has collision damage This section will cover procedures for correcting improper frame steering gear and rear toe link alignment that would affect the wheel toe pattern Before p...

Page 75: ...urn vehicle to design height 10 Lower front and rear of vehicle 25 mm 1 in below design height Measure and record front and rear wheel toe 11 Lower front and rear or vehicle 50 mm 2 in below design height Measure and record front and rear wheel toe NOTE It m a y n o t be p o s s i b l e t o obtain a w h e e l t o e reading w i t h t h e vehicle l o w e r e d 50 m m 2 in b e l o w d e s i g n If no...

Page 76: ...i i f i J f i 1 I 1 J t f r ii f i 1 i t 1 I X DESIGN A R C DESIGN A R C 1 LU o 5 0 M M 2 5 M M 2 5 M M 5 0 M M Q Z D 0 4 0 2 TOE IN 0 2 T O E O U T 4 I I I REAR I I I REAR I I I REAR 1 1 t V 1 V 1 1 I w __3 s Js DESIGN A R C s DESIGN A R C 0 4 0 2 TOE IN 0 2 0 4 T O E O U T ...

Page 77: ...ase on jounce I f a toe link is lowered the opposite would occur The toe pattern should arc from 0 30 toe in at 50 m m 2 in jounce to 0 00 toe at 50 mm 2 in rebound Refer to Rear Suspension for toe link ser vice procedures SUSPENSION INSTALLATION After toe pattern has been inspected or adjusted perform the following procedures Install the coil over shock assemblies Refer to Front or Rear Suspensio...

Page 78: ...2 56 SUSPENSION S R S P E C I A L T O O L S Remover Tie Rod End MB 991113 Or MB 990635 Remover Ball Joint C 4150A ...

Page 79: ...S R S P E C I A L T O O L S Continued SUSPENSION 2 Installer Isolator Bushing 6758 Installer Ball Joint Seal Boot MB 990891 ...

Page 80: ...hicle due to the vehicle hav ing a fully independent front a n d rear s u s p e n s i o n The vehicle c a n 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 s u s p e n s i o n components will occur C A U T I O N U s e care when removing the s u s p e n s i o n components from this vehicle T h e s u s p e n s i o n...

Page 81: ...ring The upper seat is removable for shock and spring service COIL SPRING The coil springs used on this vehicle Fig 8 are rated separately for the front and the rear of the vehicle I f a coil s p r i n g requires replacement be sure t h a t the s p r i n g needing replacement is replaced with a spring meeting the correct load rating and spring rate for the position on the vehicle it will be used T...

Page 82: ...are replaceable components of the upper control arm assembly C01TR0L A l l LOWER The rear lower control arm used on the Viper is a high strength aluminum casting Fig 5 The lower control arm is attached to the rear lower frame rail Fig 4 Upper Control Arm using cammed through bolts i n rubber isolator bush ings The rubber isolator bushings are pressed into the lower control arm The cam bolts are us...

Page 83: ...aluminum casting The knuckle has machined legs for attachment to the upper control arm ball joint toe link and machined bosses for mounting the rear disc brake caliper The lower ball joint is press fit into the knuckle and is not serviced as a separate component The rear knuckle contains the rear hub and bearing assembly which is bolted to the knuckle and is a serviceable component of the assembly...

Page 84: ...pair the remaining portion of the toe link The outer tie rod portion can be replaced without removing the toe link assembly from the vehicle OUTER TIE ROD TOE PATTERN ADJUSTMENT HOLE JAM NUT FLEX JOINT BOOT MOUNTING HOLE 9202 270 Fig 11 Rear Toe Link Assembly D I A G N O S I S A N D T E S T I N G SHOCK ABSORBER AND COIL SPRING 1 Inspect for a damaged or broken coil spring Fig 12 2 Inspect for dama...

Page 85: ...repair on the upper ball joint assembly Refer to Upper Control Arm in Removal And Installation i n this section of the service manual for the upper control arm replace ment procedure UPPER BALL JOINT WEAR INSPECTION PROCEDURE CAUTION When raising the vehicle by the lower control arm using a floor jack care must be used s o control arm does not get nicked gouged deformed or damaged in any w a y by ...

Page 86: ... crack i n the knuckle do not attempt to repair the crack by weld ing or any other method The knuckle must be replaced HUB BEARING The hub bearing is designed for the life of the vehi cle and requires no type of periodic maintenance The following procedure may be used for diagnosing the condition of the hub bearing With the wheel disc brake caliper and brake rotor removed rotate the wheel hub Any ...

Page 87: ...ter of upper control arm Fig 16 Shock Absorber Upper Mounting Bolt 2 Install the shock absorber clevis on the mount ing bracket on the lower control arm Install the shock absorber to bracket bolt Fig 15 D O N O T T I G H T E N B O L T A T T H I S T I M E C A U T I O N When the s h o c k absorbers are installed o n this vehicle t h e vehicle must be at design height before either s h o c k absorber...

Page 88: ...ckle 7 Remove the driveshaft from the side of the vehicle requiring removal of the upper control arm See group 3 Differential And Drive Line i n this ser vice manual for the drive shaft removal procedure 8 Remove the nut and washer Fig 19 mounting the yoke to the hub bearing H U B AND BEARING ASSEMBLY WASHER 9202 252 Fig 19 Yoke To Huh and Bearing Assembly Attaching 9 The yoke should be removable ...

Page 89: ...upper ball joint Fig 25 Hold hex portion of Puller Special Tool 6961 while turning the bolt to apply pressure against the stud of the upper ball joint Continue applying pressure until the upper ball joint stud sep arates from the steering knuckle T O E LINK S P E C I A L T O O L 6961 HUB BEARING LOWER C O N T R O L ARM S P E C I A L TOOL 6962 R O T O R 4 Fig 25 Tools Installed For Removing Upper B...

Page 90: ...oup of the service manual for the installation procedure 7 Install the wheel and tire Tighten the wheel mounting stud nuts i n proper sequence until all nuts are torqued to half specification Repeat the tighten ing sequence to the full specified torque of 122 N m 90 ft lbs 8 Lower the vehicle to the ground so the full weight of the vehicle is supported by the tires 9 Apply the parking brake to kee...

Page 91: ...ation section i n this group of the service manual for the procedure N O T E Axle shaft removal is required to allow the u s e of the special tool required to remove the upper control arm ball joint from the knuckle 7 Remove the driveshaft from the side of the vehicle requiring replacement of the upper ball joint seal boot See group 3 Differential And Drive Line i n this service manual for the dri...

Page 92: ... apply heat to the knuckle when removing the ball joint stud from the knuckle Apply force to the upper ball joint stud using only the special tools until the stud s e p a rates from the knuckle 14 Install Puller Special Tool C 3564 A between Adapter Special Tool 6962 and the stud of the upper ball joint Fig 37 Hold hex portion of Puller Special Tool C 3564 A while turning the threaded portion to a...

Page 93: ... Drive Line i n this service manual for the required drivehaft installation proce dure 22 Install the shock absorber Do not tighten the shock absorber upper or lower mounting bolt at this time Refer to Shock Absorber in the Removal And Installation section in this group of the service manual for the installation procedure 23 Install the wheel and tire Tighten the wheel mounting stud nuts in proper...

Page 94: ...tud Fig 42 CAUTION T h e n u t m u s t b e p o s i t i o n e d at t h e e n d of the stabilizer bar a t t a c h i n g link s t u d w h e n r e m o v i n g it from t h e lower c o n t r o l a r m T h i s will prevent t h e e n d of t h e s t u d f r o m b e i n g d a m a g e d w h e n r e m o v ing it f r o m t h e lower c o n t r o l a r m 4 Remove the stabilizer bar attaching link from lower cont...

Page 95: ...hock absorber clevis on mounting bracket of lower control arm Install the shock absorber mounting bolt and nut Fig 44 DO N O T T I G H T E N T H E M O U N T I N G B O L T A T T H I S T I M E 4 Install the stabilizer bar attaching link into the lower control arm Install the stabilizer bar attaching link mounting nut Fig 42 Tighten the stabilizer bar mounting nut to a torque of 22 N m 200 in lbs 5 I...

Page 96: ...the e n d of the stabilizer bar attaching link stud when removing it from the lower control arm This will prevent the end of the stud from being damaged when remov ing it from the lower control arm 4 Remove the stabilizer bar attaching link from lower control arm using the following procedure Position the attaching link nut at the end of attach ing link stud Fig 49 Position a center punch i n the ...

Page 97: ...er bar attaching link attaching nut Fig 48 Tighten the stabilizer bar attaching link nut to a torque of 22 N m 200 in lbs 14 Install the wheel and tire assembly Tighten the wheel mounting stud nuts i n proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 122 N m 90 ft lbs 15 Lower the vehicle to the ground 16 Position ...

Page 98: ...t the rear of the hub bearing by hand I f yoke will not come out of the hub bearing pulling on i t by hand use Puller Special Tool WASHER YOKE 9202 252 Fig 57 Yoke To Hub and Bearing Assembly Attaching CT 1003 Fig 58 to push the yoke out of the hub bearing ROTOR B R A K E CALIPER SPECIAL TOOL CT 1003 Fig 58 Removing Yoke From Hub Bearing 10 Remove the driveshaft yoke from the back side of the rear...

Page 99: ... C O N T R O L T O O L ARM 6962 K N U C K L E 80a1c3ff Fig 63 Special Tool 6962 Installed On Knuckle using only the special tools until the stud s e p a rates from the knuckle 17 Install Puller Special Tool 6961 between Adapter Special Tool 6962 and the stud of the upper ball joint Fig 64 Hold hex portion of Puller Special Tool 6961 while turning the bolt to apply pressure against the stud of the ...

Page 100: ... lower ball joints 2 Install the toe link tie rod end on the knuckle Install the castle nut on the stud of the tie rod end Tighten the castle nut to a torque of 52 N m 38 ft lbs Install cotter pin i n stud of tie rod end Fig 65 3 Tighten the lower ball joint castle nut to a torque of 183 N m 135 ft lbs Install cotter pin i n lower ball joint Fig 67 4 Tighten the upper ball joint castle nut to a to...

Page 101: ...return to its curb height 21 Correctly measure the vehicles curb height See Curb Height Setting Procedure i n this group of the service manual for the required procedure 22 Check and adjust the vehicle s rear static wheel toe position Refer to procedure i n Alignment Measurements And Adjustments i n this group of the service manual for static wheel toe position adjust ment HUB BEARING memowE 1 Rem...

Page 102: ...e Install Outboard Brake Shoe 9 Slide inboard brake shoe toward rear of vehicle until the brake shoe clears the top of the caliper Fig 74 Then lift brake shoe up and out between caliper and inboard side of rotor Fig 74 Fig 74 Remove Install Inboard Brake Shoe 10 Remove the brake rotor from the rear hub bearing while sliding i t out from rear brake caliper assembly 11 Remove the hub nut Fig 75 moun...

Page 103: ...corro sion between the hub bearing and the steering knuckle The c o r r o s i o n p r e v e n t i o n gasket m u s t be used when installing a h u b b e a r i n g in the k n u c k l e 1 Install a NEW corrosion prevention gasket Fig 79 on the hub bearing before installing it in the knuckle C O R R O S I O N G A S K E T H U B B E A R I N G Fig 79 Corrosion Gasket 2 Install rear hub bearing on yoke a...

Page 104: ... C A U S I N G P O S S I B L E INJURY 11 Install the anti rattle spring into the brake caliper Fig 72 Be sure anti rattle clip is positioned correctly between brake shoes and caliper Fig 72 Install brake shoe retaining pin into caliper assembly from the outboard side Fig 72 until small end of retaining pin is i n inboard side of caliper assembly When installing retaining pin be sure it passes thro...

Page 105: ...his vehicle 2 Remove rear wheel and tire 3 Remove the nuts one each side of vehicle attaching the stabilizer bar attaching links to the stabilizer bar Fig 85 Fig 85 Stabilizer Bar Link Attachment To Stabilizer Bar C A U T I O N Do not u s e a pickle fork or other similar type tool to separate s w a y bar link from lower c o n trol arm bracket or s w a y bar U s e of this type of tool may damage se...

Page 106: ...ng links used on the rear stabilizer bar of the Viper can be replaced without removing the stabilizer bar from the vehicle REMOVE 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting i n the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the rear wheel and tire from the side of the vehicle ...

Page 107: ...lbs 4 Lower vehicle STABILIZER BAR BUSHINGS R E M O V E 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting i n the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the bolts securing the stabilizer bar bushing retainers to the frame Fig 92 MOUNTING B O L T S AND N U T S STABILIZER BAR ATTAC...

Page 108: ...ter mounting loca tion Fig 96 is u s e d for adjusting the rear wheel Fig 95 Toe Link Tie Rod End Removal dynamic toe pattern The dynamic rear wheel toe pattern is adjusted by installing an adjustment shim at this location B e sure when removing the outer mounting bolt and nut the adjustment shim is not discarded Also note the side of the vehicle and the position the adjustment shim w a s installe...

Page 109: ...m flanges and measure vehicle curb height See Curb Height Setting Procedure i n this group of the service manual 10 Once proper curb height has been verified check and adjust the vehicle s rear static wheel toe position Refer to procedure i n Wheel Alignment i n this group of the service manual for the static rear wheel toe position adjustment WHEEL MOUNTING STUD The hub bearing assembly does not ...

Page 110: ...ard side of brake rotor Fig 101 Fig 101 Remove Install Inboard Brake Shoe 7 Remove the brake rotor from the rear hub bearing while sliding it out from rear brake caliper assembly 8 Install a lug nut on the wheel stud to be removed from the hub bearing assembly Fig 102 so threads on stud are even with end of lug nut Rotate hub so stud requiring removal is aligned with notch cast into front of steer...

Page 111: ...caliper by slid ing i t i n between the rotor and the caliper Fig 100 WARNING HOLD A N T I R A T T L E S P R I N G IN P L A C E W H I L E INSTALLING B R A K E PAD RETAINING PIN INTO C A L I P E R A S S E M B L Y IF A N T I R A T T L E S P R I N G IS NOT H E L D IN P L A C E DURING INSTAL LATION O F RETAINING PIN A N T I R A T T L E S P R I N G MAY F L Y O F F C A L I P E R C A U S I N G P O S S I ...

Page 112: ...bsorber Fig 107 1 Install the shock absorber vertically i n a vise by mounting clevis of the shock absorber i n the vise s jaws Fig 107 Fig 107 Shock Absorber Correctly Mounted In Vise 2 Mark 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 W H E N C O M...

Page 113: ... r e a d s o f t h e s h o c k a b s o r b e r a n d t h e s h o c k absorber m u s t b e t i g h t e n e d to t h e required t o r q u e s p e c i f i c a t i o n 1 Coat the threads on the shock absorber with Locktite 225 or an equivalent Thread the shock absorber into the clevis by hand as far as possible Using Adapter Special Tool 6925 Fig I l l tighten the shock absorber to a torque of 68 N m ...

Page 114: ... Removal And Installation section i n this group of the service man ual for the procedure C A U T I O N T h e j a w s of the vise must be covered with protective c a p s to protect the surface of the control arm from damage 2 Clamp the upper control arm securely i n a vise Fig 114 3 Assemble Remover Special Tool 6969 2 bolt nut and thrust washer as shown Fig 115 4 Install the assembled pieces of R...

Page 115: ...HERE SPECIAL TOOL L 44221 Fig 119 Isolator Bushing Correctly Installed 4 Install the second isolator bushing into the con trol arm 5 Position the control arm in the arbor press Support the control arm using Receiver Special Tool L 4422 1 Press the isolator bushing into the lower control arm using Driver Special Tool 6758 Fig 118 6 Press the isolator bushing into the control arm until the flange of...

Page 116: ...emover Special Tool 6969 1 and Nut Special Tool 6969 4 to the remaining isolator bushing i n lower control arm Fig 123 S P E C I A L T O O L 6969 4 S P E C I A L T O O L 6969 2 NUT Fig 123 Tool Installed For Second Bushing Removal 7 Remove the second isolator bushing from con trol arm using the following procedure Hold the bolt of Remover Special Tool 6969 2 from turning while rotating the nut Fig...

Page 117: ...nd Installa tion section i n this group of the service manual for the procedure D E S C R I P T I O N T O R Q U E L o w e r C o n t r o l A r m Ball Joint Stud Castle Nut 183 N m 135 ft lbs Adjustment Cam Bolt And Nut 101 N m 75 ft lbs U p p e r C o n t r o l A r m Ball Joint Stud Castle Nut 115 N m 85 ft lbs Isolator Bushing To Frame Pivot Bolts 95 N m 70 ft lbs H u b A n d B e a r i n g Assembly...

Page 118: ...2 l i SUSPENSE SR SPECIAL TOOLS Continued Remover Ball Joint C 4150A Adapter Rear Shock Absorber 6925 Retractor Brake Caliper Piston 6366 Installer isolator Bushing 6758 ...

Page 119: ...S R SUSPENSION 2 97 S P E C I A L T O O L S Continued Installer Ball Joint Seal Boot MB 990891 ...

Page 120: ......

Page 121: ... The axle is equipped with a special high strength ring and pinion Should service ever be required use only parts that are equal i n quality to the original parts Failure to do so could result i n premature axle failure page FINAL ASSEMBLY 17 OUTPUT SHAFT 7 OUTPUT SHAFT BEARINGS 8 OUTPUT SHAFT SEALS 7 PINION CROSSMEMBER 4 PINION GEAR 14 PINION SHAFT SEAL 5 REAR AXLE 4 RING GEAR 13 D I S A S S E M ...

Page 122: ... the noise to one area of the vehicle Many noises that are reported as coming from the differential may actually originate at other sources For example tires road surfaces wheel bearings engine transmission exhaust or vehicle body Differential noises are nor mally divided into two categories gear noise or bear ing noise A thorough and careful inspection should be completed to determine the actual ...

Page 123: ...he result of insufficient or incorrect lubricant i n the carrier housing Abnormal gear noise can be noticed easily because it produces a cycling tone This tone will be pro nounced within a given speed range The noise can occur during one or more of the following drive con ditions Drive Road load Float Coast Abnormal gear noise usually tends to peak within a narrow vehicle speed range or ranges I t...

Page 124: ...ear exhaust clamps 7 Remove center exhaust grommet 8 Remove two rear exhaust grommets 9 Remove rear exhaust pipes 10 Remove axle mounting bolts 11 Lower axle assembly from vehicle INSTALLATION CAUTION T h e inner axle shaft strap bolts incorpo rate a Loctite patch for retention on initial installa tion T h e s e s c r e w s must be replaced with new pieces or cleaned and Loctite thread locker reap...

Page 125: ... A and slide hammer to remove the pinion shaft seal Fig 2 SPECIAL TOOL 7794A PINION SEAL J9402 59X Fig 2 Seal Removal INSTALLATION 1 Apply a light coating of gear lubricant on the lip of pinion seal Install seal with Installer C 3972 A and Handle C 4171 Fig 3 2 Align the installation reference marks and position the yoke on the pinion gear 3 Install yoke on the pinion gear with Installer C 3718 an...

Page 126: ...d the pinion yoke remove the pinion nut and washer 8 Use Remover C 452 and Wrench C 3281 to remove the pinion yoke 9 Use Remover 7794 A and slide hammer to remove the pinion shaft seal Fig 5 10 Remove the front pinion bearing using a pair of suitable pick tools to pull the bearing straight off the pinion gear shaft It may be necessary to lightly tap the end of the pinion gear with a rawhide or rub...

Page 127: ...re reinstalled in the s a m e position that they were in when they were removed INSTALLATION C A U T I O N Output shafts are not interchangeable from side to side O n e shaft is longer than the other 1 Install new output shaft 2 Place the C clip i n position with snap ring pli ers Expand the snap ring while pushing the output shaft back into the differential Be sure that the snap ring is seated pr...

Page 128: ...MOVAL 1 Raise vehicle on hoist 2 Drain differential fluid from differential 3 Remove rear axle assembly from the vehicle 4 Remove rear cover 5 Using a pair of 90 degree angled snap ring pli ers expand the snap ring while pulling outward on the output shaft The snap ring cannot be removed without pulling on the output shaft CAUTION Tag snap rings a s they are being removed This will ensure that the...

Page 129: ...PUT OUTPUT H O U S I N G BEARING C U P OUTER PINION BEARING OIL PINION SLINGER SEAL DIFFERENTIAL C O V E R C O V E R BOLT CARRIER RING G E A R PINION GEAR Fig 8 Differential Assembly 38 m PINION m 31 N U T W A S H E R PINION J Y O K E z o LUBE T A G Z OUTPUT HI SHAFT BEARING P OUTPUT 3 SHAFT C a BEARING CUP INNER PINION BEARING 9403 15 ...

Page 130: ...aps slightly deform when torqued in place R e u s e of the straps may result in reduced clamp load o n the universal joint cap 4 Remove rear cover plate 5 Remove output shaft snap rings Fig 9 Then pull out output shafts from carrier SNAP RING PLIERS RING GEAR 9303 1 Fig 9 Snap Ring Removal C A U T I O N Tag s n a p rings a s they are being removed T h i s will ensure that they are reinstalled in t...

Page 131: ...ifferential case out of the differential carrier Fig 13 9303 5 Fig 13 Differential Case Removal 12 Remove spreader from carrier INSTALLATION 1 Install differential carrier spreader Special Tool W 129 B The use of adapters Kent Moore J 24385 20 will be required when using spreader Fig 14 CARRIER SPREADER 9303 3 Fig 14 Differential Carrier Spreader 2 Install dial indicator onto case Fig 15 DIAL INDI...

Page 132: ...e CAUTION The drive shaft and axle shaft strap bolts incorporate a Loctite patch for retention on initial installation These s c r e w s must be replaced with new pieces or cleaned and Loctite thread locker reapplied whenever they are removed CAUTION Replace both drive shaft and axle shaft universal joint straps whenever they are removed The straps slightly deform when torqued in place R e u s e o...

Page 133: ...i n a matched set Do not replace the ring gear without replacing the pinion gear REMOWAL 1 Remove rear axle assembly 2 Remove differential from axle housing 3 Place differential case in a suitable vise w i t h soft metal jaw protectors Fig 21 4 Remove bolts holding ring gear to differential case 5 Using a soft hammer drive ring gear from dif ferential case Fig 21 Fig 20 Install Differential Side B...

Page 134: ...e remove the pinion yoke nut and washer 4 Using Remover C 452 and Wrench C 3281 remove the pinion yoke from pinion shaft 5 Remove the pinion gear from housing Catch the pinion with your hand to prevent i t from falling and being damaged 6 Remove the pinion seal with a slide hammer or pry out with bar 7 Remove oil slinger i f equipped and the front pinion bearing 8 Remove the front pinion bearing c...

Page 135: ...e surface of bearing cup Install the pinion front bearing cup with Installer D 129 and Handle C 4171 3 Install pinion front bearing and oil slinger i f equipped Apply a light coating of gear lubricant on the lip of pinion seal Install seal with Installer C 3972 A and Handle C 4171 Fig 28 S P E C I A L S P E C I A L T O O L T O O L C 4171 C 3 9 7 2 A 80a7e2be Fig 28 Pinion Seal Installation N O T E...

Page 136: ...ed preload torque If preload torque is exceeded a new collapsible spacer must be installed T h e torque s e q u e n c e will have to be repeated N O T E If the spacer requires more than 280 ft lbs torque to crush the collapsible spacer is defective 10 Using yoke holder 6958 a short length of 1 in pipe and a torque wrench set at 380 N m 280 ft lbs crush collapsible spacer until bearing end play is ...

Page 137: ...O N Overfilling the differential c a n result in lubricant foaming and overheating 3 Refill the differential housing with gear lubri cant Refer to the Lubricant Specifications section of this group for the gear lubricant requirements 4 Install the fill hole plug D I S A S S E M B L Y A N D A S S E M B L Y TRAC LOK DIFFERENTIAL NOTE T h e Trac Lok differential is serviced a s an assembly No compone...

Page 138: ...Fig 35 Threaded Adapter installation 6 Tighten forcing screw tool 122 N m 90 ft lbs maximum to compress Belleville springs i n clutch packs Fig 36 Fig 36 Tighten Belleville Spring Compressor Tool 7 Using an appropriate size feeler gauge remove thrust washers from behind the pinion gears Fig 37 Fig 37 Remove Pinion Gear Thrust Washer 8 Insert Turning Bar C 4487 4 i n case Fig 38 9 Loosen the Forcin...

Page 139: ...ates i n correct order during removal ASSEMBLY Lubricate each component with gear lubricant before assembly 1 Assemble the clutch discs into packs and secure disc packs with retaining clips Fig 40 DIFFERENTIAL AND DRIVELINE 3 19 CLUTCH PACK RETAINER J8903 50 Fig 40 Clutch Disc Pack 2 Position assembled clutch disc packs on the side gear hubs 3 Install clutch pack and side gear i n the ring gear si...

Page 140: ...steam clean the differential components Wash bearings with solvent and towel dry or dry with compressed air DO NOT spin bearings with compressed air C u p and bearing must be replaced as matched sets only Clean axle shaft tubes and oil channels i n housing Inspect for Smooth appearance with no broken dented sur faces on the bearing rollers or the roller contact sur faces Bearing cups must not be d...

Page 141: ...ence in the depth variances Refer to the Depth Variance charts Note where Old and New Pinion Marking columns intersect Intersecting figure represents plus or minus amount needed Note the etched number on the face of the drive pin ion gear 1 2 0 1 2 etc The numbers represent thousands of an inch deviation from the standard I f the number is negative add that value to the required thickness of the d...

Page 142: ... position in axle housing so dial probe and scooter block are flush against the surface of the pinion height block Hold scooter block i n place and zero the dial indica tor face to the pointer Tighten dial indicator face lock screw 7 With scooter block still i n position against the pinion height block slowly slide the dial indicator probe over the edge of the pinion height block Observe how many ...

Page 143: ...t that amount for the pinion gear side of the differential Fig 49 Differential shim measurements are performed with axle spreader W 129 B removed S H I M SELECTION N O T E It is difficult to salvage the differential side bearings during the removal procedure Install replacement bearings if necessary 1 Remove differential side bearings from differ ential case 2 Remove factory installed shims from d...

Page 144: ...in 0 05 mm from the dial indicator reading to compensate for backlash between ring and pinion gears This total is the thickness shim required to achieve proper backlash 26 Subtract the backlash shim thickness from the total preload shim thickness The remainder is the shim thickness required on the pinion side of the axle housing 27 Rotate dial indicator out of the way on guide stud 28 Remove diffe...

Page 145: ...ydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth 2 Wrap twist and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion gear This will provide a more distinct contact pattern 3 Using a boxed end wrench on a ring gear bolt Rotate the differential case one complete revolution in both directions while a load is being applied fro...

Page 146: ...ENTERED O N THE COAST SIDE OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BAC...

Page 147: ...Cap Bolts 88 N m 65 ft lbs Diff Cover Bolts 47 N m 35 ft lbs Diff Mount Bolts 135 N m 100 ft lbs Pin Crossm At Bracket 135 N m 100 ft lbs Pin Crossm At Axle 135 N m 100 ft lbs S P E C I A L T O O L S DIFFERENTIAL TOOLS Adapter Set 6956 Holder 6958 Installer 6448 Driver 6573 Holder 6963 A Pinion Depth Set 6955 Remover 7794 A ...

Page 148: ...3 28 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS Continued SR Starting Point Shims 8107 Adapters C 293 18 Gauge Block 8144 Adapters C 293 48 Plug C 293 3 Guide Pin C 3288 B ...

Page 149: ...S R S P E C I A L T O O L S Continued DIFFERENTIAL AND DRIVELINE 3 29 Handle C 4171 ...

Page 150: ...3 30 DIFFERENTIAL AND DRIVELINE S P E C I A L T O O L S Continued Spreader W 129 B ...

Page 151: ...re safe operation The specified torque must always be applied when tightening any fasteners CAUTION Do not allow the propeller shaft to drop or hang from universal joint during removal S u s pend the shaft to the vehicles underside with wire to prevent damage to the universal joints CAUTION It is very important to protect the machined external surface of the slip yoke from damage after propeller s...

Page 152: ...g balance weights broken welds and bent areas I f the pro peller shaft is found with any of these condi tions the shaft must be replaced Ensure the universal joints are not worn are prop erly installed and correctly aligned w i t h the shaft Check the universal joint clamp screws torque Check universal joint angles 1 Raise and support the vehicle 2 Remove the wheels tires Install the wheel lug nut...

Page 153: ...T INFORMATION When two shafts intersect at any common univer sal joint the bend that is formed is called the work ing angle The larger the working angle the larger the amount of acceleration and deceleration of the joint For every revolution there are two accelera tions and deceleration of the universal joint This speeding up and slowing down of the joint must be cancelled to produce a smooth powe...

Page 154: ...1 5 degrees of each other J 23498A J9216 12 Fig 6 Rear Angle Measurement REMOVAL AND INSTALLATION PROPELLER SHAFT The Dodge Viper uses a tubular aluminum propel ler shaft to transfer engine torque from the transmis sion to the rear axle Universal joints are used to connect the propeller shaft to the transmission REMOVAL 1 Remove universal joint bolts and straps at rear of propeller shaft 2 Slide p...

Page 155: ...NSTALLATION 1 To install reverse removal procedure SINGLE CARDAN UNIVERSAL JOINT REPLACEMENT It is recommended that the Viper use only genuine Mopar universal joints listed for this vehicle Only Mopar universal joints can withstand the high torque impact loading that the Viper is capable of producing The typical aftermarket u joint is not designed to meet the extreme impact loads associated with t...

Page 156: ...e marks aligned 6 Install the propeller shaft CAUTION The drive shaft and axle shaft strap bolts incorporate a Loctite patch for retention on initial installation T h e s e s c r e w s must be replaced with new pieces or cleaned and Loctite thread locker applied whenever they are removed CAUTION Replace both drive shaft and axle shaft universal joint straps whenever they are removed The straps sli...

Page 157: ...posing fixed front calipers Single piston floating rear calipers Semi Metallic non asbestos front and rear brake linings Differential valve with a brake warning switch combination valve Combined master cylinder and brake fluid reser voir Vacuum actuated power brake booster The hydraulic brake system Fig 1 and Fig 2 on the Viper is a vertically split type braking system The Viper is hydraulically s...

Page 158: ...Fig 1 Hydraulically Split Braking System 39 ...

Page 159: ... on the vehicle The caliper halves are hydraulically connected using an external hydraulic brake fluid tube between the 2 caliper halves The caliper assembly must have each half individually bled by the bleeder screw located at the top of each caliper half Size And Tube Routing The caliper assembly is bolted directly to the steer ing knuckle using 2 bolts going through 2 machined mounting bosses T...

Page 160: ...ND A S S E M B L Y BRAKE FLUID RESERVOIR 62 FRONT DISC BRAKE CALIPER 63 REAR DISC BRAKE CALIPER BUSHINGS 69 C L E A N I N G AND INSPECTION CHASSIS TUBES AND HOSES 71 FRONT DISC BRAKES 70 REAR DISC BRAKES 71 A D J U S T M E N T S PARK BRAKE ADJUSTMENT 72 STOP LAMP SWITCH 71 S P E C I F I C A T I O N S BRAKE ACTUATING SYSTEM 73 BRAKE FASTENER TORQUE SPECIFICATION 73 BRAKE FLUID 72 BRAKE SYSTEM C O M...

Page 161: ... applies the brake pads to the brake rotor This is done using the Viper s 4 piston opposed fixed caliper Fig 2 The caliper body is cast aluminum and is 2 individual pieces which are held together by 4 attaching bolts Fig 2 Each caliper half houses 2 pistons 38 and 42 mm i n size The pistons are mounted i n the cali per halves so that the 38 mm piston is on the bottom and the 42 mm is on top when t...

Page 162: ...g Assembly Fig 5 Brake Rotor Fig 5 Shoe and Lining Assemblies Fig 5 Brake Caliper Assembly Fig 4 1 The rear disc brake components serve the same purpose for the rear brakes as the front brake com ponents do for the front disc brakes The rear disc brake caliper Fig 5 used on the Viper is a unique dual function design I t serves as the normal wheel brake caliper and also serves as the vehicle parkin...

Page 163: ...are secured to the drive disc and seat i n cam ramps machined i n the driven disc In normal braking mode the rear calipers operate the same as the front calipers The brake shoes are applied by fluid pressure acting against the caliper piston and bore surfaces When parking brakes are applied the park brake cables pull the park brake operating levers forward This rotates the discs and worm shaft cau...

Page 164: ...g the hydraulic portion of the vehicle brake system The combination valve serves 3 functions i n the brake hydraulic system I t directs diverts the brake fluid from the master cylinder to the front and rear brakes I t controls the hydraulic pressure to the rear brakes through the proportioning function of the valve and monitors for pressure loss i n the system through the pressure differential val...

Page 165: ... the Red Brake Warn ing Light can be checked each time the ignition switch is turned to the start position or the parking brake is set CHASSIS TUBES AND HOSES The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid devel oped by the master cylinder to the wheel brakes of the vehicle The chassis tubes are steel with a corro sion resistant coating applied to ...

Page 166: ...sed the vacuum booster input rod moves forward This movement opens and closes valves Fig 13 i n the vacuum booster creating a vacuum on one side of a dia phragm and allowing atmospheric pressure to enter on the other This difference i n pressure forces the output rod of the vacuum booster out against the pri mary piston of the master cylinder As the pistons i n the master cylinder move forward thi...

Page 167: ... Each pedal and its eccentric cam is connected through linkage to a second lever controlling that pedals vehicle function Fig 18 and Fig 19 H Y D R A U L I C C L U T C H M A S T E R C Y L I N D E R A T T A C H E S H E R E P E D A L B R A C K E T P E D A L ACTUATOR Fig 16 Adjustable Pedal System CLUTCH LINKAGE ECCENTRIC C A M CLUTCH PEDAL 8 0 a c d 0 0 f Fig 18 Clutch Pedal Cam And Linkage This adj...

Page 168: ...inated by completing the ground circuit either through the park brake switch the brake warning lamp switch or the igni tion switch when it is i n the crank position The brake warning switch is located i n the combi nation valve The purpose of the switch is to indicate to the driver that there is a loss of pressure i n the hydraulic system of the vehicle s brakes This loss of hydraulic pressure can...

Page 169: ...Travel 6 X NO 0 Pedal Goes To The Floor 6 X Stop Light On Without Brakes 3 All Brakes Drag 5 Rear Brakes Drag 2 NO NO Grabby Brakes 0 X Spongy Brake Pedal X NO Premature Rear Brake Lockup 4 NO NO 0 Excessive Pedal Effort 1 0 Rough Engine Idle NO 0 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 ...

Page 170: ...H ADJUSTMENT YES APPLY BRAKES A N D RELEASE TURN FRONT WHEEL BY HAND OPEN BLEEDER SCREW A N D TURN WHEEL AGAIN IF WHEELTURNS HYDRAULIC PRESSURE WAS TRAPPED IN SYSTEM N O CONTAMINATED FLUID SEALS SWOLLEN LOW ENGINE VACUUM SEE 6 Z L BINDING CALIPER PINS OR BUSHINGS REPLACE BUSHINGS BLOCKED OR PINCHED LINE OR HOSE OR BOOSTER VACUUM HOSE BOOSTER RUNOUT MAXIMUM ASSIST POINT IS OFTEN MISTAKEN FOR THE PE...

Page 171: ...EDAL VERY SLOWLY GRADUALLY INCREASE PEDAL EFFORT WHILE WATCHING WARNING LIGHT INCREASE TO VERY HIGH EFFORT BOTH FEET HOLD HEAVY EFFORT FOR 30 SECONDS RELEASE PEDAL SLOWLY WARNING LIGHT COMES O N WITH MODERATE PEDAL EFFORT AND STAYS O N WHEN PEDAL IS RELEASED MASTER CYLINDER HAS INTERNAL LEAK REPLACE OR REBUILD AND BLEED BRAKES JL WARNING LIGHT COMES O N ONLY AFTER HOLDING HEAVY PEDAL EFFORT FOR SE...

Page 172: ...E VACUUM SUPPLY HOSE TO THE BOOSTER IF VACUUM DROP EXCEEDS 1 0 INCH Hg IN O N E MINUTE REPEAT PROCEDURE TO CONFIRM READINGS LEAKAGE SHOULD BE LESS THAN 1 0 INCH Hg IN O N E MINUTE YES NO NO LEAK TEST BRAKES APPLIED YES BOOSTER IS DEFECTIVE AND SHOULD BE REPLACED IF VACUUM SUPPLY IS BELOW 12 INCHES REPLACE OR REPAIR VACUUM HOSE AND VACUUM FITTINGS ALSO TUNE OR REPAIR ENGINE AS REQUIRED APPLY LIGHT ...

Page 173: ...O U T G R E A S E R A I L S CHART 5 VEHICLE ROAD TEST 80abfe8f CHART 5 r WHEEL BRAKES ROAD TEST CAR PULL TO RIGHT OR LEFT I CHECK FOR FROZEN PISTONS CONTAMINATED LINING PINCHED LINES LEAKING SEALS PLUGGED BANJO BOLT I REFER TO GROUP 2 SUSPENSION EXCESSIVE PEDAL EFFORT EARLY mm L0QC UP INSPECT FRONT AND REAR BRAKES FOR FROZEN PISTONS CONTAMINATED LINING GLAZED LINING t LOW ENGINE VACUUM L _ LINING ...

Page 174: ...on can be caused by extreme heat and abuse of the brakes ROIOFt RUNOUT AND THICKNESS WARlATiOl On vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor The hub and rotor runouts are separable To measure runout on the vehicle remove the wheel and reinstall the lug nuts tightening the rotor to the hub Mount Dial Indicator Special Tool C 3339 wit...

Page 175: ...ts of the rotor should be made i n conjunction with runout Measure the thickness of the rotor at 12 equal points with a micrometer at a radius approximately 25 m m 1 inch from the edge of the rotor Fig 24 I f thickness measurements vary by more than 0 013 m m 0 0005 inch the rotor should be removed and resurfaced or a new rotor installed I f cracks or burned spots are evident the rotor must be rep...

Page 176: ...acturer recommends brake fluid conforming to DOT 4 specifications If DOT 4 brake fluid is not available DOT 3 brake fluid is fully compatible with DOT 4 and can be substi tuted in its a b s e n c e S e e Brake Bleeding in this section of the service manual for required bleeding procedures to be u s e d for replacing hydraulic brake f l u i d Indications of fluid contamination in the brake sys tem ...

Page 177: ...the brake system will result Fig 26 Master Cylinder Fluid Level BRAKE BLEEDING PRESSURE BLEEDING Before removing the master cylinder cover wipe i t clean to prevent dirt and other foreign matter from dropping into the master cylinder CAUTION U s e Bleeder Tank Special Tool C 3496 B with Fluid Reservoir Pressure Bleeding Adapter Special Tool 6643 Fig 27 to pressurize the brake s y s t e m for bleed...

Page 178: ...rake fluid Fig 30 6 Repeat steps 2 and 3 above on outboard half of the caliper assembly Then close the bleeder screw on the outboard caliper OUTBOARD BLEEDER SCREW I N B O A R D BLEEDER SCREW OUTBOARD CALIPER HALF NBOARD CALIPER HALF U FRONT BRAKE CALIPER ASSEMBLY 9305 206 Fig 30 Bleeding Outboard Caliper Half 7 Remove hose from bleeder screw and torque the bleeder screw to 10 N m 88 in lbs 8 Agai...

Page 179: ...ened 2 Then open the bleeder screw at least 1 full turn When the bleeder screw opens the brake pedal will drop all the way to the floor 3 Release the brake pedal only after the bleeder screw is closed 4 Repeat steps 1 through 3 four or five times at each bleeder screw This should pass a sufficient amount of fluid to expel all the trapped air from the brake system Be sure to monitor the fluid level...

Page 180: ...END REMOVED FROM INSIDE OF TUBING IS OF TUBING SQUARE BEFORE HYDRAULIC BRAKE LINE TUBING 9205 175 Fig 34 Brake Fluid Tube Preparation For Flaring with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing i n place Place gauge Form A on edge over end of brake tubing Push tubing through jaws until end of tubing contacts the recessed notch in gauge matching the t...

Page 181: ...place Fig 39 3 Position the tubing in the jaws of the Flaring Tool so that it is flush with the top surface of the flaring tool bar assembly Fig 39 4 Install the correct size adaptor for the brake tubing being flared on the feed screw of the yoke assembly Center the yoke and adapter over the end of the tubing Apply lubricant to the adapter area that contacts brake tubing Making sure the adapter pi...

Page 182: ...the above steps 6 Using a file or grinder remove the pad mate rial i n the A B C triangular areas on each end of the shoe pad 8 m m R E E ONLY 1 3 r n m S H O E PLATE 5mm Fig 41 Rear Brake Shoe 7 Repeat the procedure to the remaining rear brake pads 8 Reinstall the brake shoes on the vehicle BRAKE SHOE BURNISHING When new brake shoe and lining assemblies are installed on the vehicle this procedure...

Page 183: ...RAKE ROTOR TURNING PROCEDURES Any servicing of the brake rotor requires extreme care to keep the rotor within service tolerances thus ensuring proper brake action BRAKE ROTOR REFINISHING INF0R1AT10I I f the surface of the rotor is deeply scored warped or there is a complaint of brake roughness or pulsa tion the rotor should be resurfaced or refaced Fig 42 or Fig 43 The Brake Rotor Refinishing Limi...

Page 184: ...ism to per form the adjuster lockout procedure the console must be removed LOCKING A U T O M A T I C ADJUSTER 1 Disconnect the negative cable from the neg ative terminal on the battery Be sure the battery cable is isolated from the battery 2 Remove the 6 attaching screws on each side mounting the driver and passenger side lower fascias to the instrument panel Fig 45 Then remove both fascia panels ...

Page 185: ... 48 Wiring Harness Connections To Switches Fig 49 Console Attaching Screws sliding the park brake lever boot off the park brake lever This is required to access the shift knob attach ing nut Fig 50 Hold shift knob from turning and loosen the attaching nut Fig 50 When nut is loose turn shift knob off shifter 8 Remove the console from the tunnel of the floor pan with the shift knob and shifter boot ...

Page 186: ...r 2 Operate park brake mechanism several times to ensure proper operation Also be sure that the rear park brake cables are not binding when released 3 Install the console assembly and park brake lever boot over park brake lever Then install console assembly on tunnel area of vehicle with the rear of the console positioned as high as possible 4 Thread shift knob onto shifter until their is adequate...

Page 187: ...O N A L S A F E T Y AND H E A L T H ADMINISTRATION OSHA AND T H E ENVIRONMENTAL P R O T E C T I O N A G E N C Y EPA F O R HANDLING AND D I S P O S A L O F P R O D U C T S CONTAINING A S B E S T O S Grease or other foreign material must be kept off the brake shoes and rotor Handling of the brake shoes should be done in such a way as to avoid nicking the brake shoe fric tion material I f inspection ...

Page 188: ... o e n s u r e t h e proper p e r f o r m a n c e of t h e replacement brake s h o e Follow t h e p r o c e d u r e at t h e e n d of this installation p r o c e d u r e to correctly b u r n i s h t h e n e w brake s h o e s Before new brake shoes can be installed i n the cal iper the caliper pistons must be pushed back into the bores of the caliper Push the pistons back into the bores of the cali...

Page 189: ...a pin punch and a hammer drive the upper and lower support pins for the brake shoes into the caliper from the inboard side Fig 61 Sup port pins must be installed into the caliper until the support pin retaining rings are locked into caliper assembly 7 After the support pins are fully installed into the caliper assembly Inspect assembled caliper to be sure the spring clip is centered i n the openin...

Page 190: ...S A S B E S T O S I S AND O R C A N C E R N E V E R C L E A N B R A K E C O M P O N E N T S B Y USING C O M P R E S S E D AIR U S E ONLY A VACUUM C L E A N E R S P E C I F I C A L L Y D E S I G N E D F O R T H E R E M O V A L O F B R A K E DUST IF A VACUUM C L E A N E R IS N O T A V A I L A B L E C L E A N B R A K E P A R T S USING ONLY W A T E R D A M P E N E D S H O P T O W E L S D O N O T C R E...

Page 191: ... caliper before caliper is installed on vehicle caliper pistons must be fully seated into caliper bores for installing caliper assembly over braking disc Caliper pistons can be pushed back into bores using your fin gers and squarely pushing on face of pistons 1 Install the disc brake caliper by carefully slid ing i t down over the rotor Be carefully so that the brake shoe friction material does no...

Page 192: ...f the service manual for the correct procedure if NEW brake shoe assemblies were installed FRONT DISC BRAKE ROTOR B E H O V E 1 Raise vehicle on jackstands or centered on a hoist See Hoisting i n the Lubrication and Mainte nance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the tire and wheel from the vehicle 3 Remove the attaching bolt for the fron...

Page 193: ...L D U S T AND DIRT S U S P E C T E D O F CONTAINING A S B E S T O S F I B E R S USING ONLY S E A L E D AIRTIGHT B A G S OR C O N T A I N E R S F O L L O W A L L R E C O M M E N D E D S A F E T Y P R A C T I C E S P R E S C R I B E D B Y T H E O C C U P A T I O N A L S A F E T Y AND H E A L T H ADMINISTRATION OSHA AND T H E ENVIRONMENTAL P R O T E C T I O N A G E N C Y EPA FOR HANDLING AND D I S P ...

Page 194: ...hicle without requiring removal of the disc brake caliper from the knuckle SR Fig 73 Remove lnstail inboard Brake Shoe 7 Place a chalk mark Fig 74 on the rotor and a wheel mounting stud This is so the rotor can be replaced i n the same location on hub Then remove the rotor from the hub by sliding it off wheel mount ing studs and removing i t out from the disc brake caliper Fig 74 DISC 9305 213 Fig...

Page 195: ...rent seating m e t h o d is required T h e only acceptable m e t h o d is b y rotating the p i s t o n b a c k into t h e bore with Spanner Special Tool 63S6 Fig 76 as d e s c r i b e d below A n y other seating m e t h o d will d a m a g e t h e self adjuster m e c h a n i s m SPECIAL TOOL 9105 131 Fig 76 Caliper Piston Reseating Bottoming Tool 1 Reseat bottom the caliper piston i n the bore as f...

Page 196: ...bly retaining pin into caliper assembly Be sure i t is fully seated and retaining pin snap ring is seated i n out board side of caliper Fig 79 Refer to Fig 80 to ensure that the rear caliper brake shoes and compo nents are correctly installed 12 Install the wheel and tire assemblies Tighten the wheel mounting stud nuts i n proper sequence until all nuts are torqued to half specifica tion Then repe...

Page 197: ...r foreign material must be kept off the brake shoes caliper and rotor during any service procedures that are performed on the vehicle Care must be used when handling the rotor and caliper to avoid damage to the rotor and brake shoe friction material During removal and installation of a wheel and tire use care not to strike the caliper NOTE Before vehicle is moved after any brake service work be su...

Page 198: ... Position the replacement caliper assembly over the rotor and align with caliper mounting bosses on knuckle assembly Fig 85 Brakeshoe Removal Installation 3 Lubricate the caliper slide pins and bushings with silicone lubricant 4 Align the lower caliper slide pin bushing with lower caliper mounting hole in knuckle Install the caliper to knuckle slide pin bolt Fig 84 do not torque at this time only ...

Page 199: ... manual for the correct procedure if N E W brake shoe assemblies were installed REAR DISC BRAKE ROTOR N O T E T h e rear braking disc c a n be removed from the vehicle without requiring removal of the disc brake caliper a s s e m b l y from the knuckle REMOVE 1 Raise vehicle on jackstands or centered on a hoist See Hoisting i n the Lubrication and Mainte nance section of this manual for the requir...

Page 200: ...ff wheel mount ing studs and removing it out from the disc brake caliper Fig 92 Fig 91 Remove install Inboard Brake Shoe BRAKING DISC 9305 213 Fig 92 Rotor Removal Installation INSTALL If the original brake shoe assembly friction mate rial is worn to a thickness requiring replacement new brake shoe assemblies should be installed See procedure listed below to correctly reseat piston in caliper bore...

Page 201: ...9 Install the outboard brake shoe assembly into the caliper Fig 90 WARNING HOLD ANTI RATTLE S P R I N G IN P L A C E W H I L E INSTALLING B R A K E S H O E RETAINING PIN INTO C A L I P E R IF ANTI RATTLE S P R I N G IS NOT H E L D IN P L A C E DURING INSTALLATION O F RETAINING PIN ANTI RATTLE S P R I N G MAY F L Y OFF CALIPER CAUSING POSSIBLE INJURY 10 Install anti rattle clip into caliper Be sure...

Page 202: ...rect and properly made Use new copper seal washers on all connections using 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 caliper assembly Then bolt the hose bracket to the front hub and bearing attaching bolt allowing the bracket to position the hose to...

Page 203: ... DIFFERENTIAL ASSEMBLY VALVE FRAME ASSEMBLY FRAME ASSEMBLY VIEW IN DIRECTION OF ARROW X SCREW RT REAR BRAKE TUBE R P FRAME ASSEMBLY Y CLIP SCREW FRAME CROSSMEMBER LEFT FRONT BRAKE TUBE RIGHT FRONT BRAKE TUBE VIEW IN DIRECTION OF ARROW W PARK BRAKE CABLE BRAKE A N D FUEL LINE ASSEMBLY VIEW IN DIRECTION OF ARROW S FRAME ASSEMBLY CROSSMEMBER SCREW RIGHT FRONT BRAKE TUBE 1 FRAME ASSEMBLY SCREW LEFT RE...

Page 204: ...to a torque of 28 N m 250 in lbs 5 Connect brake tubes to master cylinder pri mary and secondary ports Tighten fittings to a torque of 17 N m 145 in lbs WACUUi BOOSTER EEmOWE 1 Remove the primary and secondary brake tubes from master cylinder Fig 100 2 Remove 2 nuts Fig 100 attaching the master cylinder assembly to the vacuum booster Fig 100 Master Cylinder Brake Tubes And Mounting 3 Carefully sli...

Page 205: ...alent coat the bearing surface of the brake pedal pin Fig 102 4 Connect power brake booster input rod to brake pedal pin and install a NEW retainer clip Fig 102 Use o n l y a n e w r e t a i n e r clip D O N O T USE the o l d clip 5 Check stop light operation 6 Connect the vacuum hose from the intake manifold onto the check valve located on the vacuum booster Fig 101 7 Position master cylinder ove...

Page 206: ...edal s y s t e m m u s t n o t be d i s a s s e m b l e d If d i s a s s e m b l e d t h e pedals will n o longer b e correctly synchronized w h i c h will require the replacement o f t h e entire adjustable pedal s y s t e m 1 Remove the ground cable from negative ter minal on the battery Be sure to isolate the ground cable from the negative terminal on the battery 2 Remove fuse box cover Fig 104...

Page 207: ...on the retaining clip and the pin on the clutch linkage 9305 210 Fig 109 Brake Pedal Retaining Clip Rotate the blade of the screwdriver enough so that the center tang on the retaining clip can pass over end of pin Then push the retaining clip sideways and pull i t off of the pin 14 Remove the actuation rod for the hydraulic clutch master cylinder from the pin 15 Remove the clutch master cylinder f...

Page 208: ...the dash panel 21 Remove powertrain control module from dash panel with wiring harness attached and lay on lower dash panel Fig 114 22 Remove bolt Fig 114 mounting adjustable pedal assembly bracket to side of dash panel 23 Remove the 4 nuts Fig 115 mounting the pedal assembly to the dash panel The nuts used to SR Fig 113 Powertrain Control Module Attachment Fig 114 Pedal Assembly Bracket Mounting ...

Page 209: ...ounting bracket to the toe box area of the dash panel 6 Tighten the clutch brake pedal mounting bracket attaching bolts and nuts i n the following sequence and torques listed below Tighten clutch brake pedal mounting bracket to vacuum booster nuts Fig 115 to a torque of 29 N m 250 in lbs Tighten clutch brake pedal mounting bracket to dash panel upper mounting bolts Fig 116 to a torque of 20 N m 18...

Page 210: ...the fuse box Fig 105 behind the knee blocker panel 22 Install the knee blocker panel Fig 106 on the lower instrument panel Install and securely tighten the knee blocker panel attaching screws 23 Install and securely tighten the fuse box mounting screws 24 Install the adjustable pedal actuator on the knee blocker panel Fig 105 Install the star washer and nut attaching Fig 105 the pedal actuator to ...

Page 211: ...ake lever up as far as i t will go Lift console assembly up from the rear while sliding park brake boot off park brake lever to gain access to shift knob attaching nut Fig 123 Hold shift knob with one hand and loosen nut Fig 123 When nut is loose turn shift knob off shifter 8 Lift the console assembly with shift knob and boot attached off the tunnel BRAKES I i i Fig 121 Wiring Harness Connections ...

Page 212: ...DPOINT 9405 212 Fig 124 Locking Out Adjuster Mechanism 10 Remove both rear park brake cables from the equalizer Fig 125 11 Remove the wiring harness connector Fig 126 from the ground switch on the park brake lever 12 Remove the 3 nuts attaching the park brake lever to the tunnel panel Fig 126 13 Remove the park brake mechanism from the tunnel panel INSTALL 1 Install park brake mechanism over mount...

Page 213: ...ment panel and console assem bly 11 Install ash tray assembly into opening i n bezel Install the ash tray assembly to console assem bly attaching screw and securely tighten Fig 119 12 Install driver side and passenger side lower instrument panel fascias Fig 118 Install the 6 screws attaching each lower fascia to the instrument panel and tunnel of vehicle 13 Reconnect the negative battery cable to ...

Page 214: ...emove the screw Fig 129 mounting the ash tray to the console Then remove the ash tray from the console CONSOLE ASSEMBLY 9205 373 Fig 129 Ash Tray Mounting Screw 4 Remove the bezel for the heater air condition ing controls and radio Fig 130 from instrument panel Remove bezel by carefully prying i t out of the PRY AROUND EDGE 9205 374 Fig 130 Radio And Air Conditioning Controls Bezel 5 Disconnect th...

Page 215: ...ckout the parking brake lever self adjuster mechanism Fig 134 using the following procedure Insert a 7 32 inch alien wrench into the alien head screw of the lockout device Fig 134 Pull on the equalizer output cable to wind up adjuster spring requires greater than 30 pounds effort Con tinue until self adjuster lockout pawl is positioned about midway on the self adjuster sector Fig 134 Rotate the lo...

Page 216: ...ame crossmember and rear frame rail Fig 127 S R 15 Remove the tie strap Fig 138 attaching the park brake cable to rear knuckle Fig 138 Park Brake Cable Attachment To Knuckle 16 Remove the park brake cable from the park brake operating lever on the caliper Fig 139 Slide park brake cable out of cable mounting hole in cali per assembly Fig 139 Park Brake Cable Attachment To Caliper INSTALL 1 Insert e...

Page 217: ...ead shift knob onto shifter until their is adequate thread engagement and knob is correctly positioned Securely tighten the shift knob to shifter retaining j a m nut Fig 133 12 Lower the console assembly onto the tunnel until correctly positioned in the vehicle Align the console assembly screw holes with holes i n tunnel and install and securely tighten the 2 screws Fig 132 13 Connect wiring harne...

Page 218: ...ke fluid reservoir 3 Using a syringe or other equivalent tool empty all brake fluid from the reservoir 4 Using a pin punch Fig 141 remove the 2 roll pins retaining the brake fluid reservoir to the master cylinder CAP RESERVOIR MASTER _ CYLINDER 9205 388 Fig 141 Remove Replace Reservoir Retaining Pins N O T E Do not pry off with tool damage to reservoir may result 5 While pulling upward on the rese...

Page 219: ...disassembled and assembled one at a time rather then doing the entire caliper at once The service pro cedures which follow list the entire disassembly and assembly of each caliper half Refer to the procedure for which caliper half that service is being performed on C A U T I O N E x c e s s i v e v i s e p r e s s u r e c a n c a u s e dis t o r t i o n of t h e caliper m o u n t i n g b o s s e s...

Page 220: ...ng Brake Tube Fitting 7 Lay a shop towel over the inboard caliper half to protect the finish Fig 149 Place an appropriate size tool such as the seal installer Fig 149 or an ISO STYLE TUBE NUT ISO STYLE TUBING FLARE PLUG OFF THIS END OF TUBING 9205 334 Fig 148 Fabricated Plug equivalent tool over one caliper piston and dust boot Fig 149 Using a C clamp Fig 149 hold the seal installer or equivalent ...

Page 221: ... using a lint free towel Inspect all surfaces of the piston for any signs of corrosion or scoring I f the corrosion on the piston can not be removed using the solvent or the piston is scored the piston must be replaced Do n o t sand the p i s t o n to remove the corrosion o r scoring Fig 152 Caliper Piston Dust Boot 12 Remove the piston seal from the inboard cal iper piston bore using a sharpened ...

Page 222: ... of the caliper 17 Squarely install the piston into the top por tion of caliper bore Then using your fingers evenly apply pressure to the piston pressing i t into the bore of the caliper until i t is past the piston seal and bot tomed i n bore Fig 155 18 Position the dust boot i n the counterbore of the caliper bore Using your fingers install the dust boot into the counterbore until i t is flush w...

Page 223: ... small screw driver The screwdriver is to be inserted between the outer edge of the dust boot and the counter bore of the caliper Fig 158 Do not insert the screw driver into the piston bore of the caliper to remove the dust boot piston bore scoring can occur 5 Remove the dust boot from the piston Fig 159 Then clean the piston using alcohol or other suitable solvent and wipe dry Inspect all surface...

Page 224: ...roove i n caliper bore until the seal is properly seated Fig 161 C CLAMP 9205 340 Fig 161 Piston S e a Installed in Caliper 10 Lightly coat the inside of the new dust boot with fresh clean brake fluid Then install the new dust boot on the caliper piston Fig 159 Be sure the dust boot is completely seated i n the retaining groove of the piston C A U T I O N Force must be applied to the piston uni fo...

Page 225: ...rake shoe assemblies were installed REAR DISC BRAKE CALIPER BUSHINGS 1 Remove the disc brake caliper from the rear knuckle Refer to Rear Disc Brake Caliper in the Removal And Installation Section i n this group of the service manual for the procedure 2 Discard the original upper and lower slide pin bolts used to mount the caliper to the knuckle 3 Remove the brake shoe assemblies from the caliper a...

Page 226: ...nt Disc Brake Shoes i n the Removal and Installation section i n this group of the service manual for the removal proce dure The brake shoe friction material thickness is to be measured at the thinnest point of the friction mate rial The minimum front brake shoe assembly friction material thickness Fig 167 is 2 5 m m 100 in When the brake shoe friction material reaches the minimum thickness the fr...

Page 227: ... bushing are a replaceable component of the rear caliper Refer to Rear Disc Brake Caliper Bushings i n the Disassem bly And Assembly section i n this group of the service manual for the service procedure to install new guide pin bushings and dust boots I f a leak or other mal function is noticed during the inspection of the rear disc brake caliper the caliper will require replace ment The rear dis...

Page 228: ...er u s e reclaimed brake fluid or fluid from an container which h a s been left open An open container will absorb moisture from the air and contaminate the fluid C A U T I O N Never u s e any type of a petroleum b a s e d fluid in the brake hydraulic system U s e of s u c h type fluids will result in seal damage of the vehicle brake hydraulic s y s t e m causing a failure of the vehicle brake sys...

Page 229: ...n Proportioning And Warning Lamp Switch Latching B R A K E P E D A L Pedal Ratio 3 48 1 BRAKE FASTENER TORQUE SPECIFICATION D E S C R I P T I O N T O R Q U E B R A K E T U B E S Tube Nuts To Fittings And Components 16 N m 145 in lbs B R A K E HOSE Front And Rear Caliper Banjo Bolt 31 N m 23 ft lbs Chassis Brake Hose Frame Bracket Bolt 20 N m 175 in lbs Chassis Brake Tube Routing Clip Bolts 10 N m ...

Page 230: ...5 74 BRAKES S P E C I A L T O O L S BASE BRAKE SYSTEM Adapter Brake Pressure Bleeder 6643 S R Retractor Brake Caliper Piston Dial Indicator C 3339 ...

Page 231: ... and is a sealed unit The release bearing is operated by a hydraulic slave cylinder located behind the release bearing The slave cylinder has no serviceable components I f slave cylinder failure occurs i t must be replaced as a unit The clutch disc has cushion springs in the disc hub The clutch disc facing is riveted to this hub The facing is made from non asbestoses materials The clutch cover pre...

Page 232: ...ated on the clutch master cylinder actuation rod Fig 1 The clutch master cylinder must be removed to replace this switch The switch is held i n place by a plastic retaining clip There is no adjustment on the clutch position switch I f the switch is not operating correctly i t must be replaced as an assembly I I 1 tt CLUTCH TO RESERVOIR TO CLUTCH CLUTCH CLUTCH ACTUATION POSITION HYDRAULIC CLUTCH RO...

Page 233: ...proper clutch release FLYWHEEL MISALIGNMENT Common causes of flywheel misalignment are Incorrect bolt tightening Mounting the flywheel on a dirty crankshaft flange Improper seating on the crankshaft flange shoul der Heat warpage Loose flywheel to crankshaft bolts The flywheel should be replaced i f warped or over heated D o n o t machine the face o f the f l y w h e e l to correct a w a r p e d o ...

Page 234: ...utch pedal to stroke it Do not apply too much force as this will cause the uncoupled male coupling to blow out 3 I f the pedal feels hard i n a relatively short dis tance air is present i n the clutch slave cylinder 4 I f the pedal feels spongy air is present i n the master cylinder assembly COMPLETE SYSTEM BLEED 1 Remove the reservoir cap and diaphragm tak ing care not to damage the diaphragm Fig...

Page 235: ...s Ridges 3 Replace parts as required 4 Clean the flywheel face with crocus cloth or fine sandpaper 400 600 grade then wipe the sur face with mineral spirits I f the surface is severely scored heat checked or warped replace the flywheel CAUTION Do not machine the flywheel face If fly wheel surface is bad the flywheel must be replaced 5 I f the flywheel is to be replaced or removed apply thread seal...

Page 236: ...ove procedure CLUTCH MASTER CYLINDER REMOVAL 1 Remove master cylinder actuation rod to clutch pedal clip 2 Disconnect clutch pedal position switch connec tor 3 Remove mounting screws on clutch fluid reser voir 4 Disconnect hydraulic line quick connector located at clutch bell housing Use special tool 6638 to separate quick connector CAUTION Do not allow brake fluid to come in con tact with painted...

Page 237: ...e vehicle 4 Reconnect the clutch switch connector 5 Check clutch position switch operation CLEANING A N D INSPECTION CLEANING PRECAUTIONS Condensation from steam vapors tend to accumu late on the internal clutch mechanism when the vehi cle is steam cleaned The facing of the disc will absorb moisture and the force exerted by the clutch cover pressure plate will bond the facings to fly wheel and or ...

Page 238: ...with crocus cloth or fine sandpaper 400 600 grade then wipe the sur D E S C R I P T I O N T O R Q U E face with mineral spirits I f the surface is severely Clutch Bleed Screw 18 N m 156 in lbs scored heat checked or warped replace the flywheel Clutch Cover Bolts 30 N m 270 in lbs Clutch Release Bearing 20 N m 200 in lbs Flywheel Bolts 74 N m 55 ft lbs ...

Page 239: ...PACITY 21 TORQUE 21 SPECIAL TOOLS COOLING 21 G E N E R A L I N F O R M A T I O N COOLING SYSTEM The cooling system consists of an engine cooling module thermostat coolant and a water pump to circulate the coolant The engine cooling module may consist of a radiator electric fan and motor assembly shroud radiator pressure cap coolant recovery sys tem CRS hoses and clamps When Engine is cold Thermost...

Page 240: ...o cover minor leaks and evaporation or boiling losses Fig 2 Refer to Coolant Level Check Service and Coolant Pressure Cap sections for operation and service COOLING FAN MODULE The fan module Fig 3 is a combination of one fan mounted i n a one piece shroud The fan system improves engine cooling i n hot weather and severe driving conditions while reducing fan noise and power consumption T h e fan mo...

Page 241: ...scape to the overflow hose There is also a gasket in the cap to seal to the top of the filler neck MAIN SPRING GASKET RETAINER OVERFLOW NIPPLE PLASTIC SWIVEL TOP RUBBER SEALS FILLER NECK DEAERATION PRESSURE BOTTLE SPRING LOAD VALVE 9407 48 Fig 5 Pressure Cap ENGINE OIL COOLER Oil cooler is a external oil to air type mounted i n front of the radiator Fig 6 Braided reinforced oil lines feed the oil ...

Page 242: ...minated drain flush and replace with fresh properly mixed solution CAUTION Do n o t u s e well water o r s u s p e c t water s u p p l y in c o o l i n g s y s t e m A 50 50 ethylene g l y c o l a n d distilled water m i x is r e c o m m e n d e d FtADiAIO HOSES AID CLA1PS WARNING IF V E H I C L E H A S B E E N RUN R E C E N T L Y WAIT 15 MINUTES B E F O R E W O R K I N G ON V E H I C L E R E L I ...

Page 243: ...le PCM Attempts to reduce high temper ature gauge reading by increasing engine speed at the same vehicle speed can increase high tempera ture WATER PUMP The pump has a sand cast aluminum body and a plastic impeller I t bolts directly to the chain case cover using a gasket Fig 8 for sealing I t is driven by the back surface of the Poly V Drive Belt WATER GASKET PUMP 80a47362 Fig 8 Water Pump and Ga...

Page 244: ...Local Hot Spots Coolant Color Coolant Recovery Bottle Level Changes Coolant NOT Returning Normal with temporary operation with heavy load high outdoor temperatures and or on a steep grade Improper refilling procedures can result in trapped air in the system As the cooling system operates the pressure cap and coolant recovery system will deaerate the cooling system A low coolant level will result i...

Page 245: ...unit used sending unit for HOT Lite not gauge 4 Check radiator and CRS for level inspect for leaks 5 Check heater controls doors see Group 24 MID H NORMAL MAXIMUM UP TO 70 F AMBIENT 4 MAXIMUM 7 NORMAL HOT W E A T H E R WITH HEAVY LOAD 1 Is it really reading high 2 If a H without other signs of boiling 3 Coolant level low in Radiator and CRS Fig 2 Gauge Reading Hot Weather Heavy Load 1 See Figure 2...

Page 246: ...r air side plugged c Low Speed NOT high speed Fan not operating Check Diagnostics Check Fan Motor by wiring to battery when disconnected from harness Check Group 8 Electrical Temperature Gauge leads Hot with Pressure Cap Blowoff and Steam and coolant to CRS and to Ground 1 Coolant Level Low in Radiator and CRS 1 a Fill Cooling System Full b Inspect for Leaks repair c Assure Pressure cap was shut a...

Page 247: ...cle 1 a Normal Fan Cycle Due to Temperature Rises Slowly Drops Fast Fig 3 m D Fig 4 Gauge Reaction to Thermostat b Normal Thermostat Cycle Fig 4 A Fig 5 G a u g e Reaction Winter Idle Heater On c Normal Cycle at Idle in Winter With Heater on High Heater Heat Transfer Exceeds Engine Heat Rejection Drops Lower With Time Sometimes Noticed in Winter Between Drive and Idle Fig 5 Fig 6 Gauge Reaction St...

Page 248: ...w 59 C 50 F be aware that 100 glycol makes engine metal run hotter even without a hot gauge reading Hoses Observed Collapsing on Cool Down 1 Check pressure cap vent valve 2 Check CRS hose for kinking or plugging 3 Inside of cap plugged with stop leak pellet green silica gel or fiberglass Fan Runs All the Time 1 Check fan relay Fan Noisy 1 Check for loose fan 2 Check for fan clearance to adjacent p...

Page 249: ...t shields all in place 2 a Yes See 3 4 and 5 b Repair as required 3 Fan control operating properly 3 a Yes See 4 and 5 b No See Fan this Group 4 Heat exchanger air side plugged 5 Engine missing or running rich 4 Clean as required 5 Repair as required Poor Driveability Suspect Failed Open Thermostat 1 Check diagnostics is code 17 set 1 If yes change thermostat Poor Heater Performance Suspect Failed...

Page 250: ...Low Speed Fan will operate when air condition ing is ON High speed fan will r u n when powertrain control module PCM is i n limp mode Fan control is accomplished based on coolant tem perature The fan will go on when Low Speed Fan ON 97 C 207 F Low Speed Fan OFF 94 C 201 F High Speed Fan ON 102 C 216 F High Speed Fan O F F 98 C 208 F ELECTRIC FAN MOTOR TEST Refer to Powertrain Diagnostic Manual for...

Page 251: ... I N G OR INJURY T H E P R E S S U R E B O T T L E C A P S H O U L D NOT B E R E M O V E D W H I L E T H E S Y S T E M IS HOT AND OR U N D E R P R E S S U R E There is no need to remove the pressure cap at any time except for the following purposes Checking and adjust antifreeze freeze point Refilling system with new coolant Conducting service procedures Checking for vacuum leaks WARNING IF VEHICL...

Page 252: ...mponent 5 Replace belt and clean pulleys BELT NOISE OBJECTIONABLE SQUEAL SQUEAK OR RUMBLE 1 Belt slippage 2 Foreign material imbedded in belt 3 Non uniform belt 4 Misaligned pulley s 5 Non uniform groove or eccentric pulley 6 Bearing noise 1 Replace belt or automatic belt tensioner 2 Replace belt 3 Replace belt 4 Align accessories 5 Replace pulley s 6 Locate and repair BELT ROLLED OVER IN G R O O ...

Page 253: ...coolant pressure bottle cap 3 Remove the cylinder block drain plug s located behind each exhaust manifold C A U T I O N T h e cooling s y s t e m normally operates at 110 124 k P a 16 18 psi pressure Exceeding this pressure may damage the radiator or h o s e s LEFT FRAME Fig 13 Drain Plug Location COOLING SYSTEM FILLING WARNING M A K E S U R E E N G I N E C O O L I N G S Y S TEM IS C O O L B E F O...

Page 254: ...d with the water pump 8 Remove pump mounting screws Fig 15 Remove pump N O T E Water pump is removed between the front upper c r o s s m e m b e r and power steering gear 80a47361 Fig 15 Water Pump 9 Remove and discard water pump gasket 10 Clean gasket surfaces on pump and chain case cover Take care not to scratch or gouge sealing surface INSTALLATION WATER PUMP G A S K E T Fig 16 Water Pump Body ...

Page 255: ...lace a new gasket on the cylinder block cross over surface center thermostat into opening i n the thermostat housing Place housing over gasket and thermostat making sure thermostat is i n recess pro vided in the housing Fig 17 2 Install housing to cylinder block and tighten bolts to 11 N m 95 in lbs 3 Install intake manifold Refer to installation procedure i n Group 11 Exhaust System and Intake Ma...

Page 256: ...ooling System i n this section 6 Operate engine until i t reaches normal operat ing temperature Check cooling system for correct fluid levels 7 Install air cleaner assembly ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION The Poly V Serpentine Drive belt is provided with a dynamic tensioner Fig 21 or Fig 22 to maintain proper belt tension 1 Remove air cleaner ducts 2 Release tension by rotating the t...

Page 257: ...lectrical connection 9407 80 Fig 23 Drain Plug Location AIR C L E A N E R A S S E M B L Y INTAKE AIR T E M P E R A T U R E S E N S O R Fig 24 Air Cleaner Assembly Coupe 3 Install air cleaner assembly FAN SHROUD All vehicles have fan shrouds to improve fan air flow efficiency The fan shroud has movable doors to prevent the shroud from restricting air flow at high speeds The shroud supports the elec...

Page 258: ...ive Belt Inspection CLEAiiie COOLiNO SYSTEi Drain cooling system see Draining Cooling Sys tem and refill with clean distilled water see Refilling Cooling System Run engine with radi ator cap installed until upper radiator hose is warm Stop engine and drain water from system I f water is dirty fill run and drain system again until water runs clear COOLING SYSTEM DRAIN CLEAN FLUSH AND FILLING Drain ...

Page 259: ... PRESSURE CAP Hold the cap i n hand r i g h t side up The vent valve at the bottom of the cap should not open I f the rubber gasket has Fig 28 swollen and prevents the valve from closing replace the cap Hold the cleaned cap i n hand upside d o w n I f any light can be seen between vent valve and rubber gas ket replace cap AAAIN SPRING GASKET RETAINER PLASTIC Fig 28 Pressure Cap S P E C I F I C A T...

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Page 261: ...he battery the water is converted to sulfuric acid i n the battery The amount of acid specific gravity i n the electrolyte can be measured with a hydrometer The factory installed battery is equipped with a built i n hydrometer as a test indicator Fig 1 Fig 2 and Fig 3 to help i n determining the battery s state of charge The factory installed battery also is sealed Water cannot and should not be a...

Page 262: ...ME NEAR BAT TERY BECAUSE E X P L O S I V E G A S E S F O R M A B O U T THE BATTERY The built i n test hydrometer measures the specific gravity of the electrolyte Specific Gravity SG of the electrolyte will show state of charge voltage The test indicator W I L L NOT show cranking capacity of the battery Refer to Battery Load Look into the sight glass and note the color of the indicator Fig 1 Fig 2 ...

Page 263: ...ll draw from 5 to 30 milliamperes from the battery This is w i t h the igni tion i n the OFF position and all non ignition con trolled circuits i n proper working order The amount of IOD will depend on body model and electrical com ponents A vehicle that has not been operated for an extended period of approximately 20 days may dis charge the battery to an inadequate level I n this case the battery...

Page 264: ...attery temperature at the time of the load test Battery temperature can be estimated by the temperature of exposure over the preceding several hours I f the bat tery has been charged boosted or loaded a few min utes prior to the test the battery would be slightly warmer Refer to Load Test Temperature table for proper loaded voltage reading 898A 10 Fig 7 Remove Surface Charge from Battery 8 I f bat...

Page 265: ...the negative cable terminal and the battery negative side terminal Fig 10 The test light may be brightly lit for up to three minutes or may not be l i t at all This depending on the electronic components on the vehicle Fig 10 IOD Test a The term brightly used throughout the fol lowing tests This implies the brightness of the test light will be the same as i f i t were connected across the battery ...

Page 266: ...ood on the left side of dash panel Refer to Group 8D Ignition for more information b The circuit to the radio c The wiring harness from the generator Refer to Group 8C Generator Check each component until excessive IOD is found Each time the test light or milliamp meter is disconnected and connected all electronic timer func tions will be activated Tests must be repeated from the beginning Test li...

Page 267: ...URS 13 9 VOLTS OR LESS UP TO 36 HOURS 1 Measure the voltage at battery side terminals with a voltmeter accurate to 1 10 volt Fig 13 I f below 10 volts charge current will be low and i t could take some time before i t accepts a current in excess of a few milliamperes Such low current may not be detectable on ammeters built into many charg ers 2 Connect charger leads Some chargers feature polarity ...

Page 268: ...ct battery cables to battery terminals making sure the bolts are tighten securely Install POSITIVE cable first 14 Install splash shield and wheel Tighten wheel to the proper torque for proper procedures refer to Group 22 Wheels and Tires R E M O V A L A N D I N S T A L L A T I O N BATTERY REMOVAL 1 Make sure ignition switch is i n OFF position and all accessories are OFF 2 The battery is located b...

Page 269: ...ns and diagrams refer to 8W 21 Starting System i n Group 8W Wiring Dia grams WARNING O N V E H I C L E S E Q U I P P E D WITH AIR B A G S R E F E R T O G R O U P 8M P A S S I V E R E S T R A I N T S Y S T E M S B E F O R E ATTEMPTING S T E E R I N G W H E E L S T E E R I N G C O L U M N O R INSTRUMENT P A N E L C O M P O N E N T DIAGNOSIS O R S E R V I C E F A I L U R E T O T A K E T H E P R O P E...

Page 270: ... SOLENOID TEST IN THIS GROUP REPLACE STARTER ASSEMBLY IF REQUIRED 7 IF ALL O T H E R STARTING SYSTEM C O M P O N E N T S A N D CIRCUITS C H E C K OK REPLACE STARTER ASSEMBLY STARTER ENGAGES FAILS T O T U R N ENGINE 1 BATTERY DISCHARGED O R FAULTY 2 STARTING CIRCUIT WIRING FAULTY 3 STARTER ASSEMBLY FAULTY 4 ENGINE SEIZED 1 REFER T O GROUP 8A BATTERY C H A R G E OR REPLACE BATTERY IF REQUIRED 2 S E ...

Page 271: ...o to Starter Control Circuit Test CAUTION 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 i f necessary Disconnect all testing equipment and connect all cables wires and ASD relay that were disconnected Start the vehicle sev eral ti...

Page 272: ... 2 volt correct poor starter to engine ground a Connect the positive voltmeter lead to the positive battery terminal and negative lead to bat tery cable terminal on starter solenoid Fig 7 Rotate and hold the ignition switch i n the START position I f voltage reads above 0 2 volt correct poor contact at battery cable to solenoid connec tion I f reading is still above 0 2 volt after correct ing poor...

Page 273: ... Fig 8 a Using an ohmmeter check for continuity Touch one lead to the 50 terminal and the other to the starter body b I f there is continuity starter solenoid is OK If no continuity the hold in winding has an open circuit Replace starter 3 Disconnect the cable from C terminal of the starter a Briefly connect a jumper wire to the auxil iary jumper post and the other end to 50 terminal of the soleno...

Page 274: ...T TERMINAL 86 NO C H E C K CLUTCH INTERLOCK SWITCH AND CIRCUIT F45 Y E S REFER TO THE PREVIOUS STARTER SOLENOID TEST IN THIS GROUP RELEASE CLUTCH PEDAL PROCEED WITH THE FOLLOWING TESTS WITH RELAY REMOVED AND IGNITION ON C H E C K FOR 12V AT TERMINAL 30 12V PRESENT CIRCUIT IS OK IS 12V STILL PRESENT AT TERMINAL 86 12V NOT PRESENT NO Y E S REPLACE CLUTCH INTERLOCK SWITCH C H E C K FOR OPEN CIRCUIT R...

Page 275: ...t 3 Remove battery cable and solenoid wire from starter 4 Remove two starter attaching bolts from engine Fig 11 5 Remove starter from vehicle IffSTALLATION For installation reverse the above procedures Clean corrosion dirt from the cables and wire termi nals before installing wiring to the solenoid SIDE TERMINAL COVER Fig 10 Remove Battery Cable Fig 11 Remove Starter SPECIFICATIONS STARTER Engine ...

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Page 277: ...lure i t detects See the On Board Diagnostics Test i n Group 8C Charging System for more information page CHARGING SYSTEM RESISTANCE TESTS 3 CURRENT OUTPUT TEST 3 ON BOARD DIAGNOSTIC TEST FOR CHARGING SYSTEM 7 REMOVAL AND INSTALLATION BATTERY TEMPERATURE SENSOR 9 GENERATOR 8 SPECIFICATIONS GENERATOR RATINGS 9 TORQUE SPECIFICATIONS 9 D E S C R I P T I O N mm O P E R A T I O N CHARGING SYSTEM OPERAT...

Page 278: ...hin the PCM The EVR is not serviced separately I f replacement is necessary the PCM must be replaced Operation The amount of DC current produced by the generator is controlled by EVR circuitry con tained within the PCM This circuitry is connected i n series with the generators second rotor field terminal and its ground Voltage is regulated by cycling the ground path to control the strength of the ...

Page 279: ...higher than 0 6 volts I f voltage is higher than 0 6 volts touch test lead to terminal mounting stud nut and then to the wiring connector I f voltage is now below 0 6 volts look for dirty loose or poor connection at this point Also check condition of the generator output wire to battery bullet connector Refer to Group 8 Wiring for connector location A voltage drop test may be performed at each con...

Page 280: ...ting manual supplied with test equipment 6 The ammeter reading must meet the Minimum Test Amps specifications as displayed i n the Genera tor Ratings chart This can be found i n the Specifica tions section at the end of this group A label stating a part reference number is attached to the generator case On some engines this label may be located on the bottom of the case Compare this reference num ...

Page 281: ...this reference num ber to the Generator Rating chart 7 Remove volt amp tester 8 Remove jumper wire 9 Use the DRB scan tool to erase the DTC Refer to the DRB screen for procedures R E S U L T S i f amp reading meets specifications i n Test 2 generator is OK I f amp reading is less than specified i n Test 2 and wire resistance voltage drop tests were OK the generator should be replaced Refer to Remo...

Page 282: ...GROUND POWERTRAIN CONTROL MODULE PCM ro MESSAGE CENTER BATTERY INDICATOR LAMP ASD RELAY POWER DISTRIBUTION CENTER PDC STARTER MOTOR BATTERY D 0 0 S o 0 O ft o w i O 0 3 3 C Charging System Components ...

Page 283: ...n in the system The preferred and most accurate method of retriev ing a DTC is by using the DRB scan tool The scan tool supplies detailed diagnostic information which can be used to more accurately diagnose causes for a DTC Remember that DTC s are the results of a sys t e m or circuit failure but do not directly iden tify the failed component or components N O T E For a list of D T C s refer to th...

Page 284: ...itive from side of generator Fig 3 Generator 8 Remove generator from vehicle INSTALLATION 1 Reverse removal procedures to install Tighten generator hardware as follows 1 Tighten the generator upper mounting bolt to 55 N m 41 ft lbs Tighten the generator lower mounting bolt to 55 N m 41 ft lbs Tighten the bat tery terminal nut to 8 5 N m 75 in lbs CAUTION Never force a belt over a pulley rim u s i ...

Page 285: ... INSTALLATION 1 Install Battery Temperature Sensor to battery tray 2 Connect electrical connector 3 Install Battery refer to Group 8B Batteries for battery installation Fig 4 Battery Hold Down Tray SPECIFICATIONS GENERATOR RATINGS T Y P E PART NUMBER RATED S A E A M P S E N G I N E S MINIMUM T E S T A M P S D E N S O 4848662AA 120 AMPS 8 0L 80 AMPS TORQUE SPECIFICATIONS D E S C R I P T I O N T O R...

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Page 287: ... VECI LABEL 18 G E N E R A L I N F O R M A T I O N INTRODUCTION This group describes the ignition systems for the 8 0L engine On Board Diagnostics is described in Group 25 Emission Control Systems Group 0 Lubrication and Maintenance contains general maintenance information for ignition related items The Owner s Manual also contains mainte nance information DESCRIPTION AND OPERATION IGNITION SYSTEM...

Page 288: ...he center electrode flat with a small flat file or jewelers file Adjust the gap between the electrodes Fig 2 to the dimensions specified i n the chart at the end of this section T A P E R G A U G E 803f5851 Fig 2 Setting Spark Plug Electrode Gap Typical Always tighten spark plugs to the specified torque Over tightening can cause distortion resulting i n a change i n the spark plug gap Tighten spar...

Page 289: ...located i n the Power Distribution Cen ter PDC Fig 5 For the location of the relay within the PDC refer to the PDC cover for location Check electrical terminals for corrosion and repair as necessary Fig 5 Power Distribution Center PDC CRANKSHAFT POSITION SENSOR The crankshaft position sensor detects slots cut into a disk i n the middle of the crankshaft Fig 6 There are 5 sets of slots Each set con...

Page 290: ...e cam shaft position sensor and crankshaft position sensor inputs The PCM uses the input to determine fuel injection synchronization and to determine which ignition coil to energize C A M S H A F T RIB M A T E R I A L FOR SENSOR DEPTH POSITIONING Fig 8 Camshaft Position Sensor The camshaft position sensor detects when a step in the camshaft sprocket passes beneath i t Fig 9 When the sensor detects...

Page 291: ...During Key On before cranking the engine the PCM determines atmospheric air pressure from the MAP sensor voltage While the engine operates the PCM determines intake manifold pressure relative to atmospheric pressure Also atmospheric pressure is updated at wide open throttle Based on MAP sensor voltage and inputs from other sensors the PCM adjusts spark advance and air fuel mixture The MAP sensor F...

Page 292: ...15 Testing For Spark CAUTION Always install the cable back on the coil tower after testing to avoid damage to the coil and catalytic converter Crank the engine and look for spark across the electrodes of the spark plug Repeat the above test for the remaining cylinders I f there is no spark dur ing all cylinder tests proceed to the failure to start test I f one or more cylinders indicate irregular ...

Page 293: ... is in either the Crankshaft position sensor 5 volt supply circuit Camshaft position sensor 5 volt supply circuit Crankshaft position sensor 5 volt output or ground circuits 6 Use the DRB scan tool to test the crankshaft position sensor and the sensor circuits Refer to the appropriate Powertrain Diagnostics Procedure Man ual For circuit information refer to Group 8W Wir ing Diagrams IGNITION TIMIN...

Page 294: ...dditives can cause ash encrustation on an entire set of spark plugs A s h encrusted spark plugs can be cleaned a n d reused HIGH SPEED MISS When replacing spark plugs because of a high speed miss condition wide open t h r o t t l e o p e r a t i o n should be avoided for a p p r o x i m a t e l y 80 k m 50 miles after i n s t a l l a t i o n o f n e w plugs This will allow deposit shifting i n the...

Page 295: ...se spark plug overheating BLISTERED WHITE OR GRAY COLORED INSULATOR J908D 13 Fig 20 Chipped Electrode Insulator PREIGNITION DAMAGE Excessive combustion chamber temperature can cause preignition damage First the center electrode dissolves and the ground electrode dissolves some what later Fig 21 Insulators appear relatively deposit free Determine i f the spark plugs are the correct type as specifie...

Page 296: ...nstall the PCM cover Fig 23 4 Connect negative battery cable and reprogram radio and clock 5 Using DRB scan tool program mileage and vehicle identification number VIN into PCM Refer to the DRB scan tool and the appropriate Powertrain Diagnostic Manual 80a58b66 Fig 23 PCM Cover SPARK PLUG SERWICE Failure to route the cables properly could cause the radio to reproduce ignition noise cross ignition o...

Page 297: ...damage the insulation cable terminal or the spark plug insulator Wipe s p a r k p l u g i n s u l a t o r clean before r e i n s t a l l i n g cable and cover 2 Remove spark plug cable from coil frist 3 Always remove the spark plug cable by grasp ing the top of the spark plug insulator turning the boot 1 2 turn and pulling straight up i n a steady motion INSTALLATION 1 Install spark plug insulator...

Page 298: ...POSITIONING 8 0 5 7 0 e 1 a Fig 30 Sensor Depth Positioning Rib Typical Refer to either of the following procedures Sensor Removal Replacing Old Sensor With Original or Sensor Removal Replacing With New Sensor SENSOR REMOVAL REPLACING OLD SENSOR WITH ORIGINAL If the original camshaft position sensor is to be removed and installed such as when servicing the timing chain timing gears or timing chain...

Page 299: ...ined 6 Install the sensor into the timing case cover with a slight rocking action until the sensor is aligned to scribe line 7 Install sensor mounting bolt and tighten to 6 N m 50 in lbs torque 8 Connect engine wiring harness to sensor SENSOR REMOVAL REPLACING WITH NEW SENSOR I f a new replacement camshaft position sensor is to be installed use this procedure 1 Disconnect the sensor wiring harness...

Page 300: ...50 in lbs torque 8 Connect sensor wiring harness to engine har ness When the engine is started the rib material will be sheared off the face of sensor This will automatically set sensor air gap CRANKSHAFT POSITION SENSOR A heat shield covers the crankshaft position sensor Fig 34 The sensor is located i n the middle of the right side of the cylinder block just above the oil pan Fig 35 REMOVAL 1 Dis...

Page 301: ...n to 5 N m 44 in lbs torque 2 Connect electrical connector to sensor MANIFOLD ABSOLUTE PRESSURE MAP SENSOR The MAP sensor is mounted on the drivers side of the intake manifold Fig 38 Fig 38 MAP Sensor REMOVAL 1 Disconnect the electrical connector from the MAP sensor 2 Remove MAP sensor mounting screws 3 A vacuum hose on the bottom of the MAP sen sor connects to the sensor to a vacuum fitting on th...

Page 302: ...witch Screw Removal 5 Gently pull switch away from column Release connector locks on 7 terminal wiring connector then remove connector from ignition switch 6 Release connector lock on 4 terminal connector then remove connector from ignition switch Fig 42 KEY IN SWITCH HALO LIGHT MULTI FUNCTION SWITCH IGNITION SWITCH TURN SIGNAL SWITCH LEVER SPEED CONTROL J918J 2 Fig 42 Key ln Switch and Halo Lamp ...

Page 303: ...from ignition switch Fig 46 958D 63 Fig 44 Key Cylinder Retaining Screw INSTALLATION 1 Connect electrical connectors to ignition switch Make sure that switch locking tabs are fully seated in wiring connectors 2 The park lock dowel pin and column lock flag must also be properly indexed before installing switch Fig 47 L RING 908D 16 Fig 45 Unseated Key Cylinder 908D 18 Fig 47 Ignition Switch View Fr...

Page 304: ...der Tighten screw to 3 5 N m 26 4 in lbs torque 9 Install steering column covers Tighten screws to 2 N m 17 in lbs torque 10 I f vehicle is equipped with a tilt steering col umn install tilt lever 11 Connect negative cable to battery 12 Check for proper operation of halo light shift lock if applicable and column lock Also check for proper operation of ignition switch accessory lock off run and sta...

Page 305: ...Ohms Per Foot 12 000 Ohms Per Foot SPARK PLUG Engine Spark Plug Gap Thread Size 8 0L R C 1 2 L Y C 0 033 T O 0 038 14mm 3 4 in reach IGNITION COIL Coil Manufacture Primary Resistance at 21 C 27 C 70 F 80 F Secondary Resistance at 21 C 27 C 70 F 80 F Diamond Toyodenso 0 52 to 0 63 Ohms 0 51 to 0 61 Ohms 11 600 to 15 800 Ohms 11 500 to 13 500 Ohms ...

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Page 307: ...R BLOWER MOTOR SWITCH 9 HEATER CONTROL 9 HEATER CONTROL LAMP 9 HEATER CONTROL SWITCH INSTRUMENT PANEL MESSAGE CENTER LAMPS PANEL DIMMER SWITCH SPEEDOMETER TACHOMETER TEMPERATURE CONTROL SWITCH VEHICLE SPEED SENSOR G E N E R A L I N F O R M A T I O N INTRODUCTION The electronic gauges have analog displays The instrument panel gauges are magnetic type When the ignition switch is i n the O F F positi...

Page 308: ...or low fluid level Door Ajar indicator turned on when one or both door are not fully closed Rear Fog indicator when the rear fog lamps are ON Front Fog indicator when the front fog lamps are ON Airbag indicator is turned on by the Airbag Control Module I f a malfunction has occurred that effects the Airbag system There should be a diagnos tic trouble code set i n the memory SEAT BELT WARNING SYSTE...

Page 309: ... MANUAL FAULTY BRAKE SYSTEM PROPORTIONING VALVE UNIT 938E 99 BRAKE WARNING LIGHT SWITCH CONNECTOR 938E 20 Fig 3 Brake Warning Lamp Switch ENGINE OIL PRESSURE SENDING UNIT TEST The sending unit provides a resistance that varies with oil pressure to the oil pressure gauge Fig 9 1 To test the sending unit measure the resis tance between the sending unit terminal and the metal housing The ohmmeter sho...

Page 310: ...switch i n the ON position engine not running ground Pin 1 and the engine coolant tem perature gauge should read maximum temperature I f OK test engine temperature sensor I f not OK repair as necessary TERMINAL END OF GAUGE CONNECTOR NO TERMINAL NAME 1 METER SENDER 2 3 IGN FEED 4 GROUND 5 6 ILLUMINATION Fig 6 Fuel Gauge TERMINAL END OF GAUGE CONNECTOR NO TERMINAL NAME 1 METER SENSOR 2 3 IGN FEED 4...

Page 311: ... 3 If no continuity replace headlamp switch If OK check headlamp relay circuit and repair as nec essary refer to Group 8W Wiring Diagrams HEADLAMP SWITCH KNOB SWITCH LOW OIL PRESSURE WARNING LAMP TEST The engine warning lamp will illuminate when the ignition key is turned to the ON position The lamp also illuminates when the engine oil pressure drops below a safe oil pressure level To test the sys...

Page 312: ...to Step b I f not OK check fuse and or circuit and repair as necessary PIN TERMINAL NAME 1 SHIFT 2 3 4 REAR FOG 5 BATTERY 6 7 ENGINE TEMPERATURE 8 SEAT BELT 9 10 FRONT FOG 11 AIRBAG 12 DOOR AJAR LAMP LOCATION PIN TERMINAL NAME 1 HIGH BEAM 2 SERVICE ENGINE SOON 3 SHIFT 4 BATTERY 5 LOW OIL PRESSURE 6 ENGINE TEMPERATURE 7 SEAT BELT 8 BRAKE 9 ALARM SET 10 DOOR AJAR 11 REAR FOG 12 FRONT FOG 13 14 AIRBA...

Page 313: ...und 5 Ground 6 Illumination TERMINAL END OF GAUGE CONNECTOR LAMPS NO TERMINAL NAME 1 Meter Pulse 2 3 Ign Feed 4 Ground 5 Ground 6 Illumination Fig 13 Tachometer TEMPERATURE WARNING LAMP TEST To test the temperature warning lamp turn the ignition switch to the O N position Disconnect the wire from the temperature switch on the engine and momentarily touch the wire to ground When the wire is grounde...

Page 314: ... sides Fig 15 3 Remove headlamp switch knob Using a stiff wire or a small tool insert i t into the hole at the bot tom of the knob Pushing up with the tool and gently pull rearward till the lock tab releases the knob Remove knob Use care not to break the locking tab 4 Remove the steering column shroud and i t may require lowering of the steering column for additional clearance 5 Remove instrument ...

Page 315: ...umn shroud and it may require lowering of the steering column for additional clearance 5 Remove instrument panel bezel Fig 15 6 Remove headlamp switch by depressing the locking tabs 7 Remove switch and disconnect wire connector INSTALLATION For installation reverse the above procedures HEATER BLOWER MOTOR SWITCH REMOVAL 1 Refer to Heater Control Removal and Installa tion for removal procedures 2 R...

Page 316: ...rearward till the lock tab releases the knob Remove knob Use care not to break the locking tab 5 Remove the steering column shroud 6 Remove steering column a Remove left steel plate assembly b Remove lower coupler bolt i n the engine compartment c Remove toe plate bolts d Remove upper mounting bolts e Disconnect all wire connectors f Remove column 7 Remove gear shift handle Remove tunnel trim beze...

Page 317: ...MER SWITCH REMOVAL Use care not to mar the instrument panel bezel Use a thin flat blade tool Apply pressure at the top and bottom of the switch to rock i t from the instru ment panel bezel INSTALLATION Use care not to pinch the wires Push the switch back into the instrument panel bezel till i t is lock i n position SPEEDOMETER TACHOMETER REMOVAL 1 Remove instrument panel center bezel Fig 14 Discon...

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Page 319: ...volt power supply INTERFERENCE ELIMINATION The engine ground cable is attach to the engine and to the right side of frame This ground cable should be securely tightened to assure good metal to metal contact Interference may occur when the engine is run ning on A M stations with a weak signal and this is not an indication of a faulty radio Inductive type spark plug cables i n the high ten sion circ...

Page 320: ...LIFIER F U S E C H E C K R E M O T E LINE HAS 12V WITH RADIO ON C H E C K GROUND LINE C H E C K S P E A K E R INPUT LINES A R E P L U G G E D IN MAKE WIRING REPAIRS TO AMPLIFIER R E T U R N HEAD UNIT FOR S E R V I C E R E T U R N AMPLIFIER FOR S E R V I C E Y E S O K T R Y ANOTHER DIN C A B L E MAKE WIRING REPAIRS TO AMPLIFIER C A B L E D E F E C T I V E R E P L A C E RETURN AMPLIFIER FOR S E R V ...

Page 321: ...S R DIAGNOSIS AND T E S T I N G Continued AUDIO SYSTEMS 8F 3 ...

Page 322: ...drop i n radio recep tion quality I f OK replace windshield I f not OK go to Step b b Connect antenna lead connector i n the front dash panel Fig 4 Disconnect bullet connector at amplifier There should be a great drop i n recep tion quality I f not OK replace antenna amplifier Fig 5 WINDSHIELD A N T E N N A A M P L I F I E R MODULE A N T E N N A LEAD 12 VOLT B U L L E T C O N N E C T O R A N T E N...

Page 323: ...ve procedures Fig 7 Front Tweeter Speaker RADIO REMOVAL 1 Remove instrument panel center bezel and dis connect the cigar lighter and fog lamp switches wire connectors Fig 8 Fig 8 Center Bezel 2 Remove right and left side knee bolster Fig 9 3 Remove headlamp switch knob by inserting a paper clip i n the hole under the knob and pushing gently to release the lock clip 4 Remove the tilt wheel handle 5...

Page 324: ...VAL 1 Remove grille with a flat bladed tool Fig 12 2 Remove speaker screws SR Fig 11 Rear Speakers Coupe 3 Remove speaker and disconnect speaker wiring connector INSTALLATION For installation reverse the above procedures S P E A K E R 80abac64 Fig 12 Rear Speaker Roadster REMOTE AMPLIFIER R E M O V A L 1 Remove retaining bracket on top of the ampli fier Fig 1 2 Disconnect DIN cables and wire conne...

Page 325: ...urrent to flow to the horns The horn is grounded to the headlamp ground Fig 1 The Electronic Entry Module EEM is i n parallel with the horn switch and can also activate the horn system for vehicle theft security The horns are located under the front bumper and fascia Mounted on the right and left outer side of the frame rails Fig 2 CLOCK SPRING HORN R E L A Y HORN HORN SWITCH S W I T C H I I f 15 ...

Page 326: ... a I f horn sounds replace relay b I f the horn does not sound install horn relay and refer to Horn Test 4 Using voltmeter test voltage at a Cavity 10 and cavity 36 for battery voltage supplied by the horn fuse b I f voltage is incorrect repair as necessary Refer to Group 8W Wiring Diagrams 5 Check relay for 70 to 75 ohms resistance between Pins 10 and 12 I f resistance not OK replace relay HORN S...

Page 327: ...RN SWITCH WIRE UNDER DRIVER AIRBAG MODULE 3 DEFECTIVE HORN SWITCH 1 REMOVE DRIVER AIRBAG MODULE AND C H E C K FOR RUBBING OR LOOSE WIRE CONNECTOR REPAIR A S NECESSARY 2 REPLACE DRIVER AIRBAG MODULE 3 REPLACE DRIVER AIRBAG MODULE HORN DOES NOT SOUND 1 CHECK FOR BATTERY VOLTAGE AT PIN 10 PIN 36 2 PLACE A JUMPER WIRE BETWEEN PIN 36 PIN 28 3 RELY CONNECTED G R O U N D PIN 12 4 DEFECTIVE HORN SWITCH 1 ...

Page 328: ...er Airbag Module I f OK repair as necessary REMOWAL A N D I N S T A L L A T I O N ELECTRONIC ENTRY MODULE EEM For service of the Electronic Entry Module EEM refer to Group 8Q Vehicle Theft Security System for Removal and Installation procedures HORN REMOVAL 1 Remove front bumper and fascia refer to Group 13 Frame and Bumper 2 Remove connector and mounting bolt Fig 2 INSTALLATION For installation r...

Page 329: ...con ventional automotive electrical test equipment I f the combination flasher is believed to be faulty test the page DIAGNOSIS AND TESTING INTRODUCTION 2 MULTI FUNCTION SWITCH 3 TURN SIGNAL AND HAZARD WARNING SYSTEMS 2 TURN SIGNAL INDICATOR LAMPS 3 REMOWAL AND INSTALLATION COMBINATION FLASHER 5 MULTI FUNCTION SWITCH 6 turn signal and hazard warning system circuits as described i n this group Then...

Page 330: ... System for further diagnosis WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY TURN SIGNAL AND HAZARD WARNING SYSTEMS 1 Turn the ignition switch to...

Page 331: ...switch is i n the Turn Position with the ignition switch i n ON position check Parking and tail lamp for lamp outage Replace lamps as necessary Check t u r n signal flasher I f not OK replace flasher I f OK check indicator lamp I f OK repair cir cuit I f not replace lamp I f indicator lamp right or left does not flash when turn signal switch is i n the TURN position and igni tion switch is i n the...

Page 332: ...AIR WIRING HARNESS CHECK C O N N E C T O R S 4 REPLACE MULTI FUNCTION SWITCH 5 REPAIR WIRING HARNESS INDICATOR LAMP ILLUMINATES BRIGHTLY EXTERNAL LAMP DOES NOT LIGHT 1 OPEN CIRCUIT IN W I R E T O EXTERNAL LAMP 2 BURNED O U T LAMP 1 REPAIR WIRING HARNESS 2 REPLACE LAMP SYSTEM DOES N O T FLASH O N EITHER SIDE 1 FAULTY FUSE 2 FAULTY FLASHER UNIT 3 LOOSE B U L K H E A D CONNECTOR 4 LOOSE OR FAULTY REA...

Page 333: ...LURE T O T A K E T H E P R O P E R P R E C A U T I O N S C O U L D R E S U L T IN A C C I D E N T A L A I R B A G D E P L O Y M E N T AND POSSI B L E P E R S O N A L INJURY REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the knee blocker lower steering column cover trim panel Fig 2 Refer to Group 8E Instru ment Panel and Systems for removal procedures 3 Remove the combination ...

Page 334: ...er fixed column shroud 6 Loosen the steering column upper bracket nuts Do not remove the nuts 7 Move the upper fixed column shroud to gain access to the rear of the multi function switch Fig 4 8 Remove the multi function switch tamper proof mounting screws tamper proof Torx Bit T T X R 2 0 B 2 or equivalent is required 9 Gently pull the switch away from the column Loosen the connector screw The sc...

Page 335: ...o all components Driver D and passenger P side wiper arms and blades Motor covers The wiper control module governs all modes of wiper operation Intermittent Mist Low speed High speed The module also synchronizes the wiper arm blades operation so they do not make contact with each other Fig 1 For the module to control the operation of two motors i t must sense the position of the wiper blades The p...

Page 336: ...trolled electri cally by a relay The wiper system completes the wipe cycle to park when the wiper switch or ignition switch is turned OFF The blades park i n the lowest portion of the wipe pattern Fig 1 D E S C R I P T I O N A N D O P E R A T I O N WINDSHIELD WASHERS All models are equipped with electric operated windshield washer pumps The wash function can be accessed i n the OFF position of the...

Page 337: ...n switch connector as described i n this group 3 Using an ohmmeter perform the switch conti nuity checks at the switch terminals as shown i n the chart Fig 3 24 2 3 2 2 CZ3 C 3 C 3 17 16 15 14 J J j J J 21 19 13 12 11 10 o 9 8 7 6 5 4 3 cm cza a n TL MULTIFUNCTION SWITCH PINS SWITCH POSITION CONTINUITY BETWEEN OFF PIN 6 AND PIN 7 DELAY PIN 8 AND PIN 9 PIN 2 AND PIN 4 PIN 1 AND PIN 2 PIN 1 AND PIN ...

Page 338: ...ot return to park posi tion when either wiper switch is turned OFF or igni tion switch is turned OFF go to Step 7 9 One or both sides do not stop when wiper switch is turned OFF go to Step 7 WIPER MOTOR TEST 1 Remove both wiper arms and blades before starting test Refer to Wiper A r m Replacement for installation 2 Turn ignition switch OFF and disconnect both wiper motor connectors 3 Using two tes...

Page 339: ... I f necessary repeat the above procedure on the other motor wiper motor connector WIRING TEST Using an ohmmeter test wires from the control module to the wiper motors and or wiper switch assembly refer to Fig 5 Fig 6 and Fig 7 I f not OK repair as necessary I f OK perform the Wiper Switch Test R E M O V A L A N D I N S T A L L A T I O N CONTROL MODULE REMOVAL 1 Remove knee blocker 2 Remove rubber...

Page 340: ...tion of pump then using a 19 m m 3 4 in socket through the liquid filler opening loosen the pump filter and nut 3 Disconnect the outside portion of the pump 4 Remove inner and outer portions of the pump INSTALLATION For installation reverse the above procedures First install rubber grommet into place i n bottom of reser voir W A S H E R R E S E R V O I R W A S H E R FLUID H O S E F E N D E R W E L...

Page 341: ...eplace ment Fig 13 and Fig 14 ARM RELEASE TAB R U B B E R VERTABRA ELEMENT 938 K 4 Fig 12 Wiper Blade and Element INSTALLATION For installation reverse above procedures Check each release point for positive locking when install ing blade element and blade assembly on vehicle R E L E A S E TAB Fig 13 Wiper Blade Removal CLAW 938 K 8 TO GRASP AND PULL RUBBER ELEMENT CHANNEL 918K 8 Fig 14 Wiper Eleme...

Page 342: ...or screw 2 N m 17 in lbs Multi function switch retaining screws 2 N m 17 in lbs Steering column upper bracket nuts 12 N m 110 in lbs WIPER MOTOR REMOVAL 1 Open hood assembly 2 Remove windshield wiper arms Fig 11 3 Remove cowl trim panel Fig 17 4 Remove hoses from hose connectors 5 Remove three motor mounting screws Fig 18 6 Disconnect motor wiring connector 7 Remove motor cover and motor INSTALLAT...

Page 343: ...8 WINDSHIELD WIPERS AND WASHERS 8K 9 inch from top edge of the cowl t r i m panel to the cen ter pivot point of the blade Fig 19 The driver s blade should be approximately 40 m m 1 9 16 inch from top edge of the cowl t r i m panel to the center pivot point of the blade 3 The passenger s blade should not touch the cowl trim panel 4 The driver s arm blade should not touch the passenger blade while g...

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Page 345: ... 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 Mopar Multi purpose Grease or equivalent to avoid corrosion page D I A G N O S I S AND T E S T I N G F O G LAMP DIAGNOSIS 3 HEADLAMP DIAGNOSIS 2 Begin any ...

Page 346: ... battery state of charge Refer to Group 8A 5 Load test battery Refer to Group 8A 6 Test for voltage drop across Z1 ground locations Refer to Group 8W 7 Replace both headlamp bulbs HEADLAMP BULBS BURN OUT FREQUENTLY 1 Charging system output too high 2 Loose or corroded terminals or splices in circuit 1 Test and repair charging system Refer to Group 8A 2 Inspect and repair all connectors and splices...

Page 347: ...N OUT FREQUENTLY 1 Charging system output too high 2 Loose or corroded terminals or splices in circuit 1 Test and repair charging system Refer to Group 8A 2 Inspect and repair all connectors and splices Refer to Group 8W FOG LAMPS A R E DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 2 Poor lighting circuit Z1 ground 3 High resistance in fog lamp circuit 4 Both fog lamp bulbs d...

Page 348: ...y proper tire inflation 4 Clean headlamp lenses 5 Verify that luggage area is not heavily loaded 6 Fuel tank should be FULL Add 2 94 kg 6 5 lbs of weight over the fuel tank for each estimated gallon of missing fuel 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...

Page 349: ...t half of the pattern will be higher than the left half i n front of each headlamp The vertical left edge of the pattern should be 25 m m 1 in to the left of the headlamp center line The horizontal top edge on the left side of the pattern should be 75 m m 3 in below the headlamp center line The high beam headlamps cannot be aligned The high beam pattern should be correct when the low beams are ali...

Page 350: ...oor up 1 52 meters 5 ft tape a vertical line on the wall representing center line of the vehicle Sight along the center line of the vehicle from rear of vehicle forward to verify accuracy of the line placement 4 Rock vehicle side to side three times to allow suspension to stabilize 5 Jounce front suspension three times by pushing downward on front bumper and releasing 6 Measure the distance from t...

Page 351: ...ft half i n front of each headlamp The vertical left edge of the pattern should be 25 m m 1 in to the left of the headlamp center line The horizontal top edge on the left side of the pattern should be 63 m m 2 5 in below the headlamp center line The high beam headlamps cannot be aligned The high beam pattern should be correct when the low beams are aligned properly To adjust headlamp alignment rot...

Page 352: ... E H I C L E C E N T E R L I N E 7 62 M E T E R S 25 F E E T F R O N T O F F O G L A M P Fig 6 Fog Lamp Alignment Screen Coupe FOG LAMP ALIGNMENT COUPE Prepare a alignment screen Refer to Alignment Screen Preparation paragraph in this section A prop erly aligned fog lamp will project a pattern on the alignment screen 100 m m 4 in below the fog lamp center line and straight ahead Pig 6 80a676f7 ...

Page 353: ...f lamp and rotate socket clockwise 2 Engage wire connector to lamp socket 3 Position headlamp rear cover to headlamp 4 Install wing nuts holding headlamp rear cover to back of headlamp page LICENSE PLATE LAMP BULB 11 PARK A N D T U R N SIGNAL LAMP BULB 9 TAIL A N D STOP LAMP BULB 10 T U R N SIGNAL A N D BACK UP LAMP BULBS 11 5 Position access panel to vehicle 6 Engage half turn fasteners holding a...

Page 354: ...TION 1 Push bulb into socket 2 Push socket into lamp and rotate side marker lamp socket clockwise one half turn 3 Install body plug to access hole in radiator clo sure panel forward of front wheel CENTER HIGH MOUNTED STOP LAMP BULB The center high mounted stop lamp CHMSL has no serviceable bulb I f the lamp does not function properly the CHMSL assembly must be replaced TAIL AND STOP LAMP BULB REMO...

Page 355: ...p INSTALLATION 1 Push and twist bulb into socket 2 Push socket into lamp and rotate socket clock wise one half turn 3 Position the turn signal and back up lamp in the tail lamp closure panel 4 Install the plastic seal nuts to hold the turn and back up lamp to the tail lamp closure panel through the access holes 5 Install plugs to cover the access holes i n the trunk pan for the turn and back up la...

Page 356: ...Headlamp Module INSTALLATION 1 Position headlamp to vehicle 2 Engage wire connector to back of headlamp 3 Install nut holding headlamp to front frame rail bracket page F R O N T SIDE M A R K E R LAMP 13 H E A D L A M P MODULE 12 LICENSE PLATE LAMP 15 TAIL A N D STOP LAMP 14 T U R N SIGNAL A N D BACK UP LAMP 14 4 Install nuts holding headlamp to radiator sup port panel 5 Install front bumper fascia...

Page 357: ...ulb to lamp 4 Install body plug to access hole i n radiator clo sure panel forward of front wheel CENTER HIGH MOUNTED STOP LAMP CHMSL The following service procedure applies to the Viper Roadster The Viper Coupe s Center High Mounted Stop Lamp CHMSL has no serviceable FASCIA SIDE MARKER LAMP 938L 14 Fig 4 Side Marker Lamp bulb I f the lamp does not function properly the CHMSL assembly must be repl...

Page 358: ...and the trunk pan or the tail lamp closure panel will need to be removed 4 Remove the t u r n and back up lamp from the tail lamp closure panel 5 Remove lamp sockets from the lamp housing 6 Remove the turn and back up lamp from the vehicle T U R N S I G N A L 80a5cec2 Fig 7 Turn Signal and Back Up Lamp INSTALLATION 1 Position lamp to vehicle 2 Install the lamp sockets i n the lamp housing 3 Positi...

Page 359: ...the tail lamp closure panel Fig 9 4 Rotate and pull license plate lamp socket from the license plate lamp 5 Remove screws holding the lamp to the lamp panel Fig 10 6 Separate the lamp from the lamp panel INSTALLATION 1 Position the license plate lamp to the lamp clo sure panel 2 Install screws to hold the lamp to the lamp clo sure panel Fig 9 License Plate Lamp Closure Panel L I C E N S E P L A T ...

Page 360: ... Signal Indictor 194 C A U T I O N Do not u s e bulbs that have a higher c a n 0 i l p r e s s u r e Gauge 74 die power than t h e bulb listed i n the Bulb Applica Speedometer WWW 103 and 194 t i o n Table Damage t o l a m p c a n result Tachometer 194 Engine Temperature Gauge 74 C A U T I O N Do not touch halogen bulbs with fingers Voltmeter 74 or other oily surfaces Bulb life will be reduced EXT...

Page 361: ... PLEX ELECTROMECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR BAG SYSTEM OR RELATED STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYS TEM CAPACITOR TO DISCHARGE BEFORE FUR THER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO THIS ...

Page 362: ...he airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal The airbag door has predetermined breakout lines concealed beneath its decorative cover Upon airbag deployment the air bag door will split at the breakout lines and the door will pivot out of the way Following an airbag deploy ment the airbag door and Passenger Airbag...

Page 363: ...D I A G N O S I S A N D T E S T I N G AIRBAG SYSTEi TEST A DRB I I I scan tool is required for diagnosis of the airbag system Refer to the proper Body Diagnostic Procedures manual for more information 1 Disconnect and isolate the battery negative cable I f the airbag system is undeployed wait two minutes for the system capacitor to discharge before further service 2 Connect the DRB I I I scan tool...

Page 364: ... are to be replaced only as required by the extent of the visible damage incurred CLEANUP PROCEDURE Following an airbag system deployment the vehi cle interior will contain a powdery residue This res idue is primarily sodium bicarbonate baking soda used as an airbag cushion lubricant However there will also be traces of sodium hydroxide powder a chemical by product of the generant used for airbag ...

Page 365: ...hrough the radio opening i n the instrument panel and unplug the Airbag Control Module wire harness connector 13 Remove the three nuts securing the Airbag Control Module ACM to the mounting bracket on the floor transmission tunnel Fig 4 14 Slide the A C M out through the radio opening in the instrument panel INSTALLATION For installation reverse the above procedures Do not connect the battery nega...

Page 366: ...or the procedures 3 Reach under the passenger side end of the instrument panel and unplug the airbag module wire harness connector 4 Remove the four screws and two nuts securing the Passenger Airbag Module to the instrument panel carrier Fig 6 5 Remove the Passenger Airbag Module from the instrument panel INSTALLATION For installation reverse the above procedures Be certain that the airbag wiring ...

Page 367: ...position Install the steering wheel being cer tain to fit the flats on the hub of the steering wheel with the formations on the inside of the clockspring Pull the wiring through the upper and lower holes i n the steering wheel hub Tighten the steering wheel nut to 61 N m 45 ft lbs torque Be certain not to pinch the wiring between the steering wheel and the nut 5 Connect the horn switch wire then t...

Page 368: ...e WARNING THE A I R B A G S Y S T E M IS A S E N S I T I V E C O M P L E X E L E C T R O M E C H A N I C A L UNIT B E F O R E ATTEMPTING TO DIAGNOSE OR SERVICE A N Y AIR B A G SYSTEM OR RELATED STEERING W H E E L STEERING C O L U M N OR INSTRUMENT PANEL C O M P O N E N T S YOU MUST FIRST DISCONNECT A N D ISOLATE THE BATTERY NEGATIVE GROUND C A B L E THEN WAIT T W O MINUTES FOR THE SYS T E M CAPACI...

Page 369: ...s on the hub of the steering wheel onto the formations on the inside of the clockspring Pull the wire harnesses through the upper and lower holes i n the steering wheel hub Tighten the steering wheel nut to 61 N m 45 ft lbs torque Be certain not to pinch any of the wiring between the steering wheel and the nut 9 Install the Drive Airbag Module Refer to Drive Airbag Module Installation above ...

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Page 371: ...f i f the ignition switch is turned to the Off position or i t can be turned off manually by depressing the instru ment panel switch Refer to the owner s manual for more information on the defogger system controls and operation Following are general descriptions of the major components i n the defogger system Refer to Group 8W 48 Rear Window Defogger for complete circuit descriptions and diagrams ...

Page 372: ... volt age reading will change as soon as the break is crossed REAR WINDOW DEFOGGER RELAY The rear window defogger relay is located i n the fuse relay block along side of the speaker amplifier i n the rear cargo area Fig 1 While this relay uses a ISO relay output terminal configuration i t differs from a conventional relay since i t incorporates the timer for the rear window defogger as well Fig 2 ...

Page 373: ...ght I f not replace defogger switch I f OK go to Step 5 5 Using a ohmmeter connect the leads to Pin 4 and Pin 5 When the switch is at rest there should be no continuity press and hold button i t should show continuity I f OK test rear window defogger relay and circuit I f not OK replace defogger switch REAR WINDOW DEFOGGER SYSTEM The rear window defogger operation can be checked by turning the sys...

Page 374: ...al on desired location To pre vent terminal from moving while the epoxy is curing it must be wedged or clamped 8 Carefully remove masking tape from grid line CAUTION Do not allow the glass surface to exceed 204 C 400 F glass may fracture 9 Allow epoxy to cure 24 hours at room tempera ture or use heat gun with a 260 to 371 C 500 to 700 F range for 15 minutes Hold gun approximately 254 m m 10 inches...

Page 375: ...rence from other automatic locking sys tems is that specific throttle angle is not required for the locks to actuate It is strictly a speed based sys tem The vehicle will automatically lock if the vehicle speed is greater than 8 to 13 Km h 5 to 8 mph or if CCD communication is lost with Ignition key in the run position The vehicle will automatically unlock if the key is in the ignition with the Dr...

Page 376: ... both doors are locked When an unlock signal is input to the EEM both doors are unlocked I f the key is on and an inside door handle input is seen and vehicle speed is below 8 Km h 5 mph both doors will be unlocked The lock switch is a momentary contact type switch and either door switch will lock or unlock both doors For complete testing of the power door locks and electric latches refer to the p...

Page 377: ...locked When an unlock signal is input to the EEM both doors are unlocked If the key is on and an inside door handle input is seen and vehicle speed is below 8 to 13 Km h 5 to 8 mph both doors will be unlocked The lock switch is a momentary contact type switch and either door will lock or unlock the entire vehicle The key fobs are unique to the Viper and utilize a rolling code system The rolling co...

Page 378: ... t t e r c o d e is received w i t h i n 60 s e c o n d s T h e t i m e r resets after e a c h s u c c e s s f u l transmitter pro g r a m m i n g Causes for the FOB to go out of sync Depressing a F O B button while disconnecting the vehicle battery or power to the E E M Pressing both F O B buttons for five seconds or longer when out of range of the vehicle or when power has been disconnected to t...

Page 379: ...ll flash and the horn will pulse indicating that the vehicle has been tampered with The alarm can be tripped by opening doors hood liftglass or turning the ignition on Once tripped the alarm will sound for 2 5 minutes The park and tail lamps will flash for approximately 18 page VTSS DISARM SWITCH 2 REMOWAL AID INSTALLATION DOOR AJAR SWITCH 2 ELECTRONIC ENTRY MODULE EEM 2 HOOD AJAR SWITCH 3 LIFTGLA...

Page 380: ...I S A R M T H E S Y S T E M U S I N G T H E V T S S D I S A R M SWITCH 1 Open the liftglass with the ignition key N O T E T h e alarm will now be triggered until the disarm switch is activated 2 Reach i n through the liftglass opening and pull down on the manual door latch lever to open the door 3 Insert the key and turn to disarm the system REAR B U L K H E A D Fig 2 VTSS Disarm Switch Location D...

Page 381: ... hood 3 Disconnect the switch wire connector 4 Gently pull up while rocking the switch from the mounting bracket Fig 4 5 Remove switch from vehicle INSTALLATION For installation reverse the above procedures Fig 4 Hood Ajar Switch Location WTSS DISARM SWITCH The VTSS Disarm Switch is hardwired into the wire harness and is not serviced separately VTSS DISARM SWITCH LOCK CYLINDER REMOVAL The rear bul...

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Page 383: ...and negative connection to either of the two motor terminals will cause the motor to rotate i n one direction Reversing current through these same two connections will cause the motor to rotate i n the opposite direction Each individual motor is grounded through the switch D I A G N O S I S A N D T E S T I N G WIRING TEST This wiring test determines whether or not voltage is continuous through the...

Page 384: ...will be observed b Likewise motor connected to move window in DOWN direction no movement will be observed if window is already i n full DOWN position c Reverse battery leads i n Step 3 and Step 4 and window should now move I f window does not move remove motor 6 I f window moved completely up or down the test leads should be reversed one more time to com plete a full window travel inspection 7 The...

Page 385: ...CAV CIRCUIT CAV C I R C U I T 1 1 2 Z06 16BK VT 2 Z06 16BK VT 3 Z06 16BK VT 3 Z06 16BK VT 4 F21 16TN 4 R21 16TN 5 Q11 16LB 5 Q 2 2 1 6 V T 6 6 7 7 8 Q21 16WT 8 Q12 16BR WINDOW SWITCH REMOVAL 1 Remove instrument panel center bezel Fig 3 Disconnect the cigar lighter power window switch and rear window defogger switch wire connectors 2 Remove attaching screws 3 Remove window switch INSTALLATION For i...

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Page 387: ...tion I t has inter nal switches which work with the security alarm sys tem and the passive restraint system The chime system also uses the signal to show when the door is open I f there is a failure i n either switch and i t effects either system the complete door latch passive restraint mechanism will need to be replaced D I A G N O S I S A N D T E S T I N G CHIME MODULE 1 Remove chime module Ref...

Page 388: ...AND DRIVERS DOOR IS OPEN 1 Check left door latch for good ground when drivers door is open 2 Check wiring connector for good contact at chime module 3 Check for battery feed at terminal 6 of chime module 4 Check key in switch CHIMES CONTINUE WHEN HEADLAMPS ARE TURNED OFF AND OR KEY IS REMOVED FROM IGNITION 1 Check wiring for a grounded condition between headlamp switch key in switch and chime modu...

Page 389: ...Y TIME BUZZER RELAY TIME BUZZER RELAY 918N 2 Fig 3 Seat Belt Warning System Diagnosis FASTEN SEAT BELTS To test the fasten seat belts function turn the igni tion switch to the ON position with The driver s seat belt unbuckled and passenger seat belt buckled The passenger seat belt unbuckled and driver seat belt buckled The driver and passenger seat belt unbuckled The seat belt warning lamp should ...

Page 390: ...el reinforcement plate 5 Remove mounting screws from chime module Fig 4 6 Disconnect chime module wiring and remove module I N S T A L L A T I O N For installation reverse the above procedures HEADLAMP SWITCH REPLACEMENT Refer to Group 8 E Instrument Panel and Systems for Removal and Installation procedures Fig 4 Chime Module Location SEAT BELT BUCKLE REPLACEMENT Refer to Group 23 Body for Removal...

Page 391: ...ITION SYSTEM 8W 30 1 FUSE FUSE BLOCK 8W 11 1 GENERAL INFORMATION 8W 01 1 GROUND DISTRIBUTION 8W 15 1 HORN CIGAR LIGHTER 8W 41 1 INSTRUMENT CLUSTER 8W 40 1 INTERIOR LIGHTING 8W 44 1 MESSAGE CENTER 8W 46 1 POWER DISTRIBUTION CENTER 8W 10 1 POWER DOOR LOCKS 8W 61 1 POWER WINDOWS 8W 60 1 REAR LIGHTING 8W 51 1 REAR WINDOW DEFOGGER 8W 48 1 SPLICE INFORMATION 8W 70 1 SPLICE LOCATIONS 8W 95 1 STARTING SYS...

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Page 393: ...ponents and modules are shown in the at rest position with the doors closed and the key removed from the ignition page T R O U B L E S H O O T I N G T O O L S 8 T R O U B L E S H O O T I N G WIRING P R O B L E M S 10 S E R V I C E P R O C E D U R E S C O N N E C T O R AND TERMINAL R E P L A C E M E N T 11 C O N N E C T O R R E P L A C E M E N T 11 DIODE R E P L A C E M E N T 14 T E R M I N A L C O...

Page 394: ... FROM ANOTHER PAGE WITHIN THE GROUP 1 M E S S A G E C E N T E R INDICATES WIRES ARE PART OF THE SAME CONNECTOR INDICATES CIRCUIT NUMBER SIZE AND WIRE COLOR G9 20 GY BK 18 1 RED BRAKE l WARNING I LAMP DRIVER t G19 G83 G84 A 20 20 20 LG OR GY BK LB BK ABS TRACTION TRACTION WARNING CONTROL CONTROL LAMP ACTIVE WARNING DRIVER LAMP LAMP DRIVER DRIVER C O N T R O L L E R A N T I L O C K 1 B R A K E INTER...

Page 395: ...NUMBER IF ONLY ONE CONNECTOR IS PRESENT ON A COMPONENT THIS NUMBER IS OMITTED 6AC4 f n J U N C T I O N B L O C K 8 W 1 2 3 NO PAGE R E F E R E N C E INDICATES SPLICE IS SHOWN COMPLETE HERE 11YC2 G9 22 GY BK OTHERS ABS DRL SOLID BOX INDICATES COMPONENT IS SHOWN COMPLETE I G N I T I O N S W I T C H 1 S T A R T 4 I 2 R U N 8 W 1 0 4 O 5 F F INDICATES gSScK I SPECIFIC 4 A C C OPERATING CONDITIONS OF T...

Page 396: ...he diagrams use an alpha numeric code to identify the wire and its function To identify which circuit code applies to a system refer to the Circuit Identification Code Chart This chart shows the main circuits only and does not show the second ary codes that may apply to some models C I R C U I T FUNCTION A B A T T E R Y F E E D B B R A K E C O N T R O L S C CLIMATE C O N T R O L S D DIAGNOSTIC C I...

Page 397: ...er group i f it contains some associated wiring SYMBOLS International symbols are used throughout the wir ing diagrams These symbols are consistent with those being used around the world G R O U P TOPIC 8W 01 thru 8W 09 General Information and Diagram Overview 8W 10thru 8W 19 Main Sources of Power and Vehicle Grounding 8W 20 thru 8W 29 Starting and Charging 8W 30 thru 8W 39 Powertrain Drivetrain S...

Page 398: ...P GROUND G101 SCREW O TERMINAL TRANSISTOR TRANSISTOR 9 i p r TONE GENERATOR OPEN SWITCH CLOSED SWITCH LED f PHOTODIODE DIODE ZENER DIODE GANGED SWITCH 1SLIDING DOOR CONTACT A OXYGEN GAUGE SENSOR I PIEZOELECTRIC CELL T V WIRE ORIGIN DESTINATION SHOWN WITHIN CELL t WIRE DESTINATION SHOWN IN ANOTHER CELL RESISTOR VARIABLE HEATER RESISTOR J b ELEMENT POTENTIOMETER EXTERNAL SPLICE S350 INTERNAL SPLICE ...

Page 399: ...f the splices i n each harness The illustrations show the splice by number and provide a written location NOTES CAUTIONS and WARNINGS Throughout this group additional important infor mation is presented i n three ways Notes Cautions and Warnings N O T E S are used to help describe how switches or components operate to complete a particular circuit They are also used to indicate different condition...

Page 400: ...n 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 two points of a circuit I t can be used to bypass an open in a circuit 948W 193 Fig 4 Electrostatic Discharge Symbol WARNING N E V E R U S E A J U M P E R W I R E A C R O S S A L O A D S U C H A S A MOTOR C O N N E C T E D B E T W E E N A B A ...

Page 401: ...may need to be turned ON to check voltage Refer to the appropri ate test procedure TESTING FOR CONTINUITY 1 Remove the fuse for the circuit being checked or disconnect the battery 2 Connect one lead of the ohmmeter to one side of the circuit being tested Fig 7 3 Connect the other lead to the other end of the circuit being tested Low or no resistance means good continuity TESTING FOR A SHORT TO GRO...

Page 402: ...s to determine what the circuit is doing where the problem most likely is occurring and where the diagnosis will continue 4 Isolate the 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 S E R V I C E P R O C E D U R E S WIRING REPAIR When replacing or repairing a wire i t is importa...

Page 403: ...ector locking finger away from the terminal using the proper pick from special tool CONNECTOR Fig 12 Connector Locking Wedge kit 6680 Pull on the wire to remove the terminal from the connector Fig 13 Fig 14 5 Reset the terminal locking tang i f i t has one 6 Irisert the removed wire i n the same cavity on the repair connector 7 Repeat steps four through six for each wire i n the connector being su...

Page 404: ...oint 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 18 Re connect the repaired connector 17 Connect the battery and test all affected sys tems TERMINAL CONNECTOR REPAIR THOMAS AND BETTS CONNECTORS 1 Disconnect battery 2 ...

Page 405: ...hat best matches the color wire being repaired 8 Cut the repair wire to the proper length and 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 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...

Page 406: ...W BAND AROUND DIODE INDICATES CURRENT FLOW N DIODE AS SHOWN IN THE DIAGRAMS 948W 197 Fig 22 Diode identification 4 Remove the insulation from the wires i n the harness Only remove enough insulation to solder i n the new diode 5 Install the new diode i n the harness making sure current flow is correct I f necessary refer to the appropriate wiring diagram for current flow 6 Solder the connection tog...

Page 407: ...og Lamp Logic Relay 8W 50 Fog Lamp Relay 8W 50 Fog Lamps 8W 50 Fuel Injectors 8W 30 Fuel Pump Module 8W 30 Fuel Pump Relay 8W 11 30 Fuse Block 8W 11 Fuse Relay Block 8W 11 48 Fuses FB 8W 11 C o m p o n e n t P a g e Fuses PDC 8W 10 Fusible Link 8W 20 Gauges 8W 40 Generator 8W 20 Grounds 8W 15 Hazard Flasher Switch 8W 52 Headlamp Dimmer Switch 8W 50 Headlamp Switch 8W 50 Headlamps 8W 50 High Beam R...

Page 408: ...8W 44 Turn Indicators 8W 46 Turn Signal Lamps 8W 52 Turn Signal Hazard Flasher 8W 52 Turn Signal Hazard Switch 8W 52 Component Page Vehicle Speed Sensor 8W 30 Voltmeter 8W 40 VTSS Disarm Switch 8W 39 VTSS L E D 8W 39 VTSS Liftglass Ajar Switch 8W 39 Windshield Washer Pump 8W 53 Wiper Control Module 8W 53 Wiper Switch 8W 53 ...

Page 409: ...0 14 16 Fuse 10 PDC 8W 10 9 Fuse 11 FB 8W 10 16 Fuse 11 PDC 8W 10 6 8 Fuse 12 FB 8W 10 15 Component Page Fuse 12 PDC 8W 10 6 15 Fuse 13 FB 8W 10 8 Fuse 13 PDC 8W 10 6 8 Fuse 14 FB 8W 10 8 Fuse 14 PDC 8W 10 6 8 Fuse 15 PDC 8W 10 6 10 Fuse 16 PDC 8W 10 6 13 Fuse 17 PDC 8W 10 6 10 Fuse 18 PDC 8W 10 6 9 Fuse 19 PDC 8W 10 6 15 Fuse Block 8W 10 8 14 15 16 G100 8W 10 14 Generator 8W 10 11 Headlamp Dimmer...

Page 410: ... I 5 8 5 4 8 4 4 f 6 9 I I 6 7 0 5 7 5 3 0 4 3 P I 6 6 T 5 6 J 5 2 3 J 3 6 2 8 3 5 2 7 3 4 2 6 I 6 5 2 5 5 J 5 1 T 3 3 2 5 NOT USED 11 ENGINE STARTER MOTOR R E L A Y 9 LOW BEAM RELAY 8 HIGH BEAM RELAY 7 AUTOMATIC SHUT DOWN RELAY 6 A C COMPRESSOR CLUTCH RELAY 5 HORN RELAY 4 FOG LAMP RELAY 3 FOG LAMP LOGIC RELAY 2 NOT USED 1 J 9 8 8 W 1 3 ...

Page 411: ... 20 F3416TN BK A0 6RD 11 20 F3416TN BK A1110DG 12 30 A214PK BK AO 6RD 12 30 A214PK BK A1110DG 13 30 A5 14RD AO 6RD 13 30 A5 14RD A11 10DG 14 20 L9 18BK WT AO 6RD 14 20 L9 18BK WT A11 10DG 15 20 A1414RD WT AO 6RD 15 20 A1414RD WT A11 10DG 16 50 A1612GY A0 6RD 16 50 A1612GY A11 10DG 17 20 L2016LG WT AO 6RD 17 20 L2016LG WT A11 10DG 18 20 A3 16RD WT AO 6RD 18 20 A3 16RD WT A11 10DG 19 40 A1 12RD A0 6...

Page 412: ...RCUIT FUNCTION 79 T4014BR ENGINE STARTER MOTOR RELAY OUTPUT 81 F45 20YL7PK CLUTCH PEDAL POSITION SWITCH OUTPUT 82 83 Z12 20BK TN GROUND 87 A1 12RD FUSED B FOG CAVITY CIRCUIT FUNCTION LAMP 7 L95 18DG YL FOG LAMP RELAY NO 2 OUTPUT RELAY 8 3 9 Z12 20BK TN GROUND 3 27 L3918LB FOG LAMP RELAY OUTPUT 35 F3918PK LG FUSED B HIGH CAVITY CIRCUIT FUNCTION BEAM 19 G3416RD GY HIGH BEAM INDICATOR DRIVER RELAY 20...

Page 413: ... OUTPUT 40 A3 16RD WT FUSED B RADIATOR FAN LOW HIGH RELAY 10 CAVITY CIRCUIT FUNCTION 89 C2512LG RADIATOR FAN LOW HIGH RELAY OUTPUT HIGH 91 F1218DB GY FUSED IGNITION SWITCH OUTPUT ST RUN 92 C2312DG RADIATOR FAN LOW HIGH RELAY OUTPUT LOW 93 C137 20YL RADIATOR FAN LOW HIGH RELAY CONTROL 97 C11612LG WT RADIATOR FAN ON RELAY OUTPUT RADIATOR CAVITY CIRCUIT FUNCTION FAN ON 90 C11612LG WT RADIATOR FAN ON ...

Page 414: ... I CENTER i i _ J 7 7 s 8W 10 I F32 1 4 P K D B T O C100 73 F U S E 1 2 3 0 A 8W 10 15 8 W 1 0 S A 5 1 4 R D T O CI 00 F U S E 1 5 2 0 A 8W 10 10 F U S E 1 6 5 0 A 8W 10 13 45 F U S E 1 7 2 0 A 8W 10 10 T O S101 IN PDC L 2 0 1 6 L G W T T O S124 L 2 0 1 6 L G W T F U S E 1 8 2 0 A 8W 10 9 T O HIGH BEAM RELAY IN PDC A 3 1 6 R D W T J988W 13 T O LOW BEAM RELAY IN PDC 4 g H 8W 10 15 A1 1 2 R D T O S1...

Page 415: ...107 X2 18 DG RD I S107 X2 18 F31 F31 F31 18 16 16 VT VT VT F30 16 RD F33 18 PK RD X2 18 DG RD DG RD S123 IN PDC 47 C3 18 DB BK RIGHT HORN 8W 41 2 F31 20 VT LEFT HORN 8W 41 2 S117 C3 18 DB BK 27 C100 C100 F30 16 RD F33 18 PK RD CIGAR F31 20 VT LIGHTER I 8W 41 2 i A C COMPRESSOR CLUTCH 2 A c A C 3 8W 42 2 BUZZER iODULE 8W 46 3 ELECTRONIC I ENTRY 1 MODULE 1 8W 39 2 8W 61 2 SR001007 J988W 13 ...

Page 416: ... HEADLAMP SWITCH 8W 50 2 STOP LAMP 1 SWITCH I 8W 51 3 HEADLAMP SWITCH 8W 50 2 1 3 33 T F U S E 1 3 X 2 0 A L 8W 11 9 POWER DISTRIBUTION CENTER F U S E I 8W 10 6 1 4 i 2 0 A A1 A t TURN I SIGNAL I 1 HAZARD I FLASHER I N FB 8W 52 2 I FUSE BLOCK 8W 11 2 J988W 13 S R 0 0 1 0 0 8 ...

Page 417: ...P I 8W 50 11 BATTAO 8W 10 6 48 FUSE 18 20A 1 POWER DISTRIBUTION I CENTER 8W 10 6 40 I w I LOW iBEAM 1 1 RELAY I I 8W 50 6 L J 32 6 8 FUSE 9 10A 7 8 L43 20 VT C114 S126 L44 20 VT RD L43 20 VT 1 C120 L44 20 VT RD L44 18 VT RD 10 Js DAYTIME 1 RUNNING Jl j RIGHT I IWIlllll LAMP I MODULE 8W 50 12 L O W B E A M I HEADLAMP 10 A C 2 M E S S A G E C E N T E R 8W 46 6 L E F T LOW BEAM I HEADLAMP 1 8W 50 9 8...

Page 418: ... F142 18 OR DG RIGHT DOWNSTREAM 1 HEATED I OXYGEN SENSOR 8W 30 12 L E F T C3 I DOWNSTREAM H E A T E D I OXYGEN SENSOR 8W 30 12 HEADLAMP DIMMER SWITCH PART O F MULTI FUNCTION SWITCH 8W 50 5 TO S119 8W 10 11 POWERTRAIN CONTROL MODULE I I 8W 30 2 6 r 2 C 1 1 4 A L3 16 RD OR L3 16 OR RD 1 A 1 RIGHT HIGH B E A M I HEADLAMP 1 8W 50 9 L E F T HIGH BEAM I HEADLAMP 8W 50 9 L J988W 13 DAYTIME I RUNNING I LA...

Page 419: ... D G O R A142 1 6 D G O R 1 A C134 A 1 4 2 1 4 D G O R A 1 4 2 1 4 D G O R GENERATOR 8W 20 3 L I LEFT UPSTREAM 1 HEATED I OXYGEN SENSOR 8W 30 11 I RIGHT UPSTREAM 1 HEATED I OXYGEN SENSOR 8W 30 11 S131 A142 1 4 D G O R LEFT IGNITION COIL P A C K 8W 30 8 A142 14 D G O R RIGHT IGNITION COIL PACK 8W 30 8 A 1 4 2 1 6 D G O R FUEL INJECTOR 1 NO 10 I 8W 30 7 A142 1 4 D G O R T O S133 8W 10 12 A142 1 4 D ...

Page 420: ...6 D G O R i FUEL INJECTOR NO 9 I 8W 30 8 A 1 4 2 1 6 D G O R A 1 4 2 1 6 D G O R A 1 4 2 1 6 D G O R A 1 4 2 1 6 D G O R FUEL INJECTOR NO 7 I 8W 30 8 FUEL INJECTOR NO 5 I 8W 30 8 FUEL INJECTOR f N 0 8 I 8W 30 7 I FUEL INJECTOR NO 6 I 8W 30 7 FUEL INJECTOR NO 4 I 8W 30 7 FUEL INJECTOR NO 3 I 8W 30 8 FUEL INJECTOR NO 2 I 8W 30 7 j FUEL INJECTOR 1 NO 1 I 8W 30 8 J 9 8 8 W 1 3 S R 0 0 1 0 1 2 ...

Page 421: ...OR FAN 1 O N I R E L A Y J 8 V V 4 2 4 1 R A D I A T O R FAN LOW HIGH I RELAY j 8W 42 4 C25 12 LG C23 12 DG FUSE 1 6 5 0 A POWER DISTRIBUTION CENTER 8W 10 6 A 1 6 12 G Y A 1 6 1 2 G Y A 1 6 1 2 G Y RADIATOR FAN MOTOR 8W 42 4 S101 IN PDC S R 0 0 1 0 1 3 J 9 8 8 W 1 3 ...

Page 422: ...8W 10 14 8W 10 POWER DISTRIBUTION T POWER DISTRIBUTION CENTER 8W 10 6 S114 IN PDC 8W 15 2 J988W 13 S102 z 2 8W 15 2 1 2 B K T N AG100 8W 15 2 S R 0 0 1 0 1 4 ...

Page 423: ...21 2 C100 l RED 1 B R A K E B R A K E I WARNING 1 W A R N I N G LAMP 1 I SWITCH L RI XIR J 8W 46 5 1 Y G99 20 G Y W T 1 M E S S A Q E BRAKE 1 CENTER 1 W A R N I N G I 8W 46 5 I L A M P I DRIVER 5 Y C 1 G 9 9 20 GY WT C100 G 9 9 20 G Y W T IGNITION SWITCH 1 S T A R T 2 R U N 0OFF 3ACC 8W 10 16 8W 10 16 S R 0 0 1 0 1 5 J988W 13 ...

Page 424: ...TRIBUTION S R BATTA2 8W 10 15 BATT A1 8W 10 15 1 IGNITION SWITCH 11 START 2 RUN 5 Y loOFF 3ACC j 8W 10 15 2 V FUSE BLOCK 8W 11 2 I CIRCUIT BREAKER 25A I 8W 11 6 1 POWER I WINDOW I CIRCUIT I BREAKER I 8W 11 6 J988W 13 SR001016 ...

Page 425: ...W 11 10 G300 8W 11 11 Component Page G302 8W 11 11 Hazard Flasher Switch 8W 11 10 Headlamp Switch 8W 11 4 Illuminated Rearview Mirror 8W 11 4 9 Key In Switch Halo Lamp 8W 11 9 Leak Detection Pump 8W 11 7 Left Door Latch Switch 8W 11 9 Left Exterior Door Handle Switch 8W 11 10 Left Front Park Turn Signal Lamp 8W 11 4 Left Interior Door Handle Switch 8W 11 10 Left License Lamp 8W 11 5 Left Side Mark...

Page 426: ...6 F U S E 1 5 15 34 F U S E 1 4 33 F U S E 1 3 32 F U S E 31 F U S E 30 F U S E 1 2 12 11 1 0 1 2 12 29 F U S E 9 28 F U S E 27 F U S E 7 26 F U S E 6 25 F U S E 5 24 23 22 F U S E F U S E F U S E 4 3 2 2 21 F U S E 1 D L 5 1 8 B K B D TURN SIGNAL HAZARD FLASHER L 9 1 8 B K W T L1918PK L618 R D W T Z120BK F 3 5 2 0 R D F 3 5 2 0 R D MI18PK Ml 1 8 P K A514RD F 1 2 1 8 D B G Y F1418LG YL A21 1 2 D B...

Page 427: ... RELAY CHART RELAY CAVITY CIRCUIT FUNCTION T U R N S I G N A L H A Z A R D F L A S H E R A1 L 9 1 8 B K W T F U S E D B T U R N S I G N A L H A Z A R D F L A S H E R A 2 L 6 1 8 R D W T T U R N S I G N A L F L A S H E R O U T P U T T U R N S I G N A L H A Z A R D F L A S H E R A 3 Z1 2 0 B K G R O U N D T U R N S I G N A L H A Z A R D F L A S H E R A 4 L1918PK H A Z A R D F L A S H E R O U T P U T...

Page 428: ... I 8W 53 2 ELECTRONIC ENTRY 1 MODULE I 8W 39 2 8W 61 2 S111 S208 L7 20 B K Y L L 7 1 8 B K Y L C207 L7 20 B K P K L 7 20 B K Y L 1 5 k 17 1 8 B K Y L L 7 1 8 B K Y L RADIO 8W 47 2 B A C3 ELECTRONIC I ENTRY i 11 C114 L 7 1 8 B K Y L 2 C122 L7 1 8 B K Y L 2k 17 1 8 B K Y L L 7 1 8 B K Y L C116 L 7 1 8 B K Y L L7 1 8 B K Y L k LEFT RIGHT SIDE 1 MARKER I LAMP J 8W 52 4 C120 x t cm L7 1 8 BK YL L7 1 8 ...

Page 429: ... YL 51 I RIGHT TAIU STOP I LAMP J 8W 51 6 8W 51 7 C2 I C3 L 7 1 8 B K Y L 1 C308 L 7 1 8 B K W L L7 1 8 B K Y L 1A 1 RIGHT 1 A 1 L E F T I LICENSE I 1 LAMP I COUPE 8W 51 4 LICENSE I L A M P I COUPE 8W 51 4 RIGHT TAIL S T O P I LAMP 8W 51 6 8W 51 7 RIGHT TAIL S T O P LAMP 8W 51 6 8W 51 7 S404 L 7 1 8 B K Y L CI 1 L E F T TAIL STOP LAMP 8W 51 4 8W 51 5 L7 1 8 B K Y L C2 I L E F T TAIL S T O P I LAMP...

Page 430: ... 8W 52 2 AIRBAG CONTROL MODULE I 8W 43 2 FUSE I BLOCK K8W 11 2 F20 20 W T 34 C100 A 2 2 1 4 B K O R C I R C U I T B R E A K E R 2 5 A POWER WINDOW CIRCUIT BREAKER F 2 0 20 W T F21 1 6 T N 5 A C155 F 2 0 20 W T POWER WINDOW SWITCH I 8W 60 2 S301 F20 20 W T 4 C330 F 2 0 20 W T k REAR F 2 0 20 W T B A BACK UP LAMP 1 SWITCH I 8W 51 8 WINDOW 1 DEFOGGER I RELAY IN FUSE RELAY BLOCK COUPE 8W 48 2 J988W 13...

Page 431: ...POWERTRAIN CONTROL 1 MODULE I 8W 30 2 DUTY CYCLE 1 EVAP I PURGE SOLENOID 8W 30 16 F 1 2 1 8 D B G Y 1 A C330 F 1 2 1 8 D B G Y F 1 2 1 8 D B G Y 5 C330 F 1 2 1 8 D B G Y F 1 2 1 8 D B G Y 4 A FUSE RELAY 1 B L O C K I 8W 11 12 1 I 2 3 LOCK OUT 1 SOLENOID I 8W 30 16 REVERSE LOCK OUT SOLENOID 8W 30 16 1 A C C O M P R E S S O R C L U T C H I R E L A Y L In L J t8 W 4 2 2 1 A U T O M A T I C SHUT 1 D O...

Page 432: ... 2 I SPEEDOMETER j 8W 40 4 I TACHOMETER 1 8W 40 5 I S204 G 5 20 DB WT G 5 20 DB WT 3 A 32 F U S E 1 2 5 A FUSE BLOCK 8W 11 2 F 4 5 1 8 Y L 7 R D CLUTCH PEDAL POSITION I SWITCH 8W 21 2 S205 G 5 2 0 DB WT G 5 20 DB WT 3 A G 5 20 DB WT ENGINE OIL PRESSURE GAUGE 8W 40 8 G 5 20 DB WT ENGINE COOLANT TEMPERATURE GAUGE 8W 40 6 C1 MESSAGE CENTER 8W 46 2 FUEL GAUGE 8W 40 7 VOLTMETER 8W 40 9 J 9 8 8 W 1 3 S ...

Page 433: ... 8 D B R D I T O S219 8W 53 3 F U S E 1 3 2 0 A BLOCK 8W 11 2 M 1 1 8 P K DATA LINK CONNECTOR 8W 30 3 M 1 1 8 P K C100 M 1 1 8 P K M 1 20 P K 1 6 m I M 1 20 P K A S215 M 2 20 Y L C207 M 2 20 B K L B d i ILLUMINATED REARVIEW MIRROR I ROADSTER 8W 44 5 M 1 1 8 P K 1 3 4 cm M 1 1 8 P K C207 M 1 20 B K R D RADIO 8W 47 2 C2 MESSAGE CENTER 8W 46 2 C155 ILLUMINATED REARVIEW 1 MIRROR I ROADSTER M 8W 44 5 S...

Page 434: ... I G N A L H A Z A R D F L A S H E R 8W 52 2 N FUSE I BLOCK I 8W 11 2 EXTERIOR DOOR 1 HANDLE M SWITCH 8W 61 5 Z1 20 B K L 6 1 8 R D W T L 1 9 1 8 P K S211 S202 8W 15 6 F 3 5 20 R D F 3 5 20 R D S320 I F 3 5 20 R D X Z1 1 8 B K a G201 8W 15 6 F 3 5 20 R D RIGHT INTERIOR DOOR 1 HANDLE SWITCH 8W 61 4 F 3 5 20 R D C AC2 1 7 1 3 HAZARD FLASHER SWITCH 8 PART OF MULTI FUNCTION SWITCH 8W 52 3 ELECTRONIC E...

Page 435: ...I S301 8W 11 6 11 I AUDIO AMPLIFIER I 8W 47 4 8W 47 5 1 F81 1 4 T N F U S E F U S E D F U S E D 4 IGNITION B 2 5 A S W I T C H 8W 11 12 O U T P U T RUN I 1 1 S W I T C H R E L A Y 1 G R O U N D S I G N A L C O N T R O L FUSE RELAY j BLOCK I R E A R W I N D O W D E F O G G E R R E L A Y C O U P E 8 W 4 8 2 L Z1 1 8 B K 10 S304 8W 15 10 Z 1 1 8 B K I C 8 0 1 8 D B W T B 4 X I B 1 J j C228 C 1 5 1 4 ...

Page 436: ... FUSE 10 10A 8W 11 7 8W 10 16 1 FUSE BLOCK 8W 11 2 30 F12 18 DB GY 25 C100 F12 18 DB GY I S104 8W 11 7 F12 18 DB GY 1 4 cm F12 18 DB GY S300 8W 11 7 8W 11 11 POWERTRAIN CONTROL 1 MODULE I 8W 30 6 MODULE I 8W 30 6 FUSE RELAY BLOCK J988W 13 SR001112 ...

Page 437: ...mponent Page Left Fog Lamp 8W 15r3 Left Front Park Turn Signal Lamp 8W 15 4 Left High Beam Headlamp 8W 15 4 Left Horn 8W 15 3 Left License Lamp 8W 15 8 9 Left Low Beam Headlamp 8W 15 4 Left Rear Turn Signal Lamp 8W 15 8 9 Left Tail Stop Lamp 8W 15 8 9 Left Turn Indicator 8W 15 6 Left Upstream Heated Oxygen Sensor 8W 15 3 Liftglass Ajar Switch 8W 15 8 Low Beam Relay 8W 15 2 Message Center 8W 15 5 P...

Page 438: ...M O T O R R E L A Y j 8 W 2 1 2 8 3 Y Z 1 2 2 0 B K T N Z 1 2 2 0 B K T N Z 1 2 2 0 BK TN Z 1 2 2 0 B K T N POWER DISTRIBUTION CENTER 8 W 1 0 6 Z 1 2 1 8 B K DATA LINK CONNECTOR 8 W 3 0 3 B K Z 1 2 Z 1 2 1 8 B K T N S114 IN PDC POWERTRAIN CONTROL 1 MODULE I 8 W 3 0 2 3 1 C100 Z 1 2 1 8 BK TN C3 Z 1 2 1 4 B K T N 3 2 YC3 Z 1 2 1 4 B K T N S102 Z 1 2 1 2 B K T N RADIATOR FAN 1 MOTOR I 8 W 4 2 4 G100...

Page 439: ... Z1 18 BK DAYTIME RUNNING LAMP MODULE 8W 50 12 I HOOD SWITCH 8W 39 6 Z1 18 BK 2 Y Z1 18 BK S112 Z1 16 BK 29 T A C COMPRESSOR 1 CLUTCH I RELAY J IN PDC 8W 42 2 G102 C3 18 DB BK 1 C107 C3 18 DB BK A C COMPRESSOR CLUTCH 2Y LEFT UPSTREAM 1 HEATED I OXYGEN SENSOR 8W 30 11 RIGHT Z1 18 BK 2Y Z1 18 BK UPSTREAM 1 HEATED I OXYGEN SENSOR 8W 30 11 S128 Z1 18 BK AG103 SR001503 J988W 13 ...

Page 440: ...LAMP 8W 50 9 Z1 16 B K Z1 16 B K V j LEFT FRONT PARK I TURN SIGNAL LAMP 8W 52 4 Z1 18 B K S134 Z1 16 B K _t_G104 RIGHT LOW BEAM I HEADLAMP 8W 50 9 Z1 16 B K RIGHT HIGH BEAM I HEADLAMP 8W 50 9 Z1 16 B K RIGHT FRONT PARK TURN SIGNAL LAMP Z1 8W 52 4 18 B K T S13S Z1 16 BK A 6105 J988W 13 SR001504 ...

Page 441: ... T I Z20 20 B K ENGINE COOLANT 1 TEMPERATURE I GAUGE 8W 40 6 ENGINE 4 7 8W 40 6 _ OIL 1 PRESSURE I GAUGE y 8W 40 8 S217 1Y C1 1YC2 4 Y C2 Z8 20 B K V T I A C HEATER I CONTROL j 8W 42 3 Z20 20 B K W T I MESSAGE CENTER 8W 46 2 4 YC1 r Z20 20 B K W T VOLTMETER j 8W 40 9 I Z20 20 B K W T 4 Y Z20 20 B K W T I FUEL GAUGE I 8W 40 7 I 4 T Z20 20 BK WT S209 Z8 16 BWT Z8 16 BK VT CIGAR LIGHTER 8W 41 2 Z20 1...

Page 442: ... 5 I I A A Z1 20 BK L 2Y Z1 20 B K I 1 SPEEDOMETER I 8W 40 4 Z1 20 B K A Z1 20 BK Z1 20 B K Z1 20 B K I S201 LER Z1 20 BK D V Z1 18 BK DOOR 1 LATCH I SWITCH 8W 61 3 1 TURN SIGNAL BUZZER MODULE 8W 46 3 A3 Y C242 HAZARD I FLASHER IN FB 8W 52 2 HEADLAMP SWITCH 8W 50 2 Z1 1 8 B K Z1 20 B K TZ1 20 B K S202 Z1 1 8 B K Z1 18 BK G201 J 9 8 8 W 1 3 S R 0 0 1 5 0 6 ...

Page 443: ... L G 5 Y 22 18 B K L G Y Z2 1 8 B K L G PASSENGER WIPER 1 MOTOR I 8W 53 3 3 Y 72 20 B K L G SWITCH HALO LAMP 8W 46 4 WIPER SWITCH PART OF IMULTI FUNCTION SWITCH 8W 53 2 Z2 1 8 B K L G S220 Z2 1 6 B K L G G202 AIRBAG CONTROL MODULE I 8W 43 2 1 0 Y Z 6 1 8 B K P K I RADIO 8W 47 3 I Z3 20 B K G203 S R 0 0 1 5 0 7 J 9 8 8 W 1 3 ...

Page 444: ... 4 C1 1 RIGHT I TAIL iSTOP j LAMP 1 Y C 2 1 Y C3 8 W 5 1 6 RIGHT BACK UP LAMP I 8W 51 8 3 Y Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK 3 Y Z1 18 BK RIGHT REAR TURN SIGNAL LAMP 8W 52 4 2 Y S402 RIGHT S403 LICENSE LAMP I 8W 51 4 Z1 18 BK LIFTGLASS AJAR SWITCH I 8W 44 2 Z1 18 BK i4c318 B Y Z1 18 BK Z1 18 BK 1 Y Z1 18 BK i CENTER HIGH MOUNTED STOP LAMP 8W 51 6 Z1 18 BK S406 C319 Z1 18 BK Z1 18 BK 3 Z1 18 BK ...

Page 445: ... BK BK BK BK RIGHT BACK UP 1 LAMP I 8W 51 8 3 Y RIGHT 3 Y REAR TURN I SIGNAL LAMP 8W 52 4 Z1 Z1 Z1 Z1 Z1 18 18 18 18 18 BK BK BK BK BK S402 S403 Z1 18 BK j LEFT LICENSE LAMP I 8W 51 5 C318 Z1 18 BK 1 V Z1 18 BK RIGHT LICENSE LAMP I 8W 51 5 Z1 18 BK I 1 I Z1 14 BK AUDIO AMPLIFIER 8W 47 5 CENTER HIGH 1 MOUNTED STOP LAMP 8W 51 7 1 Y Z1 18 BK 2 C308 Z1 18 BK Z1 18 BK 1 C319 Z1 18 BK iFUEL PUMP 1 MODUL...

Page 446: ... 1 8 B K S304 Z1 1 4 B K Z1 1 8 B K j PARK BRAKE 1 SWITCH I 8W 46 5 AG300 COUPE 1 1 DRIVER I SEAT I 1 BELT I SWITCH 8W 46 3 LEFT DOWNSTREAM HEATED OXYGEN SENSOR 8W 30 12 I Q BATTERY 8W 11 11 Z O 2 B K G302 REAR WINDOW 1 DEFOGGER I 8W 48 2 T Z1 12 B K I m I Z1 14 B K S332 8W 48 2 2 Y Z12 18 B K T N RIGHT DOWNSTREAM HEATED OXYGEN SENSOR 8W 30 12 a G303 COUPE Z1 16 B K 1Y Z1 16 B K Z12 18 B K T N FUE...

Page 447: ...e Automatic Shut Down Relay 8W 20 2 Battery 8W 20 2 Engine Starter Motor 8W 20 2 Fuse 10 FB 8W 20 2 Fuse 15 PDC 8W 20 2 Fuse Block 8W 20 2 Component Page Fusible Link 8W 20 2 G 3 0 2 8W 20 2 Generator 8W 20 3 Power Distribution Center 8W 20 2 Powertrain Control Module 8W 20 3 ...

Page 448: ...11 zo 2 B K JL G302 8W 15 10 1 POWER DISTRIBUTION CENTER 8W 10 6 A11 1 0 D G FUSIBLE LINK A11 1 0 D G S127 A11 6 B K G Y A U T O M A T I C S H U T D O W N R E L A Y 8W 30 4 n POWER i DISTRIBUTION 1 CENTER 8W 10 6 I I A11 6 B K G Y J988W 13 T O POWERTRAIN CONTROL MODULE 8W 20 3 T O S119 8W 20 3 T O GENERATOR 8W 20 3 S R 0 0 2 0 0 2 ...

Page 449: ...MATIC SHUT DOWN RELAY 8W 20 2 F R O M S127 8W 20 2 A 1 4 2 1 4 D G O R S119 8W 10 11 A 1 4 2 1 4 D G O R A T C107 A 1 4 2 1 4 D G O R S129 I 8W 10 11 A 1 4 2 1 4 D G O R A11 6 B K G Y 4 t A142 1 4 D G O R d cm f H 4 H4 2 y K 2 0 1 8 D G 1 C134 K 2 0 1 8 D G 6 C107 K 2 0 1 8 D G 1 0 A c 2 GENERATOR G E N E R A T O R F I E L D D R I V E R 1 POWERTRAIN CONTROL i MODULE 8W 30 4 J 9 8 8 W 1 3 ...

Page 450: ......

Page 451: ...Battery 8W 21 2 Clutch Pedal Position Switch 8W 21 2 Engine Starter Motor 8W 21 2 Engine Starter Motor Relay 8W 21 2 Fuse 12 FB 8W 21 2 Fuse 19 PDC 8W 21 2 Component Page Fuse Block 8W 21 2 G100 8W 21 2 G302 8W 21 2 Ignition Switch 8W 21 2 Power Distribution Center 8W 21 2 ...

Page 452: ...T N S102 8W 15 2 Z12 1 8 B K T N I A G 1 0 0 8W 15 2 F U S E 1 9 4 0 A 8W 10 15 j POWER I DISTRIBUTION I CENTER 8W 10 6 I I S118 IN PDC 8W 10 15 87 A1 1 2 R D i BATTERY 8W 11 11 Z 0 2 B K G302 A O 2 R D ENGINE STARTER MOTOR RELAY IN PDC A O 6 R D J988W 13 ENGINE STARTER MOTOR 1 P U L L I N 2 H O L D I N S R 0 0 2 1 0 2 ...

Page 453: ...0 7 Fuel Pump Module 8W 30 6 Fuel Pump Relay 8W 30 5 Fuse 1 PDC 8W 30 4 12 Fuse 4 F RB 8W 30 5 Fuse 10 FB 8W 30 2 4 5 16 Fuse 13 F B 8W 30 3 Fuse 15 PDC 8W 30 2 4 7 8 11 12 Component Page Fuse Block 8W 30 2 3 4 5 16 Fuse Relay Block 8W 30 5 G100 8W 30 2 3 G103 8W 30 11 G300 8W 30 6 G304 SW 30 6 12 Generator 8W 30 4 Idle A i r Control Motor 8W 30 15 Intake Air Temperature Sensor 8W 30 14 Leak Detec...

Page 454: ... POWER DISTRIBUTION CENTER 8W 10 6 A 1 4 1 4 RD WT 2 A C3 22 C3 F U S E D IGN S T R U N F U S E D B JROUND 31 Y C3 Z12 1 4 B K T N G R O U N D 32 V C3 Z12 1 4 B K T N S T O P L A M P S W I T C H S E N S E I POWERTRAIN I CONTROL MODULE I I 24y a K 2 9 1 8 W T P K 43 C100 S102 8W 15 2 K 2 9 1 8 W T P K Z12 1 2 B K T N 1 S T O P I L A M P I S W I T C H G100 8W 15 2 S E N S E STOP LAMP 1 SWITCH I 8W 5...

Page 455: ...D R E C E I V E B U S C C D B U S 1 8 y D 2 20 W T B K C C D B U S J i L 1 9 Y D 1 20 V T B R l AIRBAG CONTROL MODULE I 8W 43 3 TWISTED PAIR Xci I ELECTRONIC ENTRY MODULE 8W 39 8 D 1 20 V T B R Z12 1 8 B K Z12 1 8 B K V C100 Z12 1 8 B K T N Si 02 8W 15 2 D 1 20 V T B R Z12 1 2 B K T N 32 C100 G100 8W 15 2 TWISTED PAIRS _ D 1 20 V T B R 30 C1 C C D B U S 1 POWERTRAIN CONTROL I MODULE S R 0 0 3 0 0 ...

Page 456: ... DISTRIBUTION CENTER 8W 10 6 K20 18 DG F142 18 OR DG 8 A cm F142 18 OR DG f C107 K20 18 DG 11 LC 1 L J E AUTOMATIC GENERATOR I POWERTRAIN SHUT FIELD CONTROL DOWN DRIVER 1 MODULE RELAY I OUTPUT j F142 18 OR DG I AUTOMATIC I L E F T SHUT DOWNSTREAM 1 DOWN HEATED I R f Y 1 OXYGEN L 2U IEU L J SENSOR 8W 30 12 m S314 I F142 18 OR DG I AUTOMATIC I R I G H T SHUT DOWNSTREAM I 1 DOWN HEATED I Y 1 OXYGEN L...

Page 457: ...T A12 19 FUSE 4 25A 8W 11 12 8W 11 11 1 FUSE I RELAY BLOCK j 8W 11 12 I I ST RUN A21 F241 16 RD YL 8W 10 16 1 FUSE BLOCK 8W 11 2 S3G0 8W 11 7 F12 18 DB GY TO FUEL PUMP MODULE 8W 30 6 SR003005 T O C111 8W 30 6 FUSE RELAY BLOCK 8W 11 12 J988W 13 ...

Page 458: ... B K T N 2 Y Z1 1 8 B K G 4 1 8 D B S302 8W 15 10 Z12 1 4 B K T N S304 8W 15 9 8W 15 10 Z1 1 8 B K G 4 1 8 D B cm G304 8W 15 10 G3O0 8W 15 9 8W 15 10 G 4 1 8 D B 1 4 C3 I F U E L I L E V E L I S E N S O R I S I G N A L FUEL PUMP MODULE m S321 G 4 20 D B C228 G 4 20 D B FUEL 4 cm F U E L i I L E V E L GAUGE S E N S O R I 8W 40 7 S I G N A L K31 20 B R V T 1 9 C1 F U E L I P U M P I R E L A Y C O N ...

Page 459: ...1 0 5 A142 14 D G O R S131 8W 10 11 A142 16 A 1 4 2 1 6 D G O R FUEL INJECTOR NO 2 2 FUEL INJECTOR NO 4 FUEL INJECTOR NO S FUEL INJECTOR NO 8 FUEL INJECTOR NO 10 C104 F U E L I N J E C T O R NO 2 1 D R I V E R F U E L I N J E C T O R NO 4 D R I V E R F U E L I N J E C T O R NO 6 D R I V E R F U E L I N J E C T O R NO 8 D R I V E R 1 0 Y K 8 1 8 B K L G 14 A C 2 P O W E R T R A I N N J E C T O R CO...

Page 460: ...L INJECTOR NO 5 S119 8W 10 11 A 1 4 2 1 4 D G O R 2 C105 S131 j 8W 10 11 A 1 4 2 1 4 D G O R m I A 1 4 2 1 6 D G O R _____ S133 _ _ _ FUEL INJECTOR NO 9 FUEL INJECTOR NO 7 I F U E L I N J E C T O R 1 D R I V E R K 1 3 1 8 Y L W T 5 AC2 F U E L I N J E C T O R NO 3 D R I V E R F U E L I N J E C T O R NO 5 D R I V E R F U E L I N J E C T O R NO 7 D R I V E R K 5 1 8 W T L G g C104 K 5 1 8 W T L G 3 ...

Page 461: ...O U T P U T PACK O U T P U T PACK I G N I T I O N I G N I T I O N I G N I T I O N I G N I T I O N I G N I T I O N C O I L C O I L C O I L C O I L C O I L NO 1 N O 4 N O 5 NO 2 N O 3 1 Y s y 4 Y 1 Y s y K 1 9 K 3 2 K 4 3 K 1 7 K 1 8 1 8 1 8 1 8 1 8 1 8 B K G Y Y L G Y D G G Y D B T N R D Y L 3 _ I _ C 1 0 5 K 1 9 K 3 2 K 4 3 K 1 7 K 1 8 1 8 1 8 1 8 1 8 1 8 B K G Y Y L G Y D G G Y D B T N R D Y L 7 ...

Page 462: ... T O R 1 Y K 6 2 0 V T W T 2 Y K 4 1 8 B K L B 2 4 Y G 2 1 2 0 G Y L B T A C H O M E T E R S I G N A L TACHOMETER j 8 W 4 0 5 I 7 4 C155 C330 G 7 2 0 W T O R K 6 2 0 V T W T K 4 1 8 B K L B S206 8 W 3 9 6 G 1 7 2 0 W T T N S P E E D O M E T E R I S I G N A L I BATTERY TEMPERATURE SENSOR I SPEEDOMETER 8 W 4 0 4 G 7 2 0 W T O R I V E H I C L E I S P E E D S E N S O R I S I G N A L 7Y K 6 2 0 V T W T...

Page 463: ... LEFT UPSTREAM HEATED OXYGEN SENSOR B K S129 8W 10 11 A 1 4 2 1 6 D G O R 1 A A S D R E L A Y O U T P U T S E N S O R S E N S O R G R O U N D G R O U N D S I G N A L 3 V 2 V 4V K 4 Z1 K41 1 8 1 8 1 8 B K L B B K B K D G RIGHT UPSTREAM HEATED OXYGEN SENSOR C107 K 2 4 1 1 8 L G R D C1 24 3 C 1 0 8 K 4 1 8 B K L B S108 I 8W 70 2 K 4 18 B K L B S130 8W 70 2 I Z1 1 8 B K A G 1 0 3 8W 15 3 S128 8W 15 3 ...

Page 464: ...OWNSTREAM HEATED OXYGEN SENSOR 4 Y 3 Y K4 18 BK LB 2 T Z12 18 B K T N K341 18 P K W T 10 cm K341 18 P K W T 25 A C 3 I S E N S O R I S I G N A L F142 18 O R D G 1 A F U S E D A U T O M A T I C S H U T D O W N R E L A Y O U T P U T S E N S O R S E N S O R G R O U N D G R O U N D S I G N A L RIGHT DOWNSTREAM HEATED OXYGEN SENSOR 2 Y Z12 18 B K T N 3 Y K4 18 B K L B S302 8W 15 10 Z12 14 B K T N A G 3...

Page 465: ...R G R O U N D K 4 1 8 B K L B C108 K 2 4 1 8 G Y B K C3 S E N S O R S I G N A L CAMSHAFT POSITION SENSOR Y 1 Y K 4 4 1 8 T N Y L 1 A C108 K 4 4 1 8 T N Y L 1 8 C3 i C R A N K S H A F T P O S I T I O N I S E N S O R S I G N A L I C A M S H A F T P O S I T I O N S E N S O R S I G N A L 5 V S U P P L Y S E N S O R S E N S O R G R O U N D S I G N A L T l I K 4 1 K 2 2 1 8 1 8 B K L B O R D B THROTTLE ...

Page 466: ...T U R E S E N S O R L S I G N A L 1 6 Y C3 C107 I N T A K E AIR T E M P E R A T U R E S E N S O R __SIGNAL_ _ 1 5 Y C 3 POWERTRAIN 1 CONTROL I MODULE I K21 1 8 B K R D ENGINE COOLANT TEMPERATURE SENSOR SENDING UNIT A ASA v INTAKE AIR TEMPERATURE SENSOR K 4 1 8 BK LB 3 C108 K 4 1 8 BK LB J 9 8 8 W 1 3 S108 8W 70 2 K 4 18 BK LB 4 C 3 j N K POWERTRAIN A I R CONTROL I T E M P E R A T U R E MODULE S E ...

Page 467: ...O T O R M O T O R NO 1 NO 2 NO 3 NO 4 IDLE AIR CONTROL MOTOR C10S K 4 1 8 B K L B 4 Y K 3 9 1 8 G Y R D 3 Y K 6 0 1 8 Y L B K 2 Y K 4 0 1 8 B R W T 1 Y K 5 9 1 8 V T B K K 1 20 D G R D 27 S108 8W 70 2 1 0 C108 K 4 1 8 B K L B K 3 9 1 8 G Y R D K60 1 8 Y L B K C3 A C3 1 9 C3 1 0 C3 K 4 0 18 B R W T 11 AC3 K 5 9 1 8 V T B K 20 A C3 M A N I F O L D A B S O L U T E P R E S S U R E S E N S O R S I G N ...

Page 468: ...E C T O R P U M P P U M P S O L E N O I D S W I T C H C O N T R O L S E N S E LEAK DETECTION PUMP 3 Y REVERSE LOCK OUT SOLENOID 4 Y 2 _ _ 1 Y DUTY CYCLE EVAP PURGE SOLENOID K 1 0 6 20 W T D G K 1 0 7 20 O R K 5 2 20 P K B K 1 0 A C 1 1 4 A C1 20 C1 R E V E R S E L O C K O U T S O L E N O I D C O N T R O L L E A K D E T E C T O R P U M P S O L E N O I D C O N T R O L L E A K D E T E C T O R P U M P...

Page 469: ...A Y L O N XR OL J IN PDC C 2 0 1 8 B R C 1 3 2 0 D B O R 9 6 Y C 2 7 2 0 D B P K 8 W 4 2 4 G 1 2 1 8 D G Y L G 3 2 0 B K P K G 5 4 2 0 O R B K 1 6 AC1 1 7 C1 S103 C 2 0 1 8 B R C 2 0 1 8 B R G E N E R A T O R I L A M P I 11 A C 2 2 3 C1 2 2 C1 1 C1 I R A D I A T O R RADIATOR F A N I FAN 1 L O W H I G H LOW HIGH 1 D Y n RELAY L CONTROL J N p p C 9 3Y 8 W 4 2 4 C 1 3 7 2 0 Y L C1 2 1 C1 M A L F U N ...

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Page 471: ...h 8W 39 4 6 Hood Switch 8W 39 6 Horn Relay 8W 39 7 Horn Switch 8W 39 7 Component Page Illuminated Rearview Mirror 8W 39 3 Key In Switch Halo Lamp 8W 39 6 Left Door Latch Switch 8W 39 3 Left Front Park Turn Signal Lamp 8W 39 5 Left Horn 8W 39 7 Left License Lamp 8W 39 5 Left Side Marker Lamp 8W 39 5 Left Tail Stop Lamp 8W 39 5 Message Center 8W 39 6 Power Distribution Center 8W 39 2 4 7 Powertrain ...

Page 472: ...W 10 6 F 3 5 20 R D 53 8W 10 7 S211 8W 11 10 F U S E 5 1 5 A 1 POWER 1 DISTRIBUTION I CENTER i 8W 10 6 F 3 3 1 8 P K R D V 6 1 8 D B D 1 6 CI F U S E D IGNITION R U N A C C C8 y d Z20 1 8 B K W T I G 5 2 0 D B W T D 1 5 C1 F U S E D IGNITION S T R U N G R O U N D a o y c f Z20 1 8 B K W T S210 8W 15 5 Z20 1 8 B K W T F 3 5 20 R D C2 F U S E D B C100 F 3 3 1 8 P K R D C3 F U S E D B ELECTRONIC 1 EN...

Page 473: ... D O O R R I G H T I L A T C H DOOR S W I T C H LATCH S E N S E I SWITCH 8 W 6 1 3 M 2 2 0 B K D B M 1 1 8 D B R D 3 3 8 W 1 1 9 l FUSE I BLOCK 8 W 1 1 2 I I I M 1 1 8 P K L I F T G L A S S I ELECTRONIC ENTRY I SJSH MODULE I S E N S E 1 S309 8 W 1 1 9 M 1 1 8 P K DOME LAMP COUPE 1 A 3 C228 R J S E D I VTSS I B DISARM I 1 SWITCH I 8 W 3 9 4 VTSS LIFTGLASS AJAR SWITCH COUPE N C0 RT7sY LLUMINATED I L...

Page 474: ... P K FUSE BLOCK 8 W 1 1 2 8 W 1 0 6 1 POWER I DISTRIBUTION CENTER I 8 W 1 0 6 I VTSS DISARM SWITCH E 1 1 6 T N I HEADLAMP SWITCH O O F F II P A R K I 2 H E A D 3 A U T O _ I 8 W 5 0 2 1 FUSE I BLOCK 8 W 1 1 2 2 C228 N O T U S E D 8208 8 W 1 1 4 L 7 1 8 BK YL B A C3 R 1 ELECTRONIC L A M P I ENTRY S W I T C H MODULE I O U T P U T 1 C100 T O S111 8 W 3 9 5 J 9 8 8 W 1 3 S R 0 0 3 9 0 4 ...

Page 475: ...5 1 4 8 W 5 1 5 8 W 5 1 5 I L 7 1 8 B K Y L 4 P A R K I L A M P LICENSE I S W I T C H I LAMP I O U T P U T ROADSTER 1 8W 51 5 S405 t i i 18 1 B K Y L j 2 A C 3 P A R K I RIGHT I L A M P TAIL I S W I T C H I STOP B K Y L 4 0 1 2 0 L 7 1 8 B K Y L 2 A PARK RIGHT I L A M P FRONT S W I T C H I PARK OUTPUT T y R N SIGNAL LAMP 8 W 5 2 4 S311 L 7 1 8 B K Y L L 7 1 8 B K Y L iic308 L 7 1 8 B K Y L P A R K...

Page 476: ... R L E D D R I V E R L O W T I R E W A R N I N G L A M P K E Y I N I G N S W I T C H S E N S E S P E E D O M E T E R S I G N A L ELECTRONIC 1 ENTRY 1 MODULE I C 1 2 V C1 G 7 0 2 0 B R T N C100 3 6 G 7 0 2 0 B R T N C1 Y C1 G 9 4 2 0 L G D 8 ct SPEEDOMETER 8 W 4 0 4 _ S I G N A L_ HOOD SWITCH C2 L O W 1 MESSAGE I T I R E I CENTER W A R N I N G I 8 W 4 6 6 I L A M P j G 1 7 2 0 W T T N i I G 1 7 2 0...

Page 477: ...W 41 2 I I 8W 10 6 1 9 C100 X3 20 BK RD r 1 ELECTRONIC C3_A C1 HORN B I RELAY I ENTRY I CONTROL MODULE I I X 2 18 DG RD Z1 18 B K 1 POWER DISTRIBUTION CENTER 8W 10 6 LEFT HORN 8W 41 2 S107 X 2 1 8 D G R D RIGHT HORN 8W 41 2 Z1 1 8 B K S112 8W 15 3 Z1 1 6 B K G102 8W 15 3 S R 0 0 3 9 0 7 J 9 8 8 W 1 3 ...

Page 478: ...STED PAIR DATA LINK CONNECTOR 8W 30 3 D 2 20 W T B K D 1 20 V T B R C100 TWISTED PAIR 32 D 9 20 D G D 2 20 W T B K I C C D I B U S U L 18 Y D 2 20 W T B K C C D B U S _ 1 1 1 19 V i AIRBAG CONTROL MODULE 8W 43 3 C100 D 1 20 V T B R D 1 20 V T B R CJ3 A C 1 I R K E M O D U L E I C 5 TWISTED PAIR C1 C4 C1 I P R O G R A M E N A B L E C C D B U S C C D B U S J ELECTRONIC ENTRY I MODULE I RKE J988W 13 ...

Page 479: ... 8W 40 3 7 Fuel Pump Module 8W 40 7 Fuse 1 FB 8W 40 2 Fuse 2 FB 8W 40 2 Fuse 11 FB 8W 40 2 4 5 6 7 8 9 Fuse 11 PDC 8W 40 2 Fuse Block 8W 40 2 4 5 6 7 8 9 Component Page G200 8W 40 3 6 7 8 9 G201 8W 40 4 5 Headlamp Switch 8W 40 2 Left Turn Indicator 8W 40 5 Panel Lamp Dimmer Switch 8W 40 3 4 5 6 7 8 9 Power Distribution Center 8W 40 2 Powertrain Control Module 8W 40 4 5 Right Turn Indicator 8W 40 4...

Page 480: ...6 T N B K 5 C 1 0 0 I 3 i 1 2 H E A D I _4 I I 3 A U T O j 8W 50 2 1 HEADLAMP I SWITCH O O F F i 1 P A R K ST RUN A21 8W 10 16 1FUSE I BLOCK 8W 11 2 i I F U S E 11 5 A 8W 11 8 FUSE BLOCK 8W 11 2 G 5 20 DB WT E 9 0 1 8 P K O R _L T O PANEL LAMP DIMMER SWITCH 8W 40 3 T O S204 8W 40 3 J 9 8 8 W 1 3 S R 0 0 4 0 0 2 ...

Page 481: ...T C H O U T P U T S T R U N j S205 8W 11 8 FUEL GAUGE 8 W 4 0 7 G 5 2 0 DB WT F U S E D I G N S W I T C H O U T P U T S T R U N VOLTMETER 8 W 4 0 9 E 2 2 0 OR S213 8 W 7 0 3 E 2 2 0 O R E 2 2 0 O R I F U S E D l P A N E L 8 W 4 0 4 1 L A M P S I D I M M E R I i S W I T C H j SIGNALj S R 0 0 4 0 0 3 I E 2 2 0 O R F U S E D I I P A N E L 1 L A M P S I D I M M E R I I S W I T C H I IGNALJ SPEEDOMETER...

Page 482: ... _ SIGNAL _ J 8W 30 10 27 Y C 2 G17 20 WT TN ST RUN A21 C100 31 FUSE 1 1 5A 8W 11 8 8W 10 16 M 1 FUSE BLOCK 8W 11 2 I FUSED i PANEL PANEL LAMP LAMP DIMMER I J 8W 40 3 J988W 13 S202 8W 15 6 18 BK AG201 8W 15 6 SPEEDOMETER 1 RIGHT I I TURN INDICATOR j3ROUNDJ 8 W 4 6 8 2 7Z1 20 BK SR004004 ...

Page 483: ... B ST RUN A21 8 W I O 1 6 1 FUSE BLOCK 8 W 1 1 2 31 F U S E 1 1 5 A 8 W 1 1 8 S R 0 0 4 0 0 5 G201 8 W 1 5 6 F U S E D I PANEL I S LAMP 1 L A M P r M M M C D I D I M M E R I D I M M E R S W I T C H SWITCH J 8 W 4 0 3 S213 8 W 7 0 3 TACHOMETER 1 LEFT I I TURN INDICATOR _GROUND_ 8 W 4 6 8 T Z1 20 BK J 9 8 8 W 1 3 ...

Page 484: ...SENDING UNIT 8W 30 14 S210 8W 15 5 Z20 1 8 B K W T I JLG200 8W 15 5 F U S E D I PANEL P A N E L LAMP L A M P I DIMMER I D I M M E R e W i T C H I S W I T C H 5 W l l l t 1 I _ _J 8W 40 3 2 T E 2 1 8 O R S213 8W 70 3 S214 8W 70 3 ENGINE COOLANT TEMPERATURE GAUGE J 9 8 8 W 1 3 S R 0 0 4 0 0 6 ...

Page 485: ...L S E N S O R 3 T G 4 1 8 D B 1 FUEL I PUMP MODULE I 8W 30 6 F U S E D j PANEL P A N E L LAMP L A M P I DIMMER 2 T S213 8W 70 3 S214 8W 70 3 FUEL GAUGE S209 8W 15 5 Z20 1 8 B K W T I S210 8W 15 5 Z20 1 8 B K W T S R 0 0 4 0 0 7 a G200 8W 15 5 J 9 8 8 W 1 3 ...

Page 486: ...8W 10 16 1 FUSE BLOCK 8W 11 2 F U S E D I PANEL P A N E L LAMP L A M P DIMMER J 8 W 4 0 3 2 Y E2 18 O R I S213 8W 70 3 E2 20 O R S214 8W 70 3 ENGINE OIL PRESSURE GAUGE ENGINE OIL PRESSURE SENDING UNIT G200 8W 15 5 J988W 13 S R 0 0 4 0 0 8 ...

Page 487: ...0 9 8W 10 16 1 FUSE I BLOCK I 8W 11 2 3209 8W 15 5 Z20 18 BK WT S210 8W 15 5 Z20 18 BK WT I FUSED i PANEL PANEL LAMP LAMP 1 DIMMER I J 8W 40 3 T E2 18 O R I S213 8W 70 3 E2 20 OR S214 8W 70 3 VOLTMETER a G200 8W 15 5 SR004009 J988W 13 ...

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Page 489: ...zer Module 8W 41 2 Cigar Lighter 8W 41 2 Clockspring 8W 41 2 Electronic Entry Module 8W 41 2 Fuse 3 PDC 8W 41 2 Fuse 4 PDC 8W 41 2 G102 8W 41 2 Component Page G200 8W 41 2 Horn Relay 8W 41 2 Horn Switch 8W 41 2 Left Horn 8W 41 2 Power Distribution Center 8W 41 2 Right Horn 8W 41 2 ...

Page 490: ... 0 N I C I RELAY I ENTRY CONTROL MODULE I 8W 39 7 X3 20 BK RD A j CLOCKSPRING T Z1 18 B K LEFT HORN Z 1 18 BK RIGHT HORN F 3 1 2 0 VT 2 F U S E D B IUSEDI BUZZER MODULE 1 8W 46 3 I CIGAR LIGHTER HORN SWITCH 8 1 1 2 8W 15 3 Z1 16 B K G102 8W 15 3 S218 8W 15 5 Z8 1 6 B K V T A G 2 0 0 8W 15 5 J988W 13 SR004102 ...

Page 491: ...Blower Motor Switch 8W 42 3 Blower Motor Resistor Block 8W 42 3 Fuse 2 PDC 8W 42 2 F u s e 7 F B 8W 42 3 Fuse 10 FB 8W 42 2 4 Fuse 16 PDC 8W 42 4 Component Page Fuse Block 8W 42 2 3 4 G101 8W 42 4 G 1 0 3 8W 42 2 G200 8W 42 3 Power Distribution Center 8W 42 2 4 Powertrain Control Module 8W 42 2 3 4 Radiator Fan Low High Relay 8W 42 4 Radiator Fan Motor 8W 42 4 Radiator Fan On Relay 8W 42 4 Thermos...

Page 492: ...E S S O R C L U T C H R E L A Y 1 POWER DISTRIBUTION CENTER 8W 10 6 C 1 3 20 D B O R 1 A C 1 j POWERTRAIN C O M P R E S S O R CONTROL C L U T C H 1 MODULE C L U T C H MODULE 1 R E L A Y I sw 30 17 Z1 18 BK S128 8W 15 3 I C3 1 8 DB BK 2k S117 Z1 1 8 BK 1 A C COMPRESSOR CLUTCH G103 8W 15 3 J988W 13 SR004202 ...

Page 493: ... MOTOR RESISTOR BLOCK 3 Y C1 1 L O W 2 H I G H F R O M S213 8 W 7 0 3 T BLOWER MOTOR SWITCH 1 L O W 2 M E D L O W 3 M E D H I G H 4 H I G H 1 POWERTRAIN 0 i CONTROL S W I T C H I MODULE JREQUEST j 8W 30 17 2 3 Y C1 C 2 0 1 8 B R m S103 C 2 0 1 8 B R 42 C100 C 2 0 1 8 B R 2k A C LOW PRESSURE CUTOUT SWITCH THERMOSTATIC SWITCH A C HEATER CONTROL O O F F 1 H E A T 2 A C S218 8W 15 5 G200 8W 15 5 S R 0...

Page 494: ... 1 30 i T 8W 11 7 8W 10 16 F12 18 DB GY 25 C100 F12 18 DB GY S104 8W 11 7 I FUSE BLOCK 8W 11 2 RADIATOR FAN LOW HIGH RELAY RADIATOR FAN LOW HIGH RELAY CONTROL i POWERTRAIN I CONTROL I MODULE J 8W 30 17 J C25 C23 12 12 LG DG T Z1 12 BK POWER DISTRIBUTION CENTER 8W 10 6 RADIATOR FAN MOTOR J988W 13 G101 8W 15 2 SR004204 ...

Page 495: ... Control Module 8W43 2 3 Data Link Connector 8W 43 3 Driver Airbag 8W 43 2 Electronic Entry Module 8W 43 3 F u s e 5 F B 8W 43 2 Fuse9 FB 8W 43 2 Component Page Fuse Block 8W 43 2 G203 8W 43 2 Message Center 8W 43 3 Passenger Airbag 8W 43 2 Powertrain Control Module 8W 43 3 ...

Page 496: ...B A G L I N E 1 L I N E 2 DRIVER AIRBAG PASSENGER AIRBAG S W I T C H O U T P U T R U N F U S E D I G N S W I T C H O U T P U T S T R U N D R I V E R A I R B A G L I N E 1 D R I V E R A I R B A G L I N E 2 P A S S E N G E R A I R B A G L I N E 1 P A S S E N G E R AIRBAG A I R B A G 1 CONTROL L I N E 2 I MODULE JSROUNDa o Y Z 6 1 8 B K P K J 9 8 8 W 1 3 A G 2 0 3 8 W 1 5 7 S R 0 0 4 3 0 2 ...

Page 497: ...I DATA LINK CONNECTOR 8W 30 3 32 TWISTED PAIR D1 20 VT BR 100 D2 20 WT BK D1 20 VT BR CCD I BUS I _ L C 5 Y C1 CCD BUS _ w _ C4 V C1 1 ELECTRONIC I ENTRY J MODULE 8W 39 8 TWISTED PAIR r l MESSAGE 1 I CENTER 1WSGI 8 W 4 6 6 J 1 1 Y C 2 D2 20 WT BK D1 20 VT BR R41 20 BK TN 18 19 9 CCD BUS CCD BUS AIRBAG WARNING LAMP DRIVER 1 AIRBAG I CONTROL I MODULE I J SR004303 J988W 13 ...

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Page 499: ...lo Lamp Dome Lamp 8W 44 2 Left Door Latch Switch Fuse 1 FB 8W 44 3 4 5 Liftglass Ajar Switch Fuse 2 FB 8W 44 3 4 Panel Lamp Dimmer Switch Fuse 13 FB 8W 44 2 5 Radio Fuse Block 8W 44 2 3 4 5 Rear Window Defogger Switch G200 8W 44 3 4 5 Right Door Latch Switch G201 8W 44 4 Time Delay Relay G203 8W 44 4 VTSS Liftglass Ajar Switch G300 8W 44 2 Headlamp Switch 8W 44 3 4 5 ...

Page 500: ... RD K E r KEY IN i LAMP SWITCH I DRIVER I HALO I I LAMP 1 8W 46 4 C100 M1 18 PK 28 C100 M1 18 PK 13 4 c m M1 18 PK C206 M2 20 YL D D R LATCH SWITCH SENSE M2 20 YL 3 4 C207 M2 20 BK LB JI COURTCSY ILLUMINATED I L A M P REARVIEW S W I T C H MIRROR O U T P U T I ROADSTER 1 gw 44 5 RIGHT DOOR 1 LATCH I SWITCH 8W 61 3 S309 8W 11 9 CARGO LAMP COUPE DOME LAMP COUPE VTSS I LIFTGLASS I 1 AJAR I GROUND SWIT...

Page 501: ... N 21 F U S E 1 1 5 A 8 W 1 1 4 1FUSE I BLOCK 8W 11 2 I L 7 1 8 B K Y L 24s FUSE 2 4 A 8 W 1 1 4 1FUSE I BLOCK 8W 11 2 I I E 9 0 1 8 P K O R PANEL LAMP DIMMER SWITCH 8 W 4 0 3 1A C I HEATER I CONTROL I 8 W 4 2 3 I y c i S217 8 W 1 5 5 Z 8 2 0 BK VT I Z 8 1 6 B K V T Z 8 1 6 BK VT I S218 8 W 1 5 5 S R 0 0 4 4 0 3 AG200 8 W 1 5 5 J 9 8 8 W 1 3 ...

Page 502: ...RK LAMP SWITCH OUTPUT FUSED PANEL LAMP DIMMER SWITCH SIGNAL 1 RADIO 8W 47 2 8W 47 3 I SRom J 8 Y Z3 20 BK G203 8W 15 7 r l PANEL LAMP DIMMER SWITCH 8W 40 3 S203 8W 70 3 E2 20 OR 9 A E2 20 OR B2 A 1 HEADLAMP I SWITCH 8W 50 2 I Z1 20 BK 1REAR I WINDOW DEFOGGER I SWITCH J l L J COUPE B5 y 8W 48 2 IB 20 BK VT S202 8W 15 I Z8 16 BK VT S217 8W 15 5 Z1 18 BK i J988W 13 BG201 8W 15 6 S218 8W 15 5 B G200 8...

Page 503: ...DLAMP I SWITCH lOOFF 8W 10 8 6 C242 F U S E I BLOCK 8W 11 2 _p A _ DOOR I RIGHT i LATCH DOOR SWITCH I LATCH j SENSE J S W T C H 8W 61 3 I DOOR i LEFT I LATCH DOOR SWITCH I LATCH S E N S E I SWITCH 8W 61 3 RIGHT DOOR LATCH I GROUND1 SWITCH 7 8W 61 3 S210 8W 15 5 G200 8W 15 5 SR004405 J988W 13 ...

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Page 505: ...3 Fuse 11 FB 8W 46 2 3 Fuse 13 FB 8W 46 2 Fuse Block SW 46 2 3 G200 8W 46 2 7 G201 8W 46 3 4 7 8 G202 8W 46 4 G301 8W 46 3 5 Component Page Headlamp Dimmer Switch 8W 46 5 Headlamp Switch 8W 46 4 Ignition Switch 8W 46 5 Illuminated Rearview Mirror 8W 46 2 7 Key In Switch Halo Lamp 8W 46 4 Left Door Latch Switch 8W 46 4 7 Left Turn Indicator 8W 46 8 Message Center 8W 46 2 3 5 6 7 Park Brake Switch 8...

Page 506: ...0 DB WT m S205 8W 11 8 G5 20 DB WT 1 A C 1 FUSED IGNITION ST RUN GROUND 4yC1 Z20 20 BK WT S209 8W 15 5 Z20 18 BK WT I 8 2 1 0 8W 15 5 Z20 18 BK WT FUSE 13 20A 3 3 8W 11 9 FUSE BLOCK 8W 11 2 M1 18 PK S21S M1 18 PK T 6 C 2 0 7 M1 20 PK M1 20 PK 16 FUSED B RADIO 8W 47 2 M1 20 BK RD c l rFu7ED ILLUMINATED I B REARVIEW I 1 MIRROR I ROADSTER 8W 44 5 C2 FUSED B MESSAGE CENTER J988W 13 G200 8W 15 5 SR0046...

Page 507: ... A I I I S E A T I B E L T C2 G 1 3 20 D B R D MESSAGE CENTER G 5 22 D B W T F U S E D B S E A T B E L T S W I T C H S E N S E S E A T B E L T L A M P D R I V E R F U S E D IGNITION S W I T C H O U T P U T S T R U N G R O U N D 5 V BUZZER MODULE 4 C228 Z1 18 BK DRIVER SEAT BELT SWITCH JLG201 8W 15 6 JLG3C1 8W 15 10 S R 0 0 4 6 0 3 J 9 8 8 W 1 3 ...

Page 508: ... IGN SWITCH SENSE _ cio Y c f G26 20 LB I ELECTRONIC FRONT I ENTRY DOOR I MODULE JAMB 1 8W 39 6 SWITCH I 8W 61 3 SENSE j C15 Y CI S200 KEY IN SWITCH HALO LAMP G16 20 BK LB G26 20 LB I HEADLAMP SWITCH 0OFF 1 PARK i 2 HEAD 3 AUTO I 8W 50 2 Y G16 20 BK LB V 1 15 f C242 _c A _ I LEFT L E F T F R Q N T LET I I DOOR I DOOR I JAMB LATCH j SWITCH SWITCH _SENSEJ 8 W 6 1 _3 oy Z1 18 BK 16 C242 S202 8W 15 6 ...

Page 509: ...rpART OF v FUNCTION SWITCH 8W 50 5 G34 20 RD GY S 2 2 2 8W 50 5 k CI R E D B R A K E W A R N I N G L A M P A G 3 0 1 8W 15 10 M A L F U N C T I O N I N D I C A T O R L A M P G E N E R A T O R L A M P D R I V E R G 3 4 2 0 R D G Y H I G H B E A M I N D I C A T O R n MESSAGE 1 CENTER i C1 C100 C108 G 3 20 B K P K 35 1 rG 3 2 0 B K P K G 1 2 2 0 D G Y L _ J L C100 A 1 7 C1 S R 0 0 4 6 0 5 ENGINE OIL ...

Page 510: ...LANT TEMPERATURE I SENSOR SENDING UNIT _ 8W 30 14 1 F O G I LAMP i RELAY IN PDC J 8W 50 10 S110 8W 10 9 G2 20 V T T N 14 C100 1 AIRBAG A I R B A G CONTROL W A R N I N G nniii c L A M P I MODULE D R I V E R l 8W 43 3 L39 1 8 L B G54 20 O R B K C2 G94 20 L G 6 A C 2 G2 20 V T T N 7 A C 2 R 4 1 20 B K T N 38 C100 L39 1 8 L B 1 1 C2 U P S H I F T I L A M P L O W TIRE W A R N I N G L A M P E N G I N E ...

Page 511: ...B K I u J I LEFT DOOR i LATCH SWITCH 8W 61 3 G 7 5 20 T N I ci_ D O O R I RIGHT A J A R DOOR S W I T C H iLATCH S E N S E SWITCH 1 8W 61 3 BY Z 2 0 20 B K 1 ILLUMINATED IREARVIEW I MIRROR ROADSTER 8 8W 44 5 GROUND j 1 6 A C242 Z1 1 8 B K T Z1 1 8 B K 1 6 AC206 4 0 2 0 7 Z 2 0 20 B K Z20 20 B K S209 8W 15 5 3202 8W 15 6 Z1 1 8 B K G201 8W 15 6 Z20 1 8 B K W T I S210 8W 15 5 Z20 1 8 B K W T I A G200...

Page 512: ...SIGNAL HAZARD I SWITCH i PART OF MULTI FUNCTION SWITCH 8W 52 3 LEFT TURN INDICATOR RIGHT TURN INDICATOR r _ G R O U N D 4 Z1 20 B K G R O U N D j l TACHOMETER I 8W 40 5 I Z1 20 B K SPEEDOMETER I 8W 40 4 IJ3ROUND GROUND j Z1 20 B K Z1 20 B K S201 8W 15 6 Z1 20 B K S202 8W 15 6 Z1 1 8 B K a G201 8W 15 6 J988W 13 S R 0 0 4 6 0 8 ...

Page 513: ...er Fuse 1 F RB 8W 47 4 5 Left Door T w e e t e r Fuse 1 FB 8W 47 2 Left Rear Woofer Fuse 4 FB 8W 47 2 Panel Lamp Dimmer Switch Fuse 11 PDC 8W 47 2 Power Distribution Center Fuse 13 FB 8W 47 2 Powertrain Control Module Fuse Block 8W 47 2 Radio Fuse Relay Block 8W 47 4 5 Right Door Speaker G203 8W 47 3 Right Door Tweeter G300 8W 47 4 5 Right Rear Woofer ...

Page 514: ... S E 1 3 2 0 A FUSE I BLOCK 8W 11 2 I I I 3208 8W 11 4 X 1 2 20 R D W T L7 20 B K Y L 1 5 1 M 1 1 8 P K S215 8W 11 9 M 1 2 0 P K 1 6 A I P A R K 1 L A M P I S W I T C H O U T P U T I F U S E D IGN S W I T C H O U T P U T R U N A C C F U S E D B I PANEL F U S E D LAMP I PA N L DIMMER 1 L A M P I oumru I D I M M E R SWITCH S W I T C H 1 8W 40 3 1 S I G N A L E 2 1 8 O R S213 8W 70 3 E 2 20 O R 14 A ...

Page 515: ... I E R _ jnp yL V l AUDIO I AMPLIFIER I V 3206 8W 39 6 G 1 7 20 W T T N 1 3 R A D I O 1 2 V A N T E N N A O U T P U T A N T E N N A ANTENNA AMPLIFIER Y X 6 0 22 D G R D S330 X 6 0 1 8 D G R D 10 C1S5 X 6 0 20 D G R D RADIO I S P E E D O M E T E R S I G N A L A M P L I F I E R I N P U T R A D I O 1 2 V O U T P U T G R O U N D Z 3 20 B K A G 2 0 3 8W 15 7 S R 0 0 4 7 0 3 J988W 13 ...

Page 516: ... B D G J C206 X80 20 L B D G J C228 f X80 1 8 L B D G X96 1 8 T N D G lc2 2IC2 8 02 7 1 C2 1 S318 i X80 20 L B D G 7T Y RIGHT DOOR TWEETER X82 20 LB VT S319 T X98 1 8 T N V T RIGHT REAR WOOFER C2 F U S E D B A M P L I F I E D L E F T R E A R A M P L I F I E D L E F T R E A R A M P L I F I E D L E F T D O O R A M P L I F I E D L E F T D O O R A M P L I F I E D R I G H T D O O R A M P L I F I E D R ...

Page 517: ...D G A C2 A C2 X 8 2 20 L B V T 71 7 p r 2 T X 8 0 20 L B D G i RIGHT DOOR SPEAKER I F U S E D A M P L I F I E D A M P L I F I E D B R E A R R E A R I H i A M P L I F I E D L E F T D O O R G R O U N D A M P L I F I E D L E F T D O O R W S318 I X 8 0 20 L B D G 2k 1 Y X 8 2 20 L B V T RIGHT DOOR TWEETER S319 X 8 2 X 8 0 20 20 L B V T i L B D G I 3 L T _ C206 X 8 2 X 8 0 20 20 L B V T L B D G L _ i t...

Page 518: ......

Page 519: ...nt Page Fuse 3 F RB 8W 48 2 Fuse8 FB 8W 48 2 Fuse Block 8W 48 2 Fuse Relay Block 8W 48 2 G200 8W 48 2 G300 8W 48 2 Component Page G303 8W 48 2 Panel Lamp Dimmer Switch 8W 48 2 Rear Window Defogger 8W 48 2 Rear Window Defogger Relay 8W 48 2 Rear Window Defogger Switch 8W 48 2 ...

Page 520: ...E L A Y G R O U N D S I G N A L C O N T R O L Z1 1 8 B K S304 8W 15 10 Z1 1 8 B K U3 R E A R W I N D O W D E F O G G E R R E L A Y 1 0 S306 REAR WINDOW DEFOGGER SWITCH 0OFF 1 O N E 2 1 8 O R 2 I FUSED P A N E L L A M P D I M M E R S W I T C H S I G N A L GROUND 3Y Z 8 1 8 BK VT S213 I 8W 70 3 1 PANEL I LAMP 1 DIMMER j SWITCH 8W 40 3 REAR WINDOW DEFOGGER S217 8W 15 5 G300 8W 15 10 J 9 8 8 W 1 3 S21...

Page 521: ...W 50 4 9 G201 8W 50 2 G301 8W 50 12 Headlamp Dimmer Switch 8W 50 2 5 7 8 10 Component Page Headlamp Switch 8W 50 2 3 5 7 10 11 High Beam Relay 8W 50 5 7 9 12 Key In Switch Halo Lamp 8W 50 2 Left Door Latch Switch 8W 50 2 Left Fog Lamp 8W 50 10 11 Left Front Park Turn Signal Lamp 8W 50 4 Left High Beam Headlamp 8W 50 8 9 Left Low Beam Headlamp 8W 50 6 9 Left Side Marker Lamp 8W 50 4 Low Beam Relay ...

Page 522: ...H 8W 40 3 S213 8W 70 3 E2 20 OR 3203 8W 70 3 HEADLAMP SWITCH 0OFF 1 PARK 2 HEAD 3 AUTO 4 FOG L35 18 BR WT 34 I I LAMP I A I LOGIC I T RELAY N p D C 8W 50 10 L94 16 LG RD 15 y C242 C10 C 1 G16 20 BK LB KEY IN I ELECTRONIC I IGNITION ENTRY I SWITCH MODULE I S E N S E i 8W 39 6 1LOW BEAM I RELAY t j IN PDC 1 8W 50 6 S202 8W 15 6 LEFT FRONT DOOR JAMB SWITCH 1 LEFT I DOOR LATCH I SWITCH 1 FUSE I BLOCK ...

Page 523: ... FRONT LIGHTING 8W 50 3 BATT AO 8W 10 6 1 POWER DISTRIBUTION CENTER j 8W 10 6 I I 1 HEADLAMP I SWITCH O O F F 1 P A R K I 2 H E A D 3 A U T O I L _ I J 8W 50 2 3 T T O S111 8W 50 4 S R 0 0 5 0 0 3 J 9 8 8 W 1 3 ...

Page 524: ... B K Y L Y Z1 1 8 B K I I Z1 1 6 B K i N LEFT X J FRONT PARK TURN SIGNAL LAMP 8W 52 4 S134 8W 15 4 J 9 8 8 W 1 3 G104 8W 15 4 L 7 1 8 B K Y L L 7 1 8 B K Y L 4A 3 O RIGHT FRONT Y PARK I TURN 1 8 SIGNAL B K LAMP I 8W 52 4 S135 8W 15 4 1 6 B K JLG105 8W 15 4 S111 j 8W 11 4 L 7 1 8 B K Y L 2 0 1 2 2 L 7 1 8 B K Y L g ST T L 6 0 1 8 L G MARKER LAMP C122 L 6 0 1 8 T N S115 8W 52 4 L 6 0 1 8 T N 4 3 T L...

Page 525: ...NTER L 9 4 16 L G R D 6 C 1 0 0 L 9 4 16 L G R D T O LOW BEAM RELAY 8W 50 6 S222 1 8W 50 7 S R 0 0 5 0 0 5 C100 G 3 4 1 6 R D G Y 4 A XI FOG LAMP LOGIC RELAY IN PDC 8W 50 10 n R a h MESSAGE I B E A M CENTER I I N D I C A T O R I 8W 46 5 1 D R I V E R J 9 8 8 W 1 3 ...

Page 526: ...1 8 BK TN S102 8W 15 2 L 4 3 20 V T 1 C114 L43 20 V T S126 8W 10 9 L 4 4 20 V T R D L44 1 8 V T R D Z12 1 2 B K T N I L O W j L E F T I B E A M LOW H E A D L A M P I BEAM I D R E R I HEADLAMP 1 8W 50 9 C120 L 4 4 20 V T R D L O W I I B E A M I H E A D L A M P D R I V E R 1 0 LOW BEAM HEADLAMP DRIVER DAYTIME RUNNING LAMP MODULE 8W 50 12 RIGHT LOW BEAM HEADLAMP 8W 50 9 G100 8W 15 2 J988W 13 SR005006...

Page 527: ...FF 1 PARK I 2 HEAD 3 AUTO 12 y L94 16 L G R D 19 A l W 1 HEADLAMP I DIMMER I J SWITCH Tv ULTI rL FUNCTION 76 4 SWITCH RD GY 8 W 5 5 4 C100 BATTAO 8W 10 6 FUSE 17 20A 8W 10 10 1 POWER I DISTRIBUTION CENTER j 8W 10 6 I I I SR005007 S102 z 2 8W 15 2 12 BK TN A G 100 8W 15 2 TO S109 8W 50 8 TO S124 8W 50 8 J988W 13 ...

Page 528: ... RD L3 16 RD OR HEADLAMP DIMMER SWITCH HIGH BEAM OUTPUT DIMMER I RIGHT SWITCH HIGH HIGH I BEAM n EpuT HEADLAMP l2H T J 8W 50 9 L20 16 LG WT FUSED B I DAYTIME RUNNING LAMP MODULE I I I 8W 50 12 S124 8W 10 10 L20 16 LG WT C100 L20 16 LG WT FUSED HEADLAMP I B DIMMER I 1 SWITCH I I PART OF 1 MULTI FUNCTION SWITCH 8W 50 5 DIMMER I L E F T SWITCH HIGH HIGH I BEAM 1 n I HEADLAMP J988W 13 SR005008 ...

Page 529: ...8W 15 4 L4 1 8 V T W T 1 HIGH I BEAM 1 RELAY IN PDC 8W 50 7 70 78 1 8W 10 9 FUSE 10 1 0 A POWER DISTRIBUTION CENTER 8 W 1 0 6 L3 1 6 RD OR L44 1 8 V T R D S109 S126 8W 10 9 L3 1 6 RD OR L44 18 V T R D 1 0 1 HIGH I BEAM 1 R E L A Y 1 O U T P U T L O W B E A M H E A D L A M P DRIVER L3 1 6 OR RD L3 1 6 OR RD 1 DAYTIME I RUNNING I LAMP I MODULE 8W 50 12 L44 20 V T R D 1 C120 CX RIGHT 6 T HIGH BEAM HE...

Page 530: ...W 10 8 F O G L A M P R E L A Y POWER DISTRIBUTION CENTER 8W 10 6 F39 18 P K L G G100 8W 15 2 2 _ j F0G I L A M P R E L A Y O U T P U T OG I MESSAGE L A M P CENTER I R E L A Y I 8W 46 6 O U T P U T r o G i R I G H T I L A M P FOG I R E L A Y I LAMP OUTPUT I 8W 50 11 LEFT FOG LAMP I 8W 50 11 46 C100 F39 1 6 P K L G rFUSED HEADLAMP I B SWITCH I 1 8W 50 2 I J 9 8 8 W 1 3 S R 0 0 5 0 1 0 ...

Page 531: ... 0 L39 18 LB 1Y Z1 18 BK LEFT FOG LAMP L39 18 LB 2 A C X RIGHT C100 FOG LAMP Z1 18 BK 0 f 1 HEADLAMP I SWITCH 0OFF II PARK 2 HEAD 3 AUTO UFOG I 8W 50 2 10 10 A C 2 F O G MESSAGE I LAMP CENTER I RELAY I OUTPUT S112 8W 15 3 8W 46 6 Z1 16 BK 48 A C100 AG102 8W 15 3 1 F O G LAMP i LOGIC I RELAY IN PDC 8W 50 10 SR005011 J988W 13 ...

Page 532: ...0 10 L20 1 6 L G W T 6 A L 4 4 1 8 V T R D S126 1 8W 10 9 L 4 4 1 8 V T R D 1 0 A L 3 1 6 R D O R F U S E D R E D F U S E D L O W H I G H IGN R E D B B E A M B E A M S T R U N B R A K E B H E A D L A M P R E L A Y S T R U N W A R N I N G D R I V E R O U T P U T L A M P D R I V E R G R O U N D DAYTIME RUNNING LAMP MODULE 3 y G 9 2 0 G Y B K S125 G 9 20 G Y B K 2 A F E D 1 BRAKE B R A K E WARNING W ...

Page 533: ...8W 51 3 Fuse 8 FB 8W 51 8 Fuse Block 8W 51 2 8 G201 8W 51 3 G300 8W 51 4 5 6 7 8 Headlamp Switch 8W 51 2 Component Page Left Back Up Lamp 8W 51 8 Left License Lamp 8W 51 4 5 Left Tail Stop Lamp 8W 51 4 5 Power Distribution Center 8W 51 3 Powertrain Control Module 8W 51 3 Right Back Up Lamp 8W 51 8 Right License Lamp 8W 51 4 5 Right Tail Stop Lamp 8W 51 6 7 Stop Lamp Switch 8W 51 3 ...

Page 534: ...HEADLAMP SWITCH I OOFF II P A R K 2 H E A D 3 A U T O 8W 50 2 FUSE BLOCK I 8W 11 2 1FUSE I BLOCK 8W 11 2 L 7 18 B K Y L T O LEFT LICENSE LAMP 8W 51 4 8W 51 5 L 7 1 8 B K Y L T O RIGHT LICENSE LAMP ROADSTER 8W 51 5 I L 7 1 8 B K Y L vT O C318 8W 51 4 8W 51 5 I L 7 1 8 B K Y L S311 T O C319 8W 51 6 8W 51 7 J988W 13 S R 0 0 5 1 0 2 ...

Page 535: ...G 8W 51 3 8W 10 6 POWERTRAIN STOP CONTROL Ujj 1 MODULE SW TCH 8 W 3 0 2 1 POWER I DISTRIBUTION CENTER I 8W 10 6 I I G201 8W 15 6 S313 TO S400 8W 51 4 8W 51 5 TO S401 8W 51 6 8W 51 7 TO C308 8W 51 6 8W 51 7 SR005103 J988W 13 ...

Page 536: ... L50 1 8 WT TN S404 L 7 1 8 BK YL S400 L E F T LEFT XJTAIL f x x J T A y b x x STOP LAMP L50 1 8 WT TN 2 A C3 3 A C3 LEFT fx XJTAIL 1 Y C 3 STOP LAMP Z1 1 8 BK I S402 8W 1M Z1 18 BK 1 C 3 1 8 Z1 1 8 BK FROM S311 8W 51 2 1AC308 L7 1 8 BK YL 1 A CD L7 1 8 BK YL 1 LEFT LICENSE rr LAMP Z1 1 8 BK 0RIGHT LICENSE 2 Y LAMP Z1 1 8 BK S406 8W 15 8 Z1 1 8 BK C308 Z1 1 8 BK I S303 8W 15 8 Z1 1 8 BK I S304 8W ...

Page 537: ...2 F R O M 0 3 1 8 8W 51 3 2 0318 L 7 1 8 B K Y L L 7 1 8 B K Y L 2 A 0 2 L 5 0 1 8 WT TN 3 A 0 2 L E F T L50 1 8 WT TN S404 S400 L50 1 8 W T T N X TAIL X X TAE 01 0 2 S T O P L A M P 2 A 0 3 3 A 0 3 L E F T IX X T A I y S T O P L A M P 1 0 3 Z1 1 8 B K Z1 1 8 B K Z1 1 8 B K S402 8W 15 9 Z1 1 8 B K iic318 Z1 1 8 B K S R 0 0 5 1 0 5 ...

Page 538: ... RIGHT x TAIL STOP LAMP S405 L7 18 BK YL 3 A C3 02 Z1 18 BK Z1 18 BK 1 Y C 3 Z1 18 BK 2 A 03 X RIGHT x j m u STOP LAMP S403 8W 15 8 Z1 18 BK 1 C319 Z1 18 BK FROM FROM FROM C319 S311 S313 8W 51 3 8W 51 2 8W 51 3 y y y I L50 I L7 I L50 18 18 18 WT TN BK YL WT TN 2 C308 CENTER HIGH MOUNTED STOP LAMP C308 S303 8W 15 8 Z1 18 BK S304 8W 15 10 Z1 18 BK J988W 13 JLG300 8W 15 10 ...

Page 539: ... C1 L7 1 8 BK YL 2 A C 2 RIGHT X J T A I U STOP LAMP S405 C3 L7 18 B K Y L 2 A C 3 RIGHT C2 C3 XjTAIU STOP LAMP Z1 1 8 B K Z1 1 8 B K Z1 1 8 B K S403 8W 15 9 Z1 1 8 B K 1 0 3 1 9 Z1 1 8 B K 8W 51 7 ROADSTER F R O M F R O M FROM C319 S311 S313 8W 51 3 8W 51 2 8W 51 3 Y y y I L 5 0 I L7 I L50 1 8 1 8 1 8 WT TN B K Y L WT TN C308 CENTER HIGH MOUNTED STOP LAMP 1 Y Z1 1 8 B K C308 Z1 1 8 B K S304 8W 15...

Page 540: ...3 y Z1 1 8 B K LEFT BACK UP LAMP R O A D S T E R S402 8W 15 8 8W 15 9 C318 C O U P E R O A D S T E R S310 6 C 3 1 9 L1 1 8 V T B K 1A RIGHT BACK UP 3 Y LAMP Z1 1 8 B K S403 8W 15 8 8W 15 9 1 C 3 1 9 C O U P E I S303 8W 15 I S303 8W 15 8 J988W 13 S304 I 8W 15 9 I 8W 15 10 A G 3 0 0 8W 15 9 8W 15 10 S R 0 0 5 1 0 8 ...

Page 541: ...52 2 3 Left Front Park Turn Signal Lamp 8W 52 4 Left Rear Turn Signal Lamp 8W 52 4 Component P a g e Left Side Marker Lamp 8W 52 4 Left Turn Indicator 8W 52 3 Power Distribution Center 8W 52 2 Right Front Park Turn Signal Lamp 8W 52 4 Right Rear Turn Signal Lamp 8W 52 4 Right Side Marker Lamp 8W 52 4 Right Turn Indicator 8W 52 3 Turn Signal Hazard Flasher 8W 52 2 3 Turn Signal Hazard Switch 8W 52 ...

Page 542: ...P U T O U T P U T T U R N S I G N A L H A Z A R D F L A S H E R A3 A 2 Z1 20 B K S202 8W 15 6 Z1 1 8 B K A 4 FUSE BLOCK 8W 11 2 L 6 1 8 R D W T L 1 9 1 8 P K 1 3 H A Z A R D F L A S H E R 1 O U T P U T 1 HAZARD I FLASHER I SWITCH I PART OF 1 7 T U R N S I G N A L F L A S H E R O U T P U T L _ G201 8W 15 6 U U R N 1 SIGNAL HAZARD I SWITCH PART OF MULTI FUNCTION SWITCH 8W 52 3 MULTI FUNCTION SWITCH ...

Page 543: ...ZARD FLASHER SWITCH PART OF MULTI FUNCTION SWITCH 17 y TURN SIGNAL HAZARD SWITCH PART OF MULTI FUNCTION SWITCH 1 LEFT 2 RIGHT 16V L61 18 DG RD L61 18 LG L60 18 TN 1 LEFT LEFT I TURN TURN I SIGNAL I INDICATOR I 8W 46 8 44 40 L60 18 BR RD 1 C100 L61 18 LG L60 18 TN RIGHT I RIGHT i TURN TURN I SIGNAL 1 INDICATOR I I 8W 46 8 T O S113 8W 52 4 T O S115 8W 52 4 SR005203 J988W 13 ...

Page 544: ...T N L60 1 8 T N C122 C1S5 L60 1 8 T N L60 1 8 T N 4 0 3 1 9 L60 1 8 D G R D 0RIGHT REAR 3 Y TURN SIGNAL Z 1 LA1P 1 8 BK S403 8W 15 8 Z1 8W 15 9 1 8 BK 1 0 3 1 9 S115 I L 6 0 1 8 T N 1 L60 1 8 L G 2 T MARKER LAMP L60 1 8 T N L7 1 8 BK YL 2 0 1 2 2 L 7 1 8 BK YL S111 8W 11 4 L 7 1 8 BK YL 7 C 1 2 0 L7 1 8 BK YL Z1 1 8 BK R O A D S T E R C O U P E 4 z o 1 SIGNAL 1 8 BK R O A D S T E R C 0 U P E LAMP ...

Page 545: ... Connector 8W 53 3 4 Driver Wiper Motor 8W 53 3 4 F u s e 3 F B 8W 53 2 Fuse 13 FB 8W 53 3 4 Fuse Block 8W 53 2 3 4 Component Page G202 8W 53 2 3 4 Passenger Wiper Motor 8W 53 3 4 Windshield Washer Pump 8W 53 2 Wiper Control Module 8W 53 2 3 4 Wiper Switch 8W 53 2 ...

Page 546: ... 4 V 1 7 1 8 1 8 1 8 1 8 B R W T D G W T R D Y L D G Y L 3A 6 A 1 2 A W I P E R W I P E R S W I T C H S W I T C H L O W M O D E S P E E D S E N S E O U T P U T W I P E R S W I T C H H I G H S P E E D O U T P U T W I P E R S W I T C H D E L A Y O U T P U T 1 WIPER I CONTROL 1 MODULE G R O U N D 1 9 Y Z2 1 8 B K L G S220 I 8W 15 7 12 1 6 B K L G WIPER SWITCH PART OF MULTI FUNCTION SWITCH OOFF 1 M I ...

Page 547: ... B WIPER 1 MOTOR I 8W 53 4 PASSENGER WIPER MOTOR S220 8W 15 7 8 A 21 A 20 A 5 A 1 5 A J4 A _ 1 F U S E D L O W H I G H W I P E R W I P E R W I P E R i B w S P E E D S P E E D P A R K M O T O R A R M I W I P E R W I P E R S W I T C H R P M S I G N A L I M O T O R M O T O R S E N S E S E N S E 1 D R I V E R D R I V E R G 2 0 2 8W 15 7 1 WIPER S R 0 O 5 3 0 3 W I P E R A R M I CONTROL S I G N A L MOD...

Page 548: ... 1 4 V 5 4 V 5 6 V 4 5 V 4 8 1 8 1 8 18 1 8 1 8 18 1 8 D B R D R D B K R D V T D G V T V T W T V T R D G Y F U S E D B 9A__ _ J7 _2 X__ L O W H I G H W I P E R W I P E R W I P E R W I P E R S P E E D S P E E D P A R K M O T O R A R M A R M W I P E R W I P E R S W I T C H R P M S I G N A L S I G N A L M O T O R M O T O R S E N S E S E N S E D R I V E R D R I V E R S220 8W 15 7 12 1 6 B K L G G202 8...

Page 549: ... 8W 60 1 8W 60 POWER WINDOWS Component Page Component Page Circuit Breaker 8W 60 2 Power Window Circuit Breaker 8W 60 2 G200 8W 60 2 Power Window Switch 8W 60 2 Left Power Window Motor 8W 60 2 Right Power Window Motor 8W 60 2 ...

Page 550: ... 10 16 1 CIRCUIT B R E A K E R 2 5 A C242 LEFT POWER WINDOW MOTOR POWER WINDOW CIRCUIT BREAKER 8W 11 6 3 T 5 T H 6 T _ 1 T T Z8 Q11 Q 2 1 Q 1 2 Q 2 2 1 6 16 1 6 1 6 1 6 B K V T L B W T B R V T C206 POWER WINDOW SWITCH 1 U P 2 D O W N RIGHT POWER WINDOW MOTOR 4 G200 8W 15 5 J988W 13 S R 0 0 6 0 0 2 ...

Page 551: ... G201 8W 61 3 Left Door Latch Motor 8W 61 5 Left Door Latch Switch 8W 61 3 Component Page Left Exterior Door Handle Switch 8W 61 5 Left Interior Door Handle Switch 8W 61 4 5 Message Center 8W 61 3 Power Distribution Center 8W 61 2 Right Door Latch Motor 8W 61 4 Right Door Latch Switch 8W 61 3 Right Exterior Door Handle Switch 8W 61 4 Right Interior Door Handle S w i t c h 8W 61 4 5 Time Delay Rela...

Page 552: ...11 4 G5 20 DB WT F35 20 RD I S204 8W 11 I S211 8W 11 10 FUSE 5 15A 8W 11 6 1 POWER I DISTRIBUTION i CENTER I 8W 10 6 i F33 18 P K R D V6 18 D B G5 20 DB WT F35 20 RD D 1 6 r C1 D15 C1 C2 FUSED IGNITION RUN ACC FUSED IGNITION ST RUN FUSED B GROUND C8 Y C 1 Z 2 0 1 8 B K W T 27 C100 F33 1 8 P K R D C3 FUSED B D Y C2 Z20 18 B K W T T ELECTRONIC I ENTRY I MODULE Z20 18 B K W T S210 8W 15 5 J988W 13 AG...

Page 553: ...CH SENSE DOOR AJAR SWITCH SENSE LEFT DOOR LATCH SWITCH G75 20 TN c A Z 1 18 BK C242 Z 1 18 BK 15 C206 G74 20 TN RD l e i C 1 6 S202 8W 15 6 Z 1 1 8 BK LEFT FRONT DOOR JAMB SWITCH SENSE T ELECTRONIC RIGHT FRONT I ENTRY DOOR MODULE JAMB SWITCH SENSE I I G201 8W 15 6 M2 20 YL C206 M2 20 YL DOOR RIGHT DOOR AJAR FRONT LATCH SWITCH DOOR SWITCH SENSE JAMB SENSE SWITCH SENSE GROUND B Y A Y G74 Z1 20 1 8 T...

Page 554: ...N D L E L A T C H U N L A T C H L G N A L 4 Y P 9 7 C206 2 0 W T D G D O O R U N L A T C H I N D I C A T O R jPSiyEFL G 3 3 20 L B B K I4 A C242 1 LEFT I INTERIOR DOOR I HANDLE SWITCH 1 8W 61 5 RIGHT EXTERIOR DOOR HANDLE SWITCH G 3 3 20 L B B K 1 4 P122 20 O R W T P 9 6 20 W T L G P 9 7 20 W T D G G 3 3 22 L B B K G 3 3 22 L B B K D 1 2 id D 1 4 J cT D 5 C 1 RIGHT DOOR LATCH MOTOR R I G H T I N T ...

Page 555: ...A C 1 L E F T I N T E R I O R D O O R H A N D L E L A T C H U N L A T C H SIGNAL P 9 6 20 W T L G 5 k P 9 6 20 W T L G D O O R U N L A T C H I N D I C A T O R D R J V E R 5 Y G 3 3 20 L B B K 1 4 G 3 3 22 L B B K 1 RIGHT 1 INTERIOR DOOR jHANDLE SWITCH 1 8W 61 4 G 3 3 20 L B B K 1 4 1 G 3 3 22 L B B K D 5 C1 L E F T I I N T E R I O R 1 D O O R H A N D L E S W I T C H S I G N A L I L L E F T I N T E...

Page 556: ......

Page 557: ...1 3 3 8W 10 12 S 1 3 4 8W 15 4 S 1 3 5 8W 15 4 S 2 0 0 8W 39 6 S 2 0 1 8W 15 6 5 2 0 2 8W 15 6 5 2 0 3 8W 70 3 5 2 0 4 8W 11 8 5 2 0 5 8W 11 8 5 2 0 6 8W 39 6 5 2 0 7 8W 46 7 5 2 0 8 8W 11 4 Component Page S209 8W 15 5 S210 8W 15 5 S211 8W 11 10 S212 8W 11 4 S213 8W 70 3 S214 8W 70 3 S215 8W 11 9 S216 8W 42 3 S217 8W 15 5 S218 8W 15 5 S219 8W 53 3 4 S220 8W 15 7 S221 8W 42 3 S222 8W 50 5 S300 8W 1...

Page 558: ...I OXYGEN s SENSOR 8W 30 12 1 RIGHT DOWNSTREAM HEATED K4 1 8 BK LB C330 K4 1 8 BK LB 8W 30 11 I K4 1 8 BK LB K4 1 8 BK LB 3 T K4 18 BK LB RIGHT UPSTREAM HEATED I OXYGEN SENSOR 8W 30 11 I OXYGEN SENSOR 8W 30 12 BATTERY TEMPERATURE SENSOR I 8W 30 10 K4 1 8 BK LB K4 1 8 BK LB S312 K4 1 8 BK LB 3 C108 K4 1 8 BK LB I S130 _ b INTAKE AIR 1 TEMPERATURE I SENSOR 8W 3O 14 K 4 1 8 BK LB K4 1 8 BK LB 12 C111 ...

Page 559: ...ATER CONTROL E2 20 OR I 8W 42 3 S214 j REAR WINDOW 1 DEFOGGER I SWITCH J COUPE 8W 48 2 S203 E2 20 OR E2 20 OR E2 20 OR E2 20 OR E2 20 OR E2 20 OR E2 20 OR HEADLAMP SWITCH 8W 50 2 SPEEDOMETER 1 8W 40 4 I 6 FUEL GAUGE 8W 40 7 ENGINE OIL PRESSURE I GAUGE J 8W 40 8 ENGINE COOLANT TEMPERATURE iGAUGE J 8W 40 6 TACHOMETI 3 8W 40 5 VOLTMETER 8W 40 9 I SR007003 J988W 13 ...

Page 560: ......

Page 561: ...0 8 C100 8W 80 9 C104 8W 80 10 C105 8W 80 10 C107 8W 80 11 C108 8W 80 11 C l l l 8W 80 11 C114 8W 80 12 C116 8W 80 12 C120 8W 80 12 C122 8W 80 12 C126 8W 80 13 Component Page C134 8W 80 13 C155 8W 80 13 C206 8W 80 14 C207 8W 80 14 C228 8W 80 14 C242 8W 80 15 C308 8W 80 15 C315 8W 80 15 C316 8W 80 16 C318 8W 80 16 C319 8W 80 16 C330 8W 80 16 Camshaft Position Sensor 8W 80 17 Cargo Lamp 8W 80 17 Cen...

Page 562: ...mp Module 8W 80 24 Fuse Relay Block 8W 80 25 Generator 8W 80 25 Headlamp Switch 8W 80 26 Hood Switch 8W 80 26 Component Page Horn Switch 8W 80 26 Idle A i r Control Motor 8W 80 26 Ignition Switch 8W 80 27 Illuminated Rearview Mirror 8W 80 27 Intake Air Temperature Sensor 8W 80 27 Key In Switch Halo Lamp 8W 80 27 Leak Detection Pump 8W 80 28 Left Back Up Lamp 8W 80 28 Left Door Latch Motor 8W 80 28...

Page 563: ...diator Fan Motor 8W 80 39 Radio 8W 80 39 Rear Window Defogger Switch 8W 80 39 Reverse Lock Out Solenoid 8W 80 39 Component Page Right Back Up Lamp 8W 80 40 Right Door Latch Motor 8W 80 40 Right Door Latch Switch 8W 80 40 Right Door Speaker 8W 80 40 Right Door Tweeter 8W 80 40 Right Downstream Heated Oxygen Sensor 8W 80 40 Right Exterior Door Handle Switch 8W 80 41 Right Fog Lamp 8W 80 41 Right Fro...

Page 564: ...amp Switch 8W 80 45 Tachometer 8W 80 46 Throttle Position Sensor 8W 80 46 Vehicle Speed Sensor 8W 80 46 Voltmeter 8W 80 46 Component Page VTSS Disarm Switch 8W 80 47 VTSS LED 8W 80 47 VTSS Liftglass Ajar Switch 8W 80 47 Windshield Washer Pump 8W 80 47 Wiper Control Module 8W 80 48 ...

Page 565: ... 1 8 D B B K A C C O M P R E S S O R C L U T C H R E L A Y O U T P U T B L A C K ITVL C A V C I R C U I T F U N C T I O N 1 Z 8 2 0 B K V T G R O U N D 2 E 2 2 0 O R F U S E D P A N E L L A M P S D I M M E R S W I T C H S I G N A L A C HEATER CONTROL C1 RED A C HEATER CONTROL C2 C A V C I R C U I T F U N C T I O N 1 Z 8 1 6 B K V T G R O U N D 2 C 1 2 1 8 D B T N E V A P O R A T O R T E M P E R A ...

Page 566: ... 2 R45 18DG LB DRIVER AIRBAG LINE 2 3 4 5 R4218BK YL PASSENGER AIRBAG LINE 1 6 R4418DG YL PASSENGER AIRBAG LINE 2 7 8 9 R41 20BK TN AIRBAG WARNING LAMP DRIVER 10 Z618BK PK GROUND 11 12 13 14 15 16 _ 17 F1418LG YL FUSED IGNITION SWITCH OUTPUT ST RUN 18 D2 20WT BK CCD BUS 19 D1 20VT BR CCD BUS 20 F2318DB YL FUSED IGNITION SWITCH OUTPUT RUN NATURAL I 1 I CAV CIRCUIT FUNCTION 1 Z1 14BK GROUND 2 F7514V...

Page 567: ...TER C A V C I R C U I T F U N C T I O N 1 2 X 8 5 1 8 L G D G A M P L I F I E D L E F T D O O R 3 X 8 7 1 8 L G V T A M P L I F I E D L E F T D O O R 4 X 9 5 1 8 W T V T A M P L I F I E D L E F T R E A R 5 X 9 7 1 8 W T D G A M P L I F I E D L E F T R E A R 6 7 X 8 0 1 8 L B D G A M P L I F I E D R I G H T D O O R 8 X 8 2 1 8 L B V T A M P L I F I E D R I G H T D O O R B L A C K C A V CIRCUIT F U ...

Page 568: ... L O W B L O W E R M O T O R D R I V E R 2 C 7 1 4 B K T N H I G H B L O W E R M O T O R D R I V E R 3 C614LB M 2 B L O W E R M O T O R D R I V E R 4 C514LG M 1 B L O W E R M O T O R D R I V E R B L A C K 1 WHM 2 BRAKE WARNING LAMP SWITCH C A V CIRCUIT F U N C T I O N 1 G 9 9 2 0 G Y W T R E D B R A K E W A R N I N G L A M P D R I V E R 2 G 9 2 0 G Y B K R E D B R A K E W A R N I N G L A M P D R I...

Page 569: ... F 2 0 2 0 W T 3 5 G 3 2 0 B K P K 3 6 G 7 0 2 0 B R T N 3 7 G 5 4 2 0 O R B K 3 8 L3918LB 3 9 F4518RD 4 0 L6018TN a B L A C K I r r n A I I c I D I I I C100 6 1 6 22 28 34 44 50 C A V C I R C U I T 1 A 2 1 4 P K B K 2 L 9 1 8 B K W T 3 L 2 0 1 6 L G W T 4 A514RD 5 F 3 4 1 6 T N B K 6 L 9 4 1 6 L G R D 7 G 1 7 2 0 W T T N 8 D 2 0 2 0 L G 9 D 2 1 2 0 P K 1 0 G 3 4 1 6 R D G Y 11 X 6 0 1 8 D G R D 1...

Page 570: ... 3 8 1 8 G Y 6 K 5 8 1 8 B R B K 7 K 2 6 1 8 V T 8 K 2 8 1 8 G Y L G 9 K 5 18W T L G 10 K818BK LG n n a a a B a B a B B B L A C K 5 10 C104 C A V C I R C U I T 1 K11 1 8 W T D B 2 K 1 2 1 8 T N 3 K 1 3 1 8 Y L W T 4 K 1 4 1 8 L B B R 5 K 3 8 1 8 G Y 6 K 5 8 1 8 B R B K 7 K 2 6 1 8 V T 8 K 2 8 1 8 G Y L G 9 K 5 1 8 W T L G 10 K 8 1 8 B K L G 5 10 B L A C K T l I I T 1 C105 C A V C I R C U I T 1 K71...

Page 571: ...Q a Q a 5 1 0 a os C A V C I R C U I T 1 K 4 4 1 8 T N Y L 2 K 2 4 1 8 G Y B K 3 K 4 1 8 B K L B 4 K 3 9 1 8 G Y R D 5 K 4 0 1 8 B R W T 6 G 2 2 0 V T T N 7 G 6 2 0 G Y 8 9 K 5 9 1 8 V T B K 1 0 K 6 0 1 8 Y L 7 B K 1 4 B L A C K b L b d i b L b b c m C A V C I R C U I T 1 G418DB 2 G 7 2 0 W T O R 3 K 1 3 6 1 8 L B B K 4 K 3 1 2 0 B R V T 5 L 7 1 8 B K Y L 6 K 3 3 2 0 G Y O R 7 K 6 2 0 V T W T 8 F ...

Page 572: ... L o q D O Lb C114 B L A C K C A V C I R C U I T 1 L43 2 0 V T 2 L3160R RD 3 L61 1 8 L G 4 L 7 1 8 B K Y L B L A C K C A V C I R C U I T 1 L44 2 0 V T R D 2 L3160R RD 3 L6018TN 4 L 7 1 8 B K Y L C120 2 DO 15 ET C120 B L A C K C A V C I R C U I T 1 L 4 4 2 0 V T R D 2 L3160R RD 3 L6018TN 4 L 7 1 8 B K Y L J988W 13 S R 0 0 8 0 1 2 ...

Page 573: ...C A V C I R C U I T 1 L316RD 2 3 4 L316RD 5 6 7 8 9 1 0 5 1 0 0 b b b c b 0 b b dL di i far cies B L A C K C A V C I R C U I T 1 L6018TN 2 L61 1 8 L G 3 L 5 0 1 4 W T T N 4 M 2 2 0 Y L 5 F 2 0 2 0 W T 6 L 3 6 1 8 L G D B 7 G 3 1 2 0 V T L G 8 9 1 0 X 6 0 1 8 D G R D r V JL B L A C K Q D B Q Q C155 5 1 0 C A V C I R C U I T 1 L6018TN 2 L61 1 8 L G 3 L 5 0 1 8 W T T N 4 M220YL 5 F 2 0 2 0 W T 6 L 3 ...

Page 574: ...2 2 L B B K 15 G 7 4 2 0 T N R D 16 Z20 2 0 B K 16 Z20 2 0 B K 6 5 4 R E D 1 2 3 C207 ROADSTER C A V C I R C U I T 1 L 7 2 0 B K P K 2 3 M 2 2 0 B K L B 4 Z20 2 0 B K 5 6 M 1 2 0 B K R D Q Q Q R E D 6 1 C207 ROADSTER C A V C I R C U I T 1 L 7 2 0 B K Y L 2 3 M 2 2 0 Y L 4 Z20 2 0 B K 5 6 M 1 1 8 P K D A R K G R A Y fO o ou o o O o on o O 1 0 6 0228 C A V CIRCUIT 1 C1514BK WF 2 P12018LG 3 G 7 8 1 8...

Page 575: ...0 W T D G 6 M220YL 6 M 2 2 0 Y L 7 P 1 2 3 2 0 P K W T 8 F 3 5 2 0 R D 9 Q 2 1 1 6 W T 1 0 1 1 P 1 2 5 2 0 P K B K 1 2 P 1 2 9 1 8 D B Y L 1 3 P127 1 8 D B R D 1 4 G 3 3 2 2 L B B K 1 5 G 1 6 2 0 B K L B 1 5 G 1 6 2 0 B K L B 1 6 Z1 1 8 B K B L A C K C308 COUPE C A V C I R C U I T 1 L 7 1 8 B K Y L 2 L 5 0 1 8 W T T N 3 Z118BK B L A C K C308 COUPE C A V C I R C U I T 1 L 7 1 8 B K Y L 1 L 7 1 8 B ...

Page 576: ... A C K C319 C A V C I R C U I T 1 Z1 1 8 B K 2 L 7 1 8 B K Y L 3 L 5 0 1 8 W T T N 4 L 6 0 1 8 D G R D 5 6 L1 1 8 V T B K i B L A C K A5 ZT C319 C A V C I R C U I T 1 Z1 1 8 B K 2 L 7 1 8 B K Y L 3 L 5 0 1 8 W T T N 4 L6018TN 5 L 3 6 1 8 L G D B 6 L1 1 8 V T B K B L A C K fO o ou o O l O o on o O 1 0 6 C330 C A V C I R C U I T 1 F 1 2 1 8 D B G Y 2 K 3 3 2 0 G Y O R 3 L1 1 8 V T B K 4 F 2 0 2 0 W ...

Page 577: ...A J A R S W I T C H S E N S E CARGO LAMP COUPE B L A C K CENTER HIGH MOUNTED STOP LAMP C A V C I R C U I T F U N C T I O N 1 Z1 1 8 B K G R O U N D 2 L 5 0 1 8 W T T N S T O P L A M P S W I T C H O U T P U T 5 llnnn N A T U R A L n o 1 CLOCKSPRING C A V C I R C U I T F U N C T I O N 1 2 3 4 5 X 3 2 0 B K R D H O R N R E L A Y C O N T R O L G R E E N CLUTCH PEDAL POSITION SWITCH C A V C I R C U I T...

Page 578: ... U N D 6 D 2 0 2 0 L G SCI R E C E I V E 7 D 2 1 2 0 P K SCI T R A N S M I T 8 9 1 0 11 D 2 2 0 W T B K C C D BUS 1 2 1 3 1 4 1 5 1 6 F 1 3 1 8 D B R D F U S E D B 5 1 0 O o ou o B L A C K lO o on o OJ DAYTIME RUNNING LAMP MODULE C A V C I R C U I T F U N C T I O N 1 L 3 1 6 R D O R H I G H B E A M R E L A Y O U T P U T 2 3 G 9 2 0 G Y B K R E D B R A K E W A R N I N G L A M P D R I V E R 4 5 F 1 ...

Page 579: ...OR C A V C I R C U I T F U N C T I O N 1 V 5 6 1 8 V T W T D R I V E R W I P E R M O T O R R P M S E N S E 2 V 4 8 1 8 R D G Y D R I V E R W I P E R A R M S I G N A L 3 4 V4518VT D R I V E R W I P E R A R M S I G N A L 5 Z 2 1 8 B K L G G R O U N D 6 F 1 3 1 8 D B R D F U S E D B 7 V 5 4 1 8 D G V T W I P E R P A R K S W I T C H S E N S E 8 9 V 1 4 1 8 R D V T D R I V E R H I G H S P E E D W I P E...

Page 580: ...I N D I C A T O R D R I V E R D 6 G 6 9 2 0 B K O R V T S S I N D I C A T O R L E D D R I V E R D7 D 8 G 1 7 2 0 W T T N S P E E D O M E T E R S I G N A L D 9 P 1 2 5 2 0 P K B K L E F T E X T E R I O R D O O R H A N D L E S W I T C H S I G N A L D 1 0 P 1 2 4 2 0 O R B K R I G H T E X T E R I O R D O O R H A N D L E S W I T C H S I G N A L D 1 1 P 1 2 3 2 0 P K W T L E F T I N T E R I O R D O O R...

Page 581: ... M P S D I M M E R S W I T C H S I G N A L B L A C K ENGINE COOLANT TEMPERATURE SENSOR SENDING UNIT C A V C I R C U I T F U N C T I O N A 2 0 V T T N E N G I N E T E M P E R A T U R E W A R N I N G L A M P D R I V E R B G 2 0 2 0 V T Y L E N G I N E C O O L A N T T E M P E R A T U R E G A U G E S E N S O R S I G N A L C K 2 2 0 T N B K E N G I N E C O O L A N T T E M P E R A T U R E S E N S O R S ...

Page 582: ... E L S E N S O R S I G N A L 2 3 G 5 2 0 D B W T F U S E D IGNITION S W I T C H O U T P U T S T R U N 4 Z20 2 0 B K W T G R O U N D 5 6 E 2 2 0 O R F U S E D P A N E L L A M P S D I M M E R S W I T C H S I G N A L B L A C K C A V C I R C U I T F U N C T I O N 1 K11 1 8 W T D B I N J E C T O R N O 1 D R I V E R 2 A 1 4 2 1 6 D G O R A U T O M A T I C S H U T D O W N R E L A Y O U T P U T FUEL INJEC...

Page 583: ...ECTOR NO 4 B L A C K C A V C I R C U I T F U N C T I O N 1 K 3 8 1 8 G Y I N J E C T O R N O 5 D R I V E R 2 A 1 4 2 1 6 D G O R A U T O M A T I C S H U T D O W N R E L A Y O U T P U T FUEL INJECTOR NO 5 B L A C K C A V C I R C U I T F U N C T I O N 1 K 5 8 1 8 B R B K I N J E C T O R N O 6 D R I V E R 2 A 1 4 2 1 6 D G O R A U T O M A T I C S H U T D O W N R E L A Y O U T P U T FUEL INJECTOR NO 6...

Page 584: ... A U T O M A T I C S H U T D O W N R E L A Y O U T P U T FUEL INJECTOR NO 9 B L A C K C A V C I R C U I T F U N C T I O N 1 K 8 1 8 B K L G I N J E C T O R N O 1 0 D R I V E R 2 A 1 4 2 1 6 D G O R A U T O M A T I C S H U T D O W N R E L A Y O U T P U T FUEL INJECTOR NO 10 L I G H T G R A Y 3 E ibu di m FUEL PUMP MODULE C A V C I R C U I T F U N C T I O N 1 Z12 1 4 B K T N G R O U N D 2 Z1 18BK G ...

Page 585: ...N D 8 F 8 1 14TN F U S E D B 9 C 8 0 1 8 D B W T R E A R W I N D O W D E F O G G E R S W I T C H S I G N A L 1 0 C 1 5 1 4 B K W T R E A R W I N D O W D E F O G G E R R E L A Y C O N T R O L 1 1 F 2 0 2 0 W T F U S E D IGNITION S W I T C H O U T P U T R U N 1 2 A 1 2 1 2 R D W T B 1 3 F 7 5 1 4 V T F U S E D B 1 4 1 5 1 6 A 1 2 1 2 R D W T B 1 7 F81 14TN F U S E D B 1 8 A 1 2 1 2 R D W T B 1 9 F24...

Page 586: ...O L 1 2 L 9 4 1 6 L G R D L O W B E A M R E L A Y C O N T R O L 1 3 G 1 6 2 0 B K L B L E F T F R O N T D O O R J A M B S W I T C H S E N S E 1 4 1 5 G 2 6 20LB KEY IN IGNITION S W I T C H S E N S E N A T U R A L 2 3 HOOD SWITCH C A V C I R C U I T F U N C T I O N 1 G 7 0 2 0 B R T N H O O D A J A R S W I T C H S E N S E 2 Z118BK G R O U N D 3 5 llnnn N A T U R A L r o 1 HORN SWITCH C A V C I R C ...

Page 587: ...LUMINATED REARVIEW MIRROR ROADSTER C A V C I R C U I T F U N C T I O N A M 2 2 0 B K L B C O U R T E S Y L A M P S S W I T C H O U T P U T B Z20 2 0 B K G R O U N D C M 1 2 0 B K R D F U S E D B D L 7 2 0 B K P K P A R K L A M P S W I T C H O U T P U T G R A Y INTAKE AIR TEMPERATURE SENSOR C A V C I R C U I T F U N C T I O N 1 K 4 1 8 B K L B S E N S O R G R O U N D 2 K 2 1 1 8 B K R D I N T A K E...

Page 588: ...E 2 3 Z1 1 8 B K G R O U N D B L A C K C A V C I R C U I T F U N C T I O N 1 P 1 2 9 2 0 D B Y L U N L A T C H R E T U R N L E F T D O O R 2 P 1 2 7 2 0 D B R D U N L A T C H S I G N A L L E F T D O O R LEFT DOOR LATCH MOTOR B L A C K LEFT DOOR LATCH SWITCH C A V C I R C U I T F U N C T I O N A M220YL D O O R L A T C H S W I T C H S E N S E B G 7 5 2 0 T N D O O R A J A R S W I T C H S E N S E C G...

Page 589: ... BLACK LEFT EXTERIOR DOOR HANDLE SWITCH CAV CIRCUIT FUNCTION 1 P125 20PK BK LEFT EXTERIOR DOOR HANDLE SWITCH SIGNAL 2 F35 20RD FUSED B BLACK LEFT FOG LAMP CAV CIRCUIT FUNCTION 1 Z118BK GROUND 2 L3918LB FOG LAMP RELAY OUTPUT LEFT FRONT PARK TURN SIGNAL LAMP IN LEFT HEADLAMP CAV CIRCUIT FUNCTION 3 L61 18LG LEFT TURN SIGNAL 4 L718BK YL PARK LAMP SWITCH OUTPUT 2 O O 1 4 OO 3 LEFT CAV CIRCUIT FUNCTION ...

Page 590: ... L N O 4 D R I V E R 4 K 4 3 1 8 D G G Y IGNITION C O I L N O 5 D R I V E R W H I T E LEFT INTERIOR DOOR HANDLE SWITCH C A V C I R C U I T F U N C T I O N 1 P 1 2 3 2 0 P K W T L E F T I N T E R I O R D O O R H A N D L E S W I T C H S I G N A L 2 F 3 5 2 0 R D F U S E D B 3 4 P 9 7 2 0 W T D G L E F T I N T E R I O R D O O R H A N D L E L A T C H U N L A T C H S I G N A L 5 G 3 3 2 0 L B B K D O O...

Page 591: ...R WINDOW MOTOR G R A Y 1 2 3 LEFT REAR TURN SIGNAL LAMP C A V C I R C U I T F U N C T I O N 1 L61 1 8 D G R D L E F T T U R N S I G N A L 2 3 Z1 1 8 B K G R O U N D B L A C K C A V C I R C U I T F U N C T I O N 1 X 9 5 1 8 W T V T A M P L I F I E D H I G H L E F T R E A R 2 X 9 7 1 8 W T D G A M P L I F I E D H I G H L E F T R E A R LEFT REAR WOOFER snii N A T U R A L C A V C I R C U I T F U N C T...

Page 592: ... U N D 2 L 7 1 8 B K Y L P A R K L A M P S W I T C H O U T P U T 3 L50 1 8 W T T N S T O P L A M P S W I T C H O U T P U T LEFT TAIL STOP LAMP C2 BLACK C A V C I R C U I T F U N C T I O N 1 Z1 1 8 B K G R O U N D 2 L 7 1 8 B K Y L P A R K L A M P S W I T C H O U T P U T 3 L 5 0 1 8 W T T N S T O P L A M P S W I T C H O U T P U T LEFT TAIL STOP LAMP C3 BLACK C A V C I R C U I T F U N C T I O N 1 L6...

Page 593: ...MESSAGE CENTER C2 C A V C I R C U I T F U N C T I O N 1 G 5 2 0 D B W T F U S E D IGNITION S W I T C H O U T P U T S T R U N 2 3 G 3 2 0 B K P K M A L F U N C T I O N I N D I C A T O R L A M P D R I V E R 4 Z 2 0 2 0 B K W T G R O U N D 5 G 9 9 2 0 G Y W T R E D B R A K E W A R N I N G L A M P D R I V E R 6 G 1 2 2 0 D G Y L G E N E R A T O R L A M P D R I V E R 7 G 6 2 0 G Y OIL P R E S S U R E S...

Page 594: ...R D R I G H T T U R N S I G N A L O U T P U T 1 2 1 3 L1918PK H A Z A R D F L A S H E R O U T P U T 1 4 1 5 1 6 L61 1 8 L G L E F T T U R N S I G N A L O U T P U T 1 6 L61 1 8 D G R D L E F T T U R N S I G N A L O U T P U T 1 7 L 6 1 8 R D W T T U R N S I G N A L F L A S H E R O U T P U T 1 8 1 9 L 9 4 1 6 L G R D L O W B E A M R E L A Y C O N T R O L 20 G 3 4 1 6 R D G Y H I G H B E A M I N D I C...

Page 595: ... W I P E R A R M S I G N A L 3 4 V4618DG P A S S E N G E R W I P E R A R M S I G N A L 5 Z 2 1 8 B K L G G R O U N D 6 F 1 3 1 8 D B R D F U S E D B 7 V 5 5 1 8 L B D B W I P E R P A R K S W I T C H S E N S E 8 9 V 4 4 1 8 R D D B P A S S E N G E R H I G H S P E E D W I P E R M O T O R D R I V E R 1 0 V61 1 8 L B P A S S E N G E R L O W S P E E D W I P E R M O T O R D R I V E R G R A Y g U H A if ...

Page 596: ... N O I D C O N T R O L 7 8 9 1 0 K 1 0 6 2 0 W T D G L E A K D E T E C T O R P U M P S O L E N O I D C O N T R O L 11 1 2 A 1 4 2 1 4 D G O R A U T O M A T I C S H U T D O W N R E L A Y O U T P U T 1 3 1 4 K 1 0 7 2 0 O R L E A K D E T E C T O R P U M P S W I T C H S E N S E 1 5 G 3 1 2 0 V T L G B A T T E R Y T E M P E R A T U R E S E N S O R S I G N A L 1 6 G 1 2 1 8 D G Y L G E N E R A T O R L ...

Page 597: ... D D R I V E R 11 G 5 4 2 0 O R B K U P S H I F T L A M P D R I V E R 1 2 K 5 8 1 8 B R B K F U E L I N J E C T O R NO 6 D R I V E R 1 3 K 2 8 1 8 G Y L G F U E L I N J E C T O R NO 8 D R I V E R 1 4 K 8 1 8 B K L G F U E L I N J E C T O R N O 1 0 D R I V E R 1 5 K1218TN F U E L I N J E C T O R NO 2 D R I V E R 1 6 K 1 4 1 8 L B B R F U E L I N J E C T O R NO 4 D R I V E R 1 7 1 8 1 9 20 21 K 1 3 ...

Page 598: ...A K E A I R T E M P E R A T U R E S E N S O R S I G N A L 1 6 K 2 2 0 T N B K E N G I N E C O O L A N T T E M P E R A T U R E S E N S O R S I G N A L 17 K7180R 5 V O L T S U P P L Y 1 8 K 4 4 1 8 T N Y L C A M S H A F T P O S I T I O N S E N S O R S I G N A L 1 9 K 3 9 1 8 G Y R D I D L E A I R C O N T R O L NO 1 D R I V E R 20 K 5 9 1 8 V T B K I D L E A I R C O N T R O L NO 4 D R I V E R 21 22 A...

Page 599: ... L L A M P D I M M E R S W I T C H S I G N A L 1 5 L 7 2 0 B K Y L P A R K L A M P S W I T C H O U T P U T 1 6 M 1 2 0 P K F U S E D B A 4 B 5 BLACK d b d b l l dbc iLA1 d b d b c b t b d b p B 1 REAR WINDOW DEFOGGER SWITCH COUPE C A V C I R C U I T F U N C T I O N A1 A 2 A 3 A 4 A 5 B 1 C 1 5 1 4 B K W T R E A R W I N D O W D E F O G G E R R E L A Y C O N T R O L B 2 E 2 2 0 O R F U S E D P A N E...

Page 600: ...A R S W I T C H S E N S E D M220YL D O O R L A T C H S W I T C H S E N S E B L A C K RIGHT DOOR SPEAKER B L A C K RIGHT DOOR TWEETER C A V CIRCUIT F U N C T I O N 1 X 8 2 2 0 L B V T A M P L I F I E D R I G H T D O O R 2 X 8 0 2 0 L B D G A M P L I F I E D R I G H T D O O R C A V C I R C U I T F U N C T I O N 1 X 8 2 2 0 L B V T A M P L I F I E D R I G H T D O O R 2 X 8 0 2 0 L B D G A M P L I F I...

Page 601: ...ADLAMP C A V C I R C U I T F U N C T I O N 3 L6018TN R I G H T T U R N S I G N A L 4 L 7 1 8 B K Y L P A R K L A M P S W I T C H O U T P U T RIGHT HIGH BEAM HEADLAMP IN RIGHT HEADLAMP C A V C I R C U I T F U N C T I O N 2 L 3 1 6 0 R R D D I M M E R S W I T C H H I G H B E A M O U T P U T _ J oo Lbdl RIGHT HEADLAMP C A V C I R C U I T F U N C T I O N 1 L 4 4 2 0 V T R D L O W B E A M H E A D L A M...

Page 602: ...RIOR DOOR HANDLE SWITCH CAV CIRCUIT FUNCTION 1 P122 20OR WT RIGHT INTERIOR DOOR HANDLE SWITCH SIGNAL 2 F35 20RD FUSED B 3 4 P96 20WT LG RIGHT INTERIOR DOOR HANDLE LATCH UNLATCH SIGNAL 5 G33 20LB BK DOOR UNLATCH INDICATOR DRIVER N A T U R A L RIGHT LICENSE LAMP CAV CIRCUIT FUNCTION 1 L7 18BK YL PARK LAMP SWITCH OUTPUT 1 Z1 18BK GROUND 2 Z1 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTPUT RIGHT LOW ...

Page 603: ...C U I T F U N C T I O N 1 L 6 0 1 8 D G R D R I G H T T U R N S I G N A L 2 3 Z118BK G R O U N D B L A C K C A V C I R C U I T F U N C T I O N 1 X 9 8 1 8 T N V T A M P L I F I E D H I G H R I G H T R E A R 2 X 9 6 1 8 T N D G A M P L I F I E D H I G H R I G H T R E A R RIGHT REAR WOOFER N A T U R A L C A V C I R C U I T F U N C T I O N 1 L6018LG R I G H T T U R N S I G N A L 2 L 7 1 8 B K Y L P A...

Page 604: ... L 7 1 8 B K Y L P A R K L A M P S W I T C H O U T P U T 3 L 5 0 1 8 W T T N S T O P L A M P S W I T C H O U T P U T RIGHT TAIL STOP LAMP C2 B L A C K C A V C I R C U I T F U N C T I O N 1 Z1 1 8 B K G R O U N D 2 L 7 1 8 B K Y L P A R K L A M P S W I T C H O U T P U T 3 L 5 0 1 8 W T T N S T O P L A M P S W I T C H O U T P U T RIGHT TAIL STOP LAMP C3 B L A C K C A V C I R C U I T F U N C T I O N ...

Page 605: ... C U I T F U N C T I O N 1 G 1 7 2 0 W T T N S P E E D O M E T E R S I G N A L 2 3 G 5 2 0 D B W T F U S E D IGNITION S W I T C H O U T P U T S T R U N 4 Z1 2 0 B K G R O U N D 4 Z1 2 0 B K G R O U N D 5 Z1 2 0 B K G R O U N D 5 Zi 2 0 B K G R O U N D 6 E 2 2 0 O R F U S E D P A N E L L A M P D I M M E R S W I T C H S I G N A L G R A Y STOP LAMP SWITCH C A V C I R C U I T F U N C T I O N 1 K 2 9 1...

Page 606: ...U I T F U N C T I O N 1 K 4 1 8 B K L B S E N S O R G R O U N D 2 K22180R DB T H R O T T L E P O S I T I O N S E N S O R S I G N A L 3 K7180R 5 V O L T S U P P L Y B L A C K VEHICLE SPEED SENSOR C A V C I R C U I T F U N C T I O N 1 K 6 2 0 V T W T 5 V O L T S U P P L Y 2 K 4 1 8 B K L B S E N S O R G R O U N D 3 G 7 2 0 W T O R V E H I C L E S P E E D S E N S O R S I G N A L B L U E 6 1 VOLTMETER...

Page 607: ...K O R V T S S I N D I C A T O R L E D D R I V E R B L A C K VTSS LIFTGLASS AJAR SWITCH COUPE C A V C I R C U I T F U N C T I O N 1 G 7 8 1 8 B R D G L I F T G L A S S A J A R S W I T C H S E N S E 2 Z1 18BK G R O U N D 2 Z1 1 8 B K G R O U N D B L A C K WINDSHIELD WASHER PUMP C A V C I R C U I T F U N C T I O N A V 6 1 8 D B F U S E D IGNITION S W I T C H O U T P U T R U N A C C B V1018BR W A S H ...

Page 608: ...K D R I V E R L O W S P E E D W I P E R M O T O R D R I V E R 1 0 V 1 4 1 8 R D V T D R I V E R H I G H S P E E D W I P E R M O T O R D R I V E R 1 1 V4718RD P A S S E N G E R W I P E R A R M S I G N A L 1 2 V 1 7 1 8 D G Y L W I P E R S W I T C H D E L A Y O U T P U T 1 3 V1018BR W A S H E R P U M P C O N T R O L 1 4 V4618DG P A S S E N G E R W I P E R A R M S I G N A L 1 5 V 5 7 1 8 V T R D P A ...

Page 609: ...plifier C1 NAT LT Rear Quarter Panel 17 18 Audio Amplifier C2 WT LT Rear Quarter Panel 17 18 Back Up Lamp Switch BK Near Transmission 25 Battery Temperature Sensor BK Rear of Battery 24 Blower Motor Switch BK Under Radio 10 Blower Motor Resistor Block C1 NAT RT Toe Box N S Blower Motor Resistor Block C2 NAT RT Toe Box N S Brake Warning Lamp Switch BK LT Frame Rail 4 C100 BK LT Toe Box 3 8 11 Conne...

Page 610: ...ronic Entry Module C 3 GN Right Side Instrument Panel 10 11 Engine Coolant Temperature Gauge RD Rear of Gauge N S Engine Coolant Temperature Sensor BK Front of Engine 6 Connector Color Location Fig Engine Oil Pressure Gauge BL Rear of Gauge N S Engine Oil Pressure Sending Unit BK RT Front of Engine 6 Engine Oil Pressure Switch BK RT Front of Engine 6 Fuel Gauge RD Rear of Gauge N S Fuel Injector 1...

Page 611: ...Front Park Turn Signal Lamp At Lamp N S Left High Beam Headlamp At Lamp N S Left Horn BK LT Front Frame Rail N S Left Ignition Coil Pack BK LT Rear Cylinder Head N S Connector Color Location Fig Left Interior Door Handle Switch W T At Switch 22 Left License Lamp NAT At Lamp 23 Left Low Beam Headlamp At Lamp N S Left Power Window Motor BK At Motro 22 Left Rear Turn Signal Lamp GY At Lamp N S Left R...

Page 612: ... At Speaker N S Right Door Tweeter BK At Speaker N S Right Downstream Heated Oxygen Sensor BK RT Rear Floor Tunnel 15 Right Exterior Door Handle Switch BK At Switch N S Connector Color Location Fig Right Fog Lamp BK Rear of Lamp N S Right Front Park Turn Signal Lamp At Lamp N S Right High Beam Headlamp At Lamp N S Right Horn BK RT Front Frame Rail N S Right Ignition Coil Pack BK RT Rear Cylinder H...

Page 613: ...le Speed Sensor BK Near Transmission 25 Voltmeter BL Rear of Gauge N S VTSS Disable Switch At Switch N S VTSS Led BK Near LP N S VTSS Liftglass Ajar Switch BK LT Prop Rod N S C o n n e c t o r Color L o c a t i o n Fig Windshield Washer Pump BK Bottom of Reservoir N S Wiper Control Module NAT Rear of RT Knee Blocker 10 12 ...

Page 614: ...8W 90 6 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d ...

Page 615: ...S R 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d 8W 90 7 ...

Page 616: ...8W 90 8 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d S R ...

Page 617: ...B R A K E W A R N I N G SWITCH 80b3c984 o Fig 4 Engine Compartment ...

Page 618: ......

Page 619: ...H IDLE AIR CONTROL MOTOR VIEW IN DIRECTION OF ARROW E THROTTLE POSITION SENSOR VIEW IN DIRECTION OF ARROW L VALVE COVER MAP SENSOR INTAKE MANIFOLD GENERATOR INTAKE AIR TEMPERATURE SENSOR ENGINE COOLANT WARNING LAMP SWITCH VIEW IN DIRECTION OF ARROW K CAMSHAFT POSITION SENSOR VALVE COVER VIEW IN DIRECTION OF ARROW G VIEW IN DIRECTION OF ARROW F IDLER PULLEY VIEW IN DIRECTION OF ARROW H Fig 6 Engine...

Page 620: ...8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS S R D E S C R I P T I O N AND OPERATION Continued Fig 7 Upper Intake Manifold ...

Page 621: ...USE B L O C K C242 C L U T C H POSITION SWITCH G201 C100 DATA LINK C O N N E C T O R K E Y IN CHIME C L O C K S P R I N G IGNITION SWITCH U V m x X C D 3 o z o s i m o tt o o o 5 o C 0 oo 80b3c9e1 Fig 0 Steering Column co ...

Page 622: ......

Page 623: ... f t 80b3c986 C D Fig 10 Instrument Panel m ...

Page 624: ...8W 90 1 6 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d ...

Page 625: ...S R 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d 8W 90 1 7 ...

Page 626: ...m C242 80b3c989 Fig 13 Left Lower Instrument Panel m 39 ...

Page 627: ...S R 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N AND OPERATION Continued 8W 90 19 Fig 14 Console ...

Page 628: ...8W 90 20 SW 9 0 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N AND t i n u e d ...

Page 629: ...S R 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d 8W 90 21 ...

Page 630: ...E R E A R D E F O G G E R R E L A Y O m o 30 00 to J I N S 2 Z D O V m so 5 o z co to o A M P L I F I E R F U S E O 0 3 3 O 1 z o 39 O 30 O o o o z C 3 F U S E R E L A Y B L O C K C O U P E C318 80b3c98c Fig 17 Amplifier Coupe w 30 ...

Page 631: ...o m 80b3c98d SO O Fig 18 Amplifier Roadster ...

Page 632: ...8W 90 24 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N AND OPERATION Continued S R Fig 19 Left Quarter ...

Page 633: ...S R 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N AND O P E R A T I O N C o n t i n u e d 8W 90 2 5 ...

Page 634: ...8W 90 26 8W 90 CONNECTOR GROUND LOCATIONS D E S C R I P T I O N AND OPERATION Continued S R Fig 22 Right Door 80b34ec4 ...

Page 635: ...o m 80b3c98f C O Fig 23 Trunk ...

Page 636: ...8W 90 28 8W 90 CONNECTOR GROUND LOCATIONS S R D E S C R I P T I O N AND OPERATION Continued G300 T E M P E R A T U R E S E N S O R 80b34ec5 Fig 24 Battery Fig 25 Transmission 80b34ec6 ...

Page 637: ... internal to P D C 1 S119 In T O for PDC 1 S120 Internal to P D C S121 Internal to P D C i S122 Interna to P D C 1 S123 Internal to P D C 1 S124 Rear of Brake Booster 1 S125 Near T O for Engine Connectors N S S126 Near Hood Switch T O N S S127 In P D C Battery Feed 1 S128 Near G103 N S S129 Near T O for Generator Feed N S Splice No Location Fig S130 Near T P S T O N S S131 Near Inj 10 T O 2 S132 B...

Page 638: ...S S317 Near T O for LT Door Tweeter 5 Near T O for Battery Temp Sensor S318 Near T O for RT Door Tweeter 5 S306 Near Rear Body Grommet 6 S318 Near T O for RT Door Tweeter 5 S309 NearT O for Fuse Relay Block Near T O for RT Door Tweeter S309 NearT O for Fuse Relay Block D S319 Near Mid Range Speaker T O 5 S310 S R 2 9 Near C H M S L T O Near Mid Range Speaker T O S310 S R 2 9 Near C H M S L T O o S...

Page 639: ...S R 8W 95 SPLICE LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N Continued 8W 95 3 ...

Page 640: ......

Page 641: ...S R 8W 95 SPLICE LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d 8W 95 5 ...

Page 642: ...8W 95 6 8W 95 SPLICE LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d S R ...

Page 643: ......

Page 644: ...8W 95 8 8W 95 SPLICE LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d S R ...

Page 645: ...S R 8W 95 SPLICE LOCATIONS D E S C R I P T I O N A N D O P E R A T I O N C o n t i n u e d 8 W 95 9 80a53adc Fig 7 HVAC Splices S400 LEFT SIDE 958W 108 Fig 8 Tail Lamp Splices ...

Page 646: ......

Page 647: ...ns 5 Test resistance of spark plug cables Refer to Group 8D Ignition System 6 Test ignition coils primary and secondary resis tance Replace parts as necessary Refer to Group 8D Ignition System 7 Test fuel pump for pressure Refer to Group 14 Fuel System 8 The air filter elements should be replaced as specified in Group 0 Lubrication and Maintenance 9 Inspect crankcase ventilation system as out line...

Page 648: ...ne crankshaft bearing clearances can be deter mined by use of Plastigage or equivalent The follow ing is the recommended procedure for the use of Plastigage 1 Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke 2 Remove oil film from surface to be checked Plastigage is soluble i n oil 3 Place a piece of Plastigage across the entire width of the bearing shell...

Page 649: ...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 C A U T I O N Do Not U s e Starter Motor To Rotate Engine severe damage may occur 1 Inspect air cleaner induction system and intake manifol...

Page 650: ...NSERVING OIL An Energy Conserving type of fully synthetic oil is recommended for viper engine The designation of ENERGY CONSERVING is located on the label of the engine oil container CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid i n the proper selection of engine oil The identifying notations are located on the label of engine oil plastic bottles Fi...

Page 651: ...fed to the tappets causes them to become soft and allows valves to seat noisily Any leaks on intake side of pump through which air can be drawn will create the same tappet action Check the lubrication system from the intake strainer to the pump cover including the relief valve retainer cap When tappet noise is due to aeration i t may be intermittent or constant and usually more than one tappet wil...

Page 652: ...on check 7 Insert compression gage adaptor into the 1 spark plug hole i n cylinder head Crank engine until maximum pressure is reached on gage Record this pressure as 1 cylinder pressure 8 Repeat the previous step for all remaining cyl inders 9 Compression should not be less than 689kPa 100 psi and not vary more than 25 percent from cyl inder to cylinder 10 I f one or more cylinders have abnormall...

Page 653: ...er to Group 8D Ignition System 2 Clean system and replace fuel filter 3 Replace fuel pump 4 Correct valve timing 5 Replace cylinder head gasket s 6 Test cylinder compression 7 Install new or reface valves as necessary 8 Replace parts as necessary 9 Replace ignition cables as necessary 10 Test and replace as necessary Refer to Group 8D Ignition System ENGINE STALLS OR ROUGH IDLE 1 Carbon buildup on...

Page 654: ...sive bearing clearance 5 Connecting rod journal out of round 6 Misaligned connecting rods 1 Check engine oil level Refer to Group 0 Lubrication and Maintenance 2 Check engine oil level If OK perform oil pressure test Inspect oil pump relief valve and spring Refer to this group for engine oil pressure test specification 3 Change oil Refer to Engine Oil Service in this group 4 Measure bearings for c...

Page 655: ...ecessary 8 Remove oil pan and inspect oil passage and screen Clean or replace as necessary 9 Inspect tighten cover screws or install new oil pump if necessary OIL LEAKS 1 Misaligned or deteriorated gaskets 2 Loose fastener broken or porous component 1 Replace gaskets 2 Tighten repair or replace component EXCESSIVE OIL CONSUMPTION OR SPARK PLUGS OIL FOULED 1 PCV system malfunction 2 Defective valve...

Page 656: ... S 28 INTAKE MANIFOLD 21 page OIL FILTER 33 OIL PAN 31 OIL PUMP 33 PISTON AND C O N N E C T I N G ROD 34 R O C K E R A R M S AND P E D E S T A L 25 TIMING CHAIN AND S P R O C K E T 30 TIMING CHAIN C O V E R 22 VALVE AND VALVE S P R I N G 28 VALVE S T E M S E A L S O R VALVE S P R I N G S C Y L I N D E R HEAD NOT R E M O V E D 26 D I S A S S E M B L Y AND A S S E M B L Y HYDRAULIC T A P P E T S 39 ...

Page 657: ...lock and cylinder heads are aluminum The crankshaft is forged steel This engine is designed for premium unleaded fuel The cylinders are numbered from front to rear 1 3 5 7 9 on the left bank and 2 4 6 8 10 on the right bank The firing order is 1 10 9 4 3 6 5 8 7 2 CYLINDER BLOCK The cylinder block is sand cast aluminum alloy with pressed in dry cast iron liners and cross bolted iron main caps Thes...

Page 658: ...re common either right or left and installed on individual rocker arm pedestals attached to the cylinder head Viton valve stem seals provide positive intake and exhaust valve sealing Conventional type hollow push rods retainers and valve stem locks are used The relative high engine speed and high lift cam require dual valve springs Valve spring seats are used to protect the aluminum cylinder heads...

Page 659: ...moval to insure correct assembly 8 0L ENGINE S 13 B J9509 125 Fig 5 Cylinder Bore Size Measuring CYLINDER BORE AND PISTON SPECIFICATION CHART Engine Standard Bore Max Out of Round Max Taper 8 0L 1 0 1 5 9 0 101 610 mm 3 9996 4 0004 in 0 051mm 0 002 in 0 038 mm 0 0015 in Standard Piston Size 8 0L 1 0 1 4 9 6 101 514 mm 3 9959 3 9966 in Piston to Bore Clearance 0 076 0 114 mm 0 003 0 0045 in Measure...

Page 660: ...terchangeable CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for excessive wear taper and scoring Limits of taper or out of round on any crankshaft journals should be held to 0 013 mm 0 0005 inch Journal grinding should not exceed 0 508 m m 0 020 in under the standard journal diameter DO NOT grind thrust faces of No 3 main bearing DO NOT nick crank pin or bearing fillets After ...

Page 661: ... remover to soften the old gasket material A l s o to avoid damage to the mating surfaces do not u s e a metal scraper Instead u s e a plastic or wooden scraper INSTALLATION NOTE Only one main bearing should be selec tively fitted while all other main bearing c a p s are properly tightened When installing a new upper bearing shell slightly chamfer the sharp edges from the plain side 1 Start bearin...

Page 662: ...o 54 N m 40 ft lbs i n the sequence order shown i n Fig 11 13 Remove the holding tool CRANKSHAFT OIL CLEARANCE 1 Measure the journal outside diameter as shown in Fig 12 Refer to Crankshaft Specification Chart P L A S T I G A G E OIL CLEARANCE MEASUREMENT 1 Remove oil from journal and bearing shell 2 Install crankshaft 3 Cut plastigage to same length as width of the bearing and place i t i n parall...

Page 663: ...shaft cheek using care not to damage any bearing surface D o n o t loosen main bearing cap 2 Use a feeler gauge between number 3 thrust bearing and machined crankshaft surface to deter mine end play Refer to Crankshaft End Play Table for specification CRANKSHAFT END PLAY C r a n k s h a f t End Play New Part 0 05 0 18 mm 0 002 0 007 in Desired 0 013 m m 0 005 in Wear Limit 0 25 m m 0 010 in REFACI...

Page 664: ...hat correct angle and seat width are maintained Otherwise cylinder head must be replaced 4 When seat is properly positioned the width of both seats should be 1 02 1 52 m m 0 040 0 060 in Fig 15 VALVE INSTALLATION 1 Coat valve stems with clean engine oil and insert them i n cylinder head 2 I f valves or seats have been reground check valve tip height A and valve spring installed height B Fig 17 I f...

Page 665: ...Remove the dial indicator from the spark plug hole and install the dial indicator over the cylinder 1 intake valve retainer with the dial indicator shaft parallel to the valve stem Fig 19 Timing Chain Wear and Stretch Measuring 6 Rotate the crankshaft clockwise until the dial indicator reads maximum lift Back up the crank shaft until the dial indicator has dropped at least 0 050 from maximum lift ...

Page 666: ... isolator to bracket nut Tighten nut to 101 N m 75 ft lbs 5 Remove lifting fixture ENGINE ASSEMBLY REMOWAL 1 Disconnect battery 2 Remove hood and support from front support Refer to Group 23 for procedure 3 Remove air cleaner assembly Refer to Group 25 Emission Control System for removal procedure 4 Drain cooling system Refer to Cooling System Group 7 for procedure 5 Remove upper radiator hose and...

Page 667: ...r to Group 7 Cooling System for procedure 9 Lower vehicle and connect all vacuum lines 10 Connect all electrical connections and ground strap 11 Connect fuel lines and accelerator cable 12 Install radiator hoses and connect heater hoses Fill cooling system Refer to Group 7 Cooling System for filling procedure 13 Fill engine crankcase with proper oil to cor rect level 14 Install hood support bracke...

Page 668: ...lock 3 Install camshaft thrust plate with two screws as shown i n Fig 24 Tighten to 24 N m 210 i n lbs 4 Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores 5 Place timing chain around both sprockets 6 Turn crankshaft and camshaft to line up with keyway location on crankshaft sprocket and on c...

Page 669: ...olant hoses from engine and radia tor 5 Remove drive belt Refer to Group 7 Cooling System for procedure 6 Remove generator wiring Remove generator Fig 29 7 I f equipped with A C remove compressor mounting bolts Fig 28 Air Cleaner Assembly Roadster 8 I f replacing timing chain cover remove oil filter adapter and discard gasket Fig 30 I f only remov ing timing chain cover remove oil cooler lines at ...

Page 670: ...ulley Removal UNIVERSAL PULLER VIBRATION D A H P E R Fig 32 Vibration Damper Removal 80a47354 CHAIN CASE COVER FASTENERS RIGHT SIDE ENGINE CHAIN CASE COVER FASTENERS LEFT SIDE ENGINE FASTENERS TO OIL PAN 8oa47357 Fig 33 Timing Chain Case Cover Fasteners INSTALLATION 1 Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs Crankshaft oil seal must be removed to...

Page 671: ... 11 I f equipped with A C install compressor mounting bolts to cover and block Torque screws to 23 N m 200 in lbs 12 Install generator and torque screws to 40 N m 30 ft lbs 13 Connect cam sensor electrical connector and generator wiring 14 Install drive belt Refer to Group 7 Cooling System for installation procedure 15 Fill cooling system Refer to Group 7 Cooling System for procedure 16 Connect ba...

Page 672: ...ine so the No 1 pis ton is at Top Dead Center on compression stroke 6 Remove rocker arms with pivots The rocker arms should not be disturbed and left on pivots 7 With air hose attached to spark plug adapter installed i n No 1 spark plug hole apply 620 5 to 689 kPa 90 to 100 psi air pressure This is to hold valves into place while servicing components 8 Using a suitable tool compress valve spring a...

Page 673: ...sket material from cylinder head and block using a plastic scraper only DO NOT u s e a metal scraper a s damage to sealing sur face may occur N O T E A multi layer steel head gasket is used 2 Install new gasket s on cylinder block Fig 41 CAUTION Cylinder head bolts are coated DO NOT oil 3 Tighten the cylinder head bolts 1 12 i n the sequence shown i n Fig 42 2 Step Torque Sequence First to 47 N m ...

Page 674: ...LIC TIPPETS REMOVAL 1 Refer to Cylinder Head Removal of this section to remove intake manifold and cylinder heads for access to tappets for service 2 Remove aligning yoke assemblies Fig 46 3 Use Special Tool C 4129 to remove tappets from bores I f all tappets are to be removed identify tappets to insure installation i n original location C A U T I O N T h e plunger and tappet bodies are not interc...

Page 675: ...essor Install retaining locks and release tool i f valves and or seats are r e g r o u n d measure the installed height o f springs B Fig 48 make sure measurements are taken from top of spring seat to the bottom surface of spring retainer I f height is greater than 42 65 m m 1 670 in install a 0 794 m m 1 32 in spacer i n head counter bore under the valve spring seat to bring spring height back to...

Page 676: ...urface Fig 52 Crankshaft Oil Seal Removal Fig 53 Crankshaft Oil Seal Installation INSTALLATION 1 Position a new crankshaft sprocket on crank shaft Install sprocket with suitable tool and mallet Be sure sprocket is seated into position 2 Rotate crankshaft sprocket so the timing mark is to the 12 O clock position 3 Place timing chain around camshaft sprocket and place the timing mark to the 6 O cloc...

Page 677: ...TALLATION 1 Use a new pan gasket i f necessary Fig 56 2 Install pan and tighten screws to 11 N m 95 i n lbs INLET OIL PAN B A F F L E OIL PAN INSTALLED 80a983b1 Fig 56 Oil Pan and Gasket 3 Lower vehicle and connect negative battery cable 4 Fill crankcase with oil to proper level CRANKSHAFT OIL SEAL AND RETAINER REAR REMOVAL 1 Remove transmission Refer to Group 21 Transmission for procedures 2 Remo...

Page 678: ...r block 2 Install crankshaft 3 Lubricate main journals with clean engine oil Install each main cap and tighten bolts finger tight 4 Tighten main cap bolts in the following tight ening sequence 5 Step 1 Tighten only the center m a i n caps bolts in the sequence order shown i n Fig 60 to 20 N m 15 ft lbs This will seat the bearing caps onto the engine block 6 S t e p 2 To ensure correct thrust beari...

Page 679: ...sket of new filter with clean engine oil 4 Install and tighten filter to 20 N m 15 ft lbs torque after gasket contacts base Use filter wrench i f necessary 5 Start engine and check for leaks OIL PUMP It is necessary to remove the chain case cover CCC to service the oil pump rotors Refer to Timing Chain Cover Removal and Installation in this section for procedures The oil pump pressure relief valve...

Page 680: ...with piston to ensure it is square in bore The ring gap measurement must be made with the ring positioning at least 12 mm 0 50 inch from bottom of cylinder bore Check gap with feeler gauge Fig 64 refer to Piston Ring Specification Chart 2 Check piston ring side clearance Fig 65 Refer to Piston Ring Specification Chart SR Fig 62 Connecting Rod to Cylinder Identification Fig 63 Connecting Rod Bolt P...

Page 681: ...een the piston ring groove and the expander Hold end firmly and press down the portion to be installed until side rail is i n position Do n o t use a p i s t o n r i n g expander Fig 67 SIDE RAIL Fig 67 Side Rail Installation 7 Install lower side rail first and then the upper side rail 8 Install No 2 piston ring and then No 1 piston ring Fig 68 9 Position piston ring end gaps as shown in Fig 69 10...

Page 682: ...ore using a hammer handle 5 Install connecting rod bolt protectors on rod bolts Fig 71 Piston I D Arrows 6 Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore Insert rod and piston into cylinder bore and guide rod over the crankshaft journal 7 The arrow on top of piston must be pointing toward front of engine Fig 71 8 Install rod caps Install nuts on cleaned ...

Page 683: ...Using universal puller remove vibration damper Fig 74 Fig 73 Crankshaft Pulley Removal INSTALLATION 1 Install vibration damper Fig 75 and tighten bolt to 340 N m 250 ft lbs 2 Install Crankshaft pulley 3 Install drive belt 4 Install air cleaner assembly UNIVERSAL P U L L E R VIBRATION DAMPER Fig 74 Vibration Damper Removal 80a47354 USE VIBRATION DAMPER RETAINING BOLT TO INSTALL DAMPER c y 9309 309 ...

Page 684: ...R CAP 9309 66 Fig 77 Oil Pressure Relief Valves 5 Remove oil pump cover screws and lift off cover 6 Remove pump rotors 7 Wash all parts i n a suitable solvent and inspect carefully for damage or wear Fig 78 OIL PUMP OUTER ROTOR OIL PUMP INNER ROTOR SCREWS Fig 78 Oil Pump OIL PUMP O C O V E R CHAIN C A S E C O V E R APPLY S E A L A N T TO OIL PUMP C O V E R IN A C O M P L E T E C I R C L E Fig 79 O...

Page 685: ... AND ASSEMBLY 1 Clean all tappet parts i n a solvent that will remove all varnish and carbon 2 Replace tappets that are unfit for further ser vice with new assemblies 3 I f plunger shows signs of scoring or wear and valve is pitted or i f valve seat on end of plunger indicates any condition that would prevent valve from seating install a new tappet assembly 4 Assemble tappets Fig 80 C L E A N I N ...

Page 686: ...r e a m the valve guides f r o m standard d i r e c t l y t o 0 40 mm 0 015 i n Use a step proce d u r e o f 0 15 m m 0 005 in to 0 40 m m 0 015 in so the valve guides may be reamed true i n relation to the valve seat After reaming guides the seat runout should be measured and resur faced if necessary See Refacing Valves and Valve Seats VALVE GUIDE SPECIFICATION CHART Valve Guide Dial Indicator Re...

Page 687: ...NG C A U T I O N R e m o v e all gasket material f r o m c y l i n der head a n d cover u s i n g a plastic gasket scraper T h i s will prevent d a m a g e to either t h e head or t h e cover INSPECTION Inspect the cylinder head covers and gaskets for cracks or broken areas around fastener holes that may cause a oil leak Replace gasket i f necessary OIL PUMP CLEANING Fig 84 Oil Pump Clean all part...

Page 688: ... 6 Inspect oil pressure relief valve plungers for scoring and free operation i n its bore Small marks may be removed with 400 grit wet or dry sandpaper 7 The relief valve springs have a free length of approximately 49 5 m m 1 95 Inch and should test between 22 5 and 24 5 pounds when compressed to 34 m m 1 11 32 inches Replace spring that fails to meet specifications 8 I f oil pressure is low and p...

Page 689: ... cylinder walls should be checked for out of round and taper with Special Tool C 119 Fig 90 If the cylinder walls are badly scuffed or scored the cylinder bore can be machined oversize Oversize pis ton and rings are available 8 0L ENGINE 9 4 3 Measure the cylinder bore at three levels in direc tions A and B Fig 90 Top measurement should be 12 mm 0 50 in down and bottom measurement should be 12 mm ...

Page 690: ...to remove all nicks and burrs PISTON PINS The piston pin rotates i n the piston only and is retained by the press interference fit of the piston pin in the connecting rod S P E C I F I C A T I O N S 8 0L ENGINE TVpe 90 V 10 Engine Bore 101 6 mm 4 00 in Stroke 98 6 m m 3 88 in Compression Ratio 9 6 1 Displacement 8 0L 488 Cubic in Brake Horsepower 450 5200 RPM Torque 490 Lb Ft 3700 RPM Firing Order...

Page 691: ... 094 in Diametrical Clearance 0 051 0 102 m m 0 002 0 004 in Max Allowable 0 127 mm 0 005 in End Play 0 127 0 381 m m 0 005 0 015 in Valve Timing Exhaust Valve Closes ATC 42 5 Opens BBC 82 5 Duration 305 0 Valve Timing Intake Valve Closes BTDC 86 5 O p e n s 23 5 Duration 297 0 Valve Overlap 66 0 Hydraulic Tappets Body Diameter 22 949 22 962 mm 0 9035 0 9040 in Clearance i n Block 0 203 0 0610 mm ...

Page 692: ...u n t i n g Bolts 41 N m 30 ft lbs Camshaft Sprocket Bolt 74 5 N m 55 ft lbs Camshaft T h r u s t Plate Bolts 24 N m 210 in lbs D E S C R I P T I O N TORQUE C h a i n Case Cover Bolts 41 N m 30 ft lbs Connecting R o d Caps Bolts 61 N m 45 ft lbs Crankshaft M a i n B e a r i n g Caps B o l t s Refer to Procedure Outlined in This Section C y l i n d e r Head B o l t s Refer to Procedure Outlined in ...

Page 693: ...Main Bearing Installer Remover C 3059 ...

Page 694: ......

Page 695: ...nique design The system consists of two side mounted catalytic converters and resonators with a single rear mounted muffler Fig page REMOVAL AND INSTALLATION CATALYTIC CONVERTERS 4 EXHAUST MANIFOLDS 8 INTAKE MANIFOLD 5 MUFFLER 4 RESONATOR INTERMEDIATE PIPE 5 CLEANING AND INSPECTION EXHAUST MANIFOLD 9 INTAKE MANIFOLD 9 SPECIFICATIONS TORQUE CHART 9 1 The two downstream oxygen sensors are located be...

Page 696: ...st system must be replaced C A U T I O N Due to exterior physical similarities of s o m e catalytic converters with pipe a s s e m b l i e s extreme care should be taken with replacement parts HEAT SHIELDS Heat shields Fig 3 are needed to protect both the car and the environment from the high temperatures developed i n the vicinity of the catalytic converters and exhaust manifolds Fig 4 Additional...

Page 697: ...otor mounting is located at the front of the right plenum The dual log runners design is tuned for high speed Dual throttle bodies are mounted to the front of the intake plenums Sealing of the intake DIAGNOSIS AND TESTING EXHAUST SYSTEM DIAGNOSIS CONDITION P O S S I B L E C A U S E C O R R E C T I O N EXCESSIVE EXHAUST NOISE UNDER HOOD 1 Exhaust manifold cracked or broken 2 Manifold to cylinder he...

Page 698: ...s be used to insure proper alignment with other parts in the system Provide acceptable exhaust noise levels a n d does not change exhaust s y s t e m back pressure that could affect e m i s s i o n s a n d performance i f f S T A L L A T f O W 1 Install converter to resonator intermediate pipe Do not tighten band clamp at this time to per mit alignment of all parts 2 Install N E W V Band clamp at ...

Page 699: ...ighten band clamps at this time 2 Install muffler isolators and tighten bolts to 28 N m 250 in lbs 3 Tighten muffler band clamps to 70 N m 55 ft lbs RESONATOR INTERMEDIATE PIPE REMOVAL 1 Raise vehicle on hoist and remove side sill panel rocker panel cover Refer to Group 23 Body for procedure 2 Apply penetrating oil to band clamps of compo nent being removed Fig 5 3 Remove muffler Refer to procedur...

Page 700: ...TPS elec trical connector from intake manifold Fig 10 7 Remove brake booster hose from air intake ple num Fig 11 S R Fig 10 Electrical Connection to Throttle Body Fig 11 Brake Booster Hose 8 Disconnect Idle A i r Control IAC motor electri cal and hose connection Fig 12 9 Remove cowl cover Refer to Group 23 Body for procedure 10 Disconnect the electrical connectors at the ignition coils Fig 13 11 D...

Page 701: ...H A N Y GASOLINE SPILLAGE ELECTRICAL CONNECTORS 80a58b9e Fig 13 Coil Electrical Connectors 13 Remove intake manifold bolts Lift the front of intake manifold and pull forward to remove 14 Cover intake manifold with suitable cover when servicing Fig 14 Intake Manifold Electrical Connectors CONNECT 80abd24d Fig 15 Quick Connect Fuel Fitting to Fuel Line INSTALLATION CAUTION When cleaning the cylinder...

Page 702: ...ical and hose connectors 7 Connect CCV and canister purge hoses to intake plenum 8 Connect brake booster hose to intake plenum 9 Connect ignition coils Fig 13 and the two electrical connectors at rear of engine Fig 14 10 Install cowl cover Refer to Group 23 Body for procedure 11 Connect the wiring connector to the throttle position sensor TPS 12 Install throttle cable 13 Install air cleaner and th...

Page 703: ...A N D I N S P E C T I O N INTAKE MANIFOLD Check for Damage and cracks of each section Gouged surfaces on sealing surface EXHAUST MANIFOLD Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface with a straightedge and thickness gauge Fig 21 STANDARD 101 mm 004 inch LIMIT 203 mm 008 inch d l EXHAUST MANIFOLD MOUNTING SURFACE Fig 21 Exhaust Manifold ...

Page 704: ......

Page 705: ...o cowl latches leave front of hood up 7 Remove nuts holding bumper reinforcement to frame plates 8 Separate front bumper and fascia assembly from vehicle Fig 1 9 Disengage sockets from side marker lamps 10 Disengage wire harness connectors from fog lamps INSTALLATION 1 Engage wire harness connectors to fog lamps 2 Engage sockets to side marker lamps 3 Position front bumper and fascia to vehicle pa...

Page 706: ...el 6 Through opening between upper portion of radiator closure panel and fascia remove upper nuts holding fascia to frame rail plates 7 Remove the outboard nuts holding bumper reinforcement to frame rail plates through the grille opening 8 Separate front bumper and fascia assembly from vehicle 9 Retrieve any shims found between the bumper reinforcement and the frame rail plates 10 Disengage socket...

Page 707: ... bumper and fascia assembly from vehicle Fig 6 8 Retrieve any shims found between the bumper reinforcement and the frame rail extensions Fig 4 Rear Fascia Attachments Coupe INSTALLATION 1 Install any shims found during removal to the studs on the bumper reinforcement 2 Position rear bumper and fascia to vehicle 3 Loosely install nuts holding bumper reinforce ment to frame extension plates Fig 6 Re...

Page 708: ...omponents from being contaminated by metal fragments during grinding or cutting operations page SAFETY PRECAUTIONS A N D WARNINGS 4 SPECIFICATIONS F R A M E DIMENSIONS 5 To achieve proper vehicle ride height after a sus pension component has been loosened the vehicle must be at design weight and resting on the tires before the suspension can be tightened Refer to Group 2 Suspension for proper proc...

Page 709: ...ener location The tolerance on all dimensions except for suspension locations is 3 mm The tol erance on all dimensions for suspension locations is 1 mm VEHICLE PREPARATION Position vehicle on a level work surface Using suitable lifting devices and fixtures adjust the vehi cle PLP heights to the specified dimensions above the work surface Refer to Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 and Fig 6 for the pro...

Page 710: ...13 6 FRAME AND BUMPERS S P E C I F I C A T I O N S C o n t i n u e d S R ...

Page 711: ...S R S P E C I F I C A T I O N S C o n t i n u e d FRAME AND BUMPERS 1 3 7 ...

Page 712: ......

Page 713: ......

Page 714: ...13 10 FRAME AND BUMPERS S P E C I F I C A T I O N S Continued S R ...

Page 715: ...e with the proper octane rating gasolines that contain detergents corrosion and stability additives are rec ommended Using gasolines that have these additives will help improve fuel economy reduce emissions and maintain vehicle performance Generally pre mium unleaded gasolines contain more additive than regular unleaded Poor quality gasoline can cause problems such as hard starting stalling and st...

Page 716: ... reduce vehicle emissions and improve air quality Chrysler Corporation strongly supports the use of reformulated gasolines whenever available Although your vehicle was designed to provide optimum 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 F u ...

Page 717: ...odule rollover valve and a pressure vacuum filler cap Also to be considered part of the fuel system is the evaporation control system This is designed to page FUEL SYSTEM PRESSURE RELEASE PROCEDURE 10 HOSES A N D CLAMPS 10 QUICK CONNECT FITTINGS 11 THROTTLE CABLE ADJUSTMENT 10 REMOVAL A N D INSTALLATION ACCELERATOR PEDAL 15 AUTOMATIC S H U T D O W N RELAY ASD 11 FUEL FILLER TUBE 15 FUEL FILTER 12 ...

Page 718: ...livery systems contain a fuel tank roll over valve The valve is mounted on the fuel pump module The valve contains a check valve that pre vents fuel from escaping from the fuel tank when the vehicle is turned over The fuel filler cap also acts as a pressure vacuum valve When air pressure inside the fuel tank gets too high or too low the fuel filler cap opens to relieve the difference i n pressure ...

Page 719: ...ing the retainer locks the shoulder of the nipple i n place and the O rings seal the tube METAL QUICK CONNECT FITTINGS The fuel filter outlet and fuel rail use metal quick connect fittings The fitting contains non serviceable sealed O rings The fittings contain a plastic discon nect tool release ring Use special tool 6751 to dis connect and connect the fittings at the fuel rail Special tool 6751 c...

Page 720: ...t the A S D relay and fuel pump relay remain energized for 7 minutes or until the test is stopped or until the ignition switch is turned to the Off position Fig 6 Checking Fuel Pressure at intake Manifold 3 Place the ignition key i n the ON position Using the DRB Scan Tool access ASD Fuel System Test The ASD Fuel System Test will activate the fuel pump and pressurize the system I f the gauge readi...

Page 721: ...l System Pressure Install Adapter 6539 Between Fuel Pump and the Fuel Filter Connect Gauge C 4799B to Adapter 6539 Pressurize System Check Pressure Restriction in Fuel Supply Tube Check For Kinked or Plugged Fuel Supply Tube Fuel Pressure Does Not Change Still Low Check For Plugged Fuel Pump Inlet Strainer Fuel PressLire Correct Replace Fuel Filter Inlet Strainer Plugged Replace Inlet Strainer Pin...

Page 722: ...ot touch the ribbed surface on the level sensor Replace the level sensor i f the resistance is not within speci fications FUEL INJECTORS For fuel injector diagnosis refer to the Fuel Injec tor Diagnosis charts For poor fuel economy diagnosis or engine miss also refer to Transmission Driveplate in this section F U E L P U M P M O D U L E C O N N E C T O R T E R M I N A L P I N O U T S VIEW INTO C O...

Page 723: ...CE INJECTOR IF VISUALLY PLUGGED AT INJECTOR FUEL INLET C L E A N FUEL P A S S A G E IF VISUALLY P L U G G E D O R RESTRICTED N O REPLACE INJECTOR H O USING AN OHMMETER TEST THE INJECTOR RESISTANCE A C R O S S THE INJECTOR TERMINALS WITH THE INJECTOR C O N N E C T O R REMOVED PLACE A 12 VOLT TEST LAMP ACROSS WE INJECTOR ELECTRICAL CONNECTOR TERMINALS OBSERVE THE TEST LAMP WHILE CRANKING THE ENGINE ...

Page 724: ...clamps and quick con nect fittings for completeness and leaks Replace cracked scuffed or swelled hoses Replace hoses that rub against other vehicle components or show sign of wear Fig 9 Releasing Fuel Pressure Fuel injected vehicles use specially constructed hoses When replacing hoses only use hoses marked EFM EFI When installing hoses ensure that they are routed away from contact with other vehic...

Page 725: ...e and retainer 2 Prior to connecting the fitting to the fuel tube coat the fuel tube nipple with clean 30 weight engine oil 3 Push the quick connect fitting over the fuel tube until the retainer seats and a click is heard 4 The plastic quick connect fitting has windows in the sides of the casing When the fitting com pletely attaches to the fuel tube the retainer locking ears and the fuel tube shou...

Page 726: ...battery cable at the PDC 3 Access fuel pump module cover by pulling trunk rug back Refer to Group 23 Body 4 Drill pop rivets from fuel pump module cover using a 1 4 drill 5 Remove cover 6 Use Special Tool 6856 to remove fuel pump module locknut 7 Lift module up to remove being careful not to spill the residual fuel that is left i n it The float arm of the level sensor catches on the inside of the ...

Page 727: ...ews 3 Install wires to sensor FUEL INJECTORS N O T E Remove all fuel from the fuel p a s s a g e before servicing the injectors T h e bottom of the fuel injector sits in the fuel passage If the p a s s a g e is not purged of fuel the p a s s a g e will drain into the cylinder when the injector is removed EMPTYING FUEL PASSAGE 1 Perform Fuel System Pressure Release Proce dure Leave fuel hose C 4799...

Page 728: ... A S D relay a n d fuel p u m p relay remain energized f o r 7 m i n u t e s or until t h e test is s t o p p e d o r until t h e ignition s w i t c h is t u r n e d t o t h e Off p o s i t i o n 5 Use the DRB Scan Tool ASD Fuel System Test to pressurize the fuel system Check for leaks FUEL TANK FtOAiSTEFt REMOVAL 1 Disconnect positive battery cable at the PDC 2 Drain the fuel tank before removing...

Page 729: ...23 Body 12 Clean trunk area CAUTION When u s i n g t h e A S D Fuel S y s t e m Test the A S D relay a n d fuel p u m p relay remain energized for 7 minutes or until t h e test is stopped or until the ignition switch is t u r n e d t o the Off position 80a58b65 Fig 20 Fuel Filler Neck Removal Installation FUEL FILLER TUBE REMOWAL 1 Loosen fuel filler tube cap 2 Remove fuel filler neck screws Fig 2...

Page 730: ...opening i n dash panel Seat cable retainer i n dash panel 2 From inside the vehicle hold up the pedal and install the throttle cable and cable retainer i n the upper end of the pedal shaft 3 Connect the throttle cable to the driver side throttle body Slide the cable end into the throttle arm cam 4 Push cable into retaining clip S P E C I F I C A T I O N S TORQUE D E S C E I P T I O N T O B Q U E A...

Page 731: ...R A L I N F O R M A T I O N INTRODUCTION All engines have a sequential Multi Port Electronic Fuel Injection system The MPI system is computer page SCI RECEIVE PCM INPUT 24 SCI RECEIVE PCM OUTPUT 28 SENSOR RETURN PCM INPUT 24 SKIP SHIFT SOLENOID PCM OUTPUT 28 SYSTEM DIAGNOSIS 20 T A C H O M E T E R P C M OUTPUT 28 THROTTLE POSITION S E N S O R P C M INPUT 24 VEHICLE SPEED S E N S O R P C M INPUT 24...

Page 732: ...eam heated oxygen sensor the PCM can fine tune injector pulse width Fine tuning injector pulse width allows the PCM to achieve opti mum fuel economy combined with low emissions For the PCM to enter CLOSED LOOP operation the following must occur 1 Engine coolant temperature must be over 35 F I f the coolant is over 35 F the PCM will wait 44 seconds I f the coolant is over 50 F the PCM will wait 38 ...

Page 733: ...ed Engine idle speed is adjusted through the idle air control motor CRUISE OR IDLE MODE When the engine is at operating temperature this is a CLOSED LOOP mode During cruising or idle the following inputs are received by the PCM Intake air temperature Engine coolant temperature Manifold absolute pressure Crankshaft position engine speed Camshaft position Throttle position Exhaust gas oxygen content...

Page 734: ...air conditioning system The PCM does not monitor the heated oxygen sen sor inputs during wide open throttle operation except for downstream heated oxygen sensor and both shorted diagnostics The PCM adjusts injector pulse width to supply a predetermined amount of addi tional fuel IGNITION SWITCH OFF MODE When the operator turns the ignition switch to the OFF position the following occurs A l l outp...

Page 735: ...ithin approximately one second of engine cranking i t deac tivates the ASD relay and fuel pump relay When these relays deactivate power is shut off from the fuel injectors ignition coils heating element in the oxygen sensors and the fuel pump The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor crank shaft pos...

Page 736: ...ltage from the sensor to the PCM will then switch from a low approximately 0 3 volts to a high approximately 5 volts When the sensor detects the high machined area the input voltage switches back low to approx imately 0 3 volts CRANKSHAFT POSITION SENSOR PGM INPUT The crankshaft position sensor detects slots cut into a disk i n the middle of the crankshaft Fig 4 There are 5 sets of slots Each set ...

Page 737: ...acity and converter efficiency Also the PCM 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 0 2 sensors produce voltages from 0 to 1 volt depending upon the oxygen content of the exhaust gas i n the ...

Page 738: ...ngine operates the PCM determines intake manifold pressure from the MAP sensor voltage Based on MAP sensor voltage and inputs from other sensors the P C M adjusts spark advance and the air fuel mixture The MAP sensor Fig 8 mounts to the drivers side intake manifold plenum Fig 8 Map Sensor SENSOR RETURN PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of ...

Page 739: ... off RELAYS POWER DISTRIBUTION CENTER Fig 11 Relay Location AUTOMATIC SHUTDOWN RELAY PCM OUTPUT The Automatic Shutdown ASD relay supplies bat tery voltage to the fuel injectors electronic ignition coil and the heating elements i n the oxygen sensors 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 when the ignit...

Page 740: ...pors are purged from the canister and flow to the throttle body The purge solenoid also energizes during certain idle conditions to update the fuel delivery calibration Refer to Group 25 Evaporative Emissions for more information IDLE AIR CONTROL MOTOR PCM OUTPUT The idle air control motor is mounted at the front right of the intake manifold Fig 13 The motor con trols air flow through a passage co...

Page 741: ...M energizes the individual coils i n each pack by providing a ground path to the particular coil The P C M determines cylinder identification from the crankshaft position sensor and camshaft position sensor inputs ELECTRICAL CONNECTORS 80a58b9e Fig 15 Coil Packs MALFUNCTION INDICATOR CHECK ENGINE LAMP PCM OUTPUT The PCM supplies the malfunction indicator check engine lamp on off signal to the inst...

Page 742: ...ssion i n first gear Engine speed greater than 608 RPM Throttle position less than 23 percent less than 0 68 volts over closed throttle TPS voltage Coolant temperature above 41 C 106 F SKIP SHIFT SOLENOID PCM OUTPUT The skip shift solenoid prevents the operator from shifting into second or third gear during certain con ditions The PCM controls the skip shift solenoid Fig 13 The PCM locks out secon...

Page 743: ... and leaks ELECTRICAL CONNECTOR 9214 148 Fig 18 MAP Sensor Electrical Connection 5 Check the electrical connection at the heated oxygen sensor on each exhaust manifold Fig 20 Inspect the connectors for damaged terminals 6 Verify the ignition cables are connected to the spark plug cables 7 Check the electrical connection at the idle air control motor Fig 21 8 Inspect PCV valve hoses for leaks at th...

Page 744: ...corrosion Fig 23 12 Inspect the camshaft position sensor electrical connection for damage or corrosion Fig 24 13 Inspect the crankshaft position sensor electri cal connector for damage or corrosion Fig 25 Fig 23 Generator Fig 24 Camshaft Position Sensor Fig 25 Crankshaft Position Sensor 14 Check electrical connections at the starter motor for damage or corrosion Fig 26 15 Check the Auto Shutdown A...

Page 745: ... RELAYS The following d e s c r i p t i o n o f operation a n d tests apply o n l y t o t h e Automatic S h u t d o w n A S D a n d fuel pump relays The terminals on the bottom of each relay are numbered Fig 30 or Fig 31 30 86 TERMINAL LEGEND N U M B E R I D E N T I F I C A T I O N 30 C O M M O N FEED 85 COIL GROUND 86 COIL BATTERY 87 NORMALLY OPEN 87A NORMALLY CLOSED 9514 16 Fig 30 ASD and Fuei P...

Page 746: ...ween 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 operates properly Check the remainder of the ASD and fuel pump relay circuits Refer to group 8W Wir ing Diagrams CAMSHAFT AND CRANKSHAFT POSITION SENSOR Refer to Group 8D Ignition for Diagnosis and Test ing of Camshaft and Crankshaft...

Page 747: ... is a 5 volt supply and the remaining ter minal is ground Connect the D V M between the center and sensor ground terminal Refer to Group 8W Wiring Dia grams for correct pinout With the ignition switch i n the ON position check the output voltage at the center terminal wire of the connector Check the output voltage at idle and at Wide Open Throttle WOT A t idle TPS output volt age should be approxi...

Page 748: ...rical connector 2 Remove the TPS mounting screws 3 Remove the TPS INSTALLATION The throttle shaft end of the throttle body slides into a socket i n the TPS Fig 35 When indexed cor rectly the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body I f the sensor will not rotate into place install the sensor with the throttle shaft on the other side...

Page 749: ... manifold plenum Fig 38 Pull MAP sensor and vacuum hose off of intake manifold INSTALLATION 1 Reverse procedure for installation Tighten mounting screws to 3 N m 23 in lbs torque INTAKE AIR TEMPERATURE SENSOR R E M O V A L 1 Disconnect electrical connector from intake air temperature sensor Fig 39 2 Remove sensor 9214 146 Fig 38 MAP Sensor Intake Manifold Connection INSTALLATION 1 Install sensor T...

Page 750: ...roup 8D Ignition System Service Procedures CAMSHAFT POSITION SENSOR For removal installation procedures refer to group 8D Ignition System Service Procedures UPSTREAM HEATEi 0XY0EN SENSOR C A U T I O N Do not puff on the heated oxygen s e n s o r wire when disconnecting the electrical c o n n e c tor W A R N I N G T H E E X H A U S T MANIFOLD MAY B E E X T R E M E L Y HOT USE C A R E W H E N SERVIC...

Page 751: ...the sensor threads with an anti seize compound such as Loctite 771 64 or equiva lent New sensors have compound on the threads and do not require an additional coating 2 Install sensor using an oxygen sensor crow foot wrench such as Snap On tool YA8875 or equivalent 3 Tighten the sensor to 27 N m 20 ft lbs torque 4 Plug sensor connector 5 Lower vehicle Fig 43 Left Rear Heated Oxygen Sensor AIR CLEA...

Page 752: ...i n place 3 Screws attach the lower section of the inlet duct to the frame rails Access the screws through the opening for the upper section 4 Remove the screws that attach the inlet duct to the frame rails 5 Disconnect the left hood release cable from the latch Pull up on duct and slide cable through the inlet duct 6 Disconnect the right hood release cable from the latch Pull up on duct and slide...

Page 753: ...cifications use specifica tions on VECI label The VECI label is located i n the engine compartment TORQUE D E S C R I P T I O N TOEQUE Accelerator Bracket Bolt 11 N m 95 in lbs Accelerator Pedal 12 N m 105 in lbs Air Cleaner Screws 2 2 N m 20 in lbs Coolant Sensor 27 N m 20 ft lbs Crankshaft Position Sensor Bolt 23 N m 200 in lbs Fuel Injector Clamp 11 N m 95 in lbs Fuel Pump Module Locknut 34 N m...

Page 754: ...14 40 FUEL SYSTEM S P E C I A L T O O L S Continued S R 02S Oxygen Sensor Remover Installer C 4907 ...

Page 755: ...sion bar which initially steers the vehicle As required steering effort increases as i n a turn The torsion bar twists causing relative rotary motion between the rotary valve body and the valve spool This move ment directs oil behind the integral rack piston page DIAGNOSIS AND TESTING STEERING SYSTEM DIAGNOSIS CHARTS 1 which i n turn builds up hydraulic pressure and assists i n the turning effort ...

Page 756: ...ame of the vehicle 6 Noise internal to power steering gear 1 Check the steering gear to mounting bracket attaching bolts Tighten to specified torque if found to be loose 2 Check tie rod end for wear Replace worn loose parts as required 3 Tighten control arm mounting bolts to the specified torques 4 Check upper control arm to pivot bar and pivot bar to frame rail mounting nuts for looseness If requ...

Page 757: ...ump 1 Tighten or replace hose clamp 2 Inspect connection and replace O Ring as required 3 Fill power steering fluid reservoir to proper level and perform leakage diagnosis 4 Inspect and repair or replace power steering fluid reservoir as required SQUEAK OR RUBBING SOUND 1 Sound coming from steering column 1 Check for squeak in steering column Inspect for contact between shroud intermediate shaft c...

Page 758: ...termediate shaft 9 Steering column coupler binding 10 Binding upper or lower ball joint 11 Excessive friction in steering gear 1 Fill power steering fluid reservoir to specified level and perform leakage diagnosis 2 Inflate tires to the specified pressure 3 Properly lubricate ball joints If lubricating ball joint does nt correct condition replace lower ball joint or upper control arm 4 Replace the...

Page 759: ...POSSIBLE C A U S E S CORRECTION STIFF HARD TO TURN SURGES MOMENTARY INCREASE IN EFFORT W H E N TURNING 1 Tires not properly inflated 2 Low power steering fluid level 3 Loose power steering pump drive belt 4 Lack of lubrication in control arm ball joints 5 Worn upper or lower ball joint 6 Low power steering pump pressure Verify using Power Steering System Test Procedure 7 High internal leak in stee...

Page 760: ...ension components 5 Mispositioned dash cover 5 Reposition dash cover To evaluate items 6 and 7 disconnect the intermediate shaft Turn the steering wheel and feel or listen for internal rubbing in steering column 6 Steering wheel binding against the 6 Adjust steering column shrouds to upper shrouds of the steering eliminate binding condition column 7 Damaged mis positioned or 7 Determine condition ...

Page 761: ...d the air out of the power steering system Perform leakage diagnosis 2 Check the steering rear to frame mounting bolts Tighten to specified torque if found to be loose 3 Check for worn universal joint broken isolator or loose fasteners 4 Check components of the steering system and repair or replace as required 5 Check and or replace the ball joint or control arm as required 6 Check attaching nuts ...

Page 762: ...eering gear POWER STEERING FLUID LEAK CONDITION POSSIBLE C A U S E S C O R R E C T I O N LOW FLUID LEVEL WITH NO VISIBLE SIGNS O F A LEAK O N T H E STEERING GEAR POWER STEERING PUMP FLOOR OR A N Y W H E R E ELSE 1 Overfilled power steering pump fluid reservoir 1 Adjust the power steering fluid fill to the correct level LOW FLUID LEVEL WITH VISIBLE LEAK O N STEERING GEAR POWER STEERING PUMP FLOOR O...

Page 763: ...nder Sucking Air Diagnosis and correct condition 2 Extremely cold temperatures may cause power steering fluid aeration if the power steering fluid is low Add power steering fluid as required to bring level up to specification 3 Remove power steering pump from vehicle and inspect the power steering pump housing for cracks If a defect in the housing is found replace the power steering pump 4 Drain t...

Page 764: ...wer steering pump Fig 1 The service procedures for the Saginaw power steering pump are limited to only the areas and components covered i n this service manual No repair procedures are to be done on the internal components of the Saginaw power steering pump The Saginaw T C style power steering pump Fig 1 consists of the power steering pump internal com ponents and pump housing This style power ste...

Page 765: ...peration 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 i f the power steering pump or power steering gear is not functioning properly The following pressure and flow test is performed using Pressure Flo...

Page 766: ...or more than 5 s e c o n d s at a time power steering pump damage will result 11 Fully open the valve on Special Tool 6815 Turn the steering wheel to extreme left until the wheel stops then reverse the motion until the wheel stops i n the extreme right position Record the high est indicated pressure at each position Compare the readings to specifications I f the highest output pres sures are not t...

Page 767: ...eal deteriora tion and affect steering gear spool valve operation 1 Raise the front end of the vehicle off the ground until the wheels are free to turn 2 Remove the return line from the pump 3 Plug the return line port on the pump 4 Position the return line into a large container to catch the draining fluid 5 While an assistant is filling the pump reservoir with fresh power steering fluid start th...

Page 768: ...teering h o s e s power steering pump fittings and steering gear ports T h i s will prevent the entry of foreign material into the components during servicing WARNING T H E P O W E R S T E E R I N G OIL AND T H E E N G I N E MAY B E E X T R E M E L Y H O T IF E N G I N E H A S B E E N RUNNING DO NOT START ENGINE WITH A N Y L O O S E OR DISCONNECTED H O S E S B E S U R E THAT W H E N T H E P O W E ...

Page 769: ...e 10 Raise front wheels of vehicle off the ground 11 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops Then turn the engine off 12 Add power steering fluid i f necessary 13 Lower the vehicle and turn the steering wheel slowly from lock to lock 14 Stop the engine Check the fluid level and refill as required 15 I f the fluid is extremely foamy allow th...

Page 770: ...does not contact any surfaces that will cause abrasion to the hose 4 Install the hose clamp on the power steering return hose Fig 9 Be sure clamp is installed on hose past the upset bead on steering gear return hose fitting 5 Install the power steering fluid return hose Fig 11 requiring replacement on the correct fitting of the power steering fluid cooler Move the hose clamp to the end of the retu...

Page 771: ...eering wheel right and left lightly contacting the wheel stops 8 Add power steering fluid i f necessary 9 Stop the engine Check the fluid level and refill as required 10 I f the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure POWER STEERING PUMP WARNING P O W E R S T E E R I N G OIL E N G I N E C O M P O N E N T S AND T H E E X H A U S T S Y S T E...

Page 772: ...ir Fig 16 Remove the power steering return hose from the power steering pump fluid reservoir Use care w h e n removing return hose from power steering fluid reservoir fitting F l u i d reservoir is plastic and could crack if excessive force is used Fig 16 Power Steering Fluid Return Hose 6 Remove the 3 bolts mounting the power steer ing pump to the power steering pump bracket Fig 17 Access for the...

Page 773: ...ng pressure hose i n the power steering pump discharge fitting Fig 15 Tighten the power steering pressure hose tube nut to a torque of 29 N m 252 in lbs 5 Install the serpentine accessory drive belt on the power steering pump pulley See Fig 19 Fig 20 for the correct serpentine accessory drive belt routing See Cooling Group 7 for the detailed instal lation procedure of the serpentine accessory driv...

Page 774: ...Viper u s e d a metal pulley T h e offset of the two pulleys is different Do not u s e a metal replacement pulley on a vehicle originally equipped with a plastic pulley T h i s will damage the s e r p e n tine drive belt REMOVE 1 For the removal and replacement of the power steering pump pulley the power steering pump pul ley must be removed from the vehicle Refer to Power Steering Pump i n the Re...

Page 775: ... remain aligned with the shaft so pulley does not become cocked 4 Continue installing pulley onto shaft of power steering pump until the pulley is flush with the end of the power steering pump shaft Fig 25 5 Remove the Pulley Installer Special Tool C 4063 from the shaft of the power steering pump NOTE Position the power steering pump on engine and compare the drive puiiey alignment with the adjace...

Page 776: ... Lubricate the new power steering fluid reser voir O ring Seal Fig 27 with fresh clean Mopar Power Steering Fluid or equivalent 2 Install the O ring seal i n the power steering pump housing Fig 27 3 Install reservoir onto housing Fig 27 4 Slide and tap i n reservoir retainer clips until tab locks to housing Fig 26 CAP RING PUMP BODY J9219 28 Fig 27 Reservoir Removed 5 Install power steering pump a...

Page 777: ...S R STEERING 19 23 S P E C I A L T O O L S Puller C 4333 ...

Page 778: ...ering gear Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle As required steering effort increases as i n a turn The torsion bar twists causing relative rotary motion between the rotary valve body and the valve spool This move ment directs oil behind the integral rack piston which i n turn builds up hydraulic pressure and assists i n the turning effort The...

Page 779: ...re and flow test is performed using Pressure Flow Analyzer Special Tool 6815 Fig 2 along with the correct adapters Fig 3 OUTLET 6 7 1 3 80b3aef2 Fig 2 Power Steering Pump Flow Pressure Analyzer 6815 6 8 6 6 Fig 3 Power Steering Flow Pressure Analyzer Adapters 6893 POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE CAUTION To prevent personal injury safety gog gles should be w o r n at all times ...

Page 780: ...eel stops then reverse the motion until the wheel stops i n the extreme right position Record the high est indicated pressure at each position Compare the readings to specifications I f the highest output pres sures are not the same against either stop the steer ing gear is leaking internally and must be replaced Kly ML Mm I N S T A L L A T I O N STEERING GEAR NOTE T h e power steering gear c a n ...

Page 781: ...e outer tie rod end to steering knuckle attaching nuts and cotter pins on both sides of vehi cle Fig 6 TIE R O D END 7 Remove both outer tie rod ends from the steer ing knuckles using Puller Special Tool C 3894 A Fig 7 H U B BEARING UNIT SPECIAL T O O L C 3894A 80a1c3e4 Fig 7 Tie Rod End Removal 8 Lower the vehicle to the ground 9 Remove the 2 fasteners that mount the air cleaner housing to the ra...

Page 782: ...installing s h i m s b e t w e e n t h e steering gear a n d t h e steering gear m o u n t i n g brackets If t h e steering gear requires r e m o v a l f r o m vehicle note t h e a m o u n t o f s h i m s installed between t h e steering gear a n d each m o u n t i n g bracket W h e n a n e x i s t i n g o r a n e w steer i n g gear is installed t h e s a m e a m o u n t o f s h i m s M U S T be i...

Page 783: ...g gear m o u n t i n g brackets A n y m o v e m e n t o f t h e steering gear will adversely affect f r o n t w h e e l t o e pattern a n d h a n d l i n g o f the vehicle 3 Using Adapter Special Tool 6632 Fig 14 torque both steering gear mounting bolts to 203 N m 150 ft lbs When using Adapter Special Tool 6632 for final torquing of steering gear mounting bolts Torque wrench must be positioned as ...

Page 784: ...r cleaner housing Fig 8 Install the crank case vent and Automatic Idle Speed AIS hoses onto their fittings i n the air cleaner housing Fig 8 12 Connect the battery negative cable to bat tery negative post C A U T I O N D o n o t u s e a u t o m a t i c t r a n s m i s s i o n f l u i d in p o w e r steering s y s t e m O n l y u s e Mopar Power Steering Fluid o r equivalent 13 Fill the power steer...

Page 785: ...AMP VIEW IN CIRCLE A BOOT CLAMP OUTER J A M NUT 9 1 1 9 8 Fig 20 Snorkel To Breather Tube Clamp 3 Install tie rod boot over lip on housing of steering gear and on the end of the breather tube Fig 20 4 Install the tie rod boot to breather tube snor kel clamp Fig 20 5 Install new tie rod boot to steering gear clamp Fig 20 6 Lubricate inner tie rod boot groove with sili cone type lubricant Fig 20 The...

Page 786: ...e cot ter pin Fig 21 i n the tie rod end 4 Install the wheel and tire assemblies Note the location tire and wheel were removed from on vehi cle They must be replaced i n the same location due to the tires being uni directional Tighten the wheel mounting stud nuts i n proper sequence until all nuts are torqued to half specification T h e n repeat the tightening sequence to the full specified torque...

Page 787: ...Adapter Torque Wrench 6632 A 8011C958 P S System Analyzer 6815 ...

Page 788: ...ock cylinder is located i n the ignition switch which is mounted to the lock housing of the steering column Fig 1 INTERMEDIATE STEERING SHAFT This vehicle uses a sliding type collapsible interme diate steering shaft Fig 2 The intermediate steer page R E M O V A L A N D INSTALLATION STEERING C O L U M N 41 STEERING W H E E L 36 STEERING W H E E L COVER REAR 39 SPECIFICATIONS STEERING C O L U M N FA...

Page 789: ... following conditions 1 Look for rough areas or flash i n the casting and i f found remove with a file Fig 3 Fig 3 Steering Column Flash Removal And Non Serviceable Components 2 Remove the link and slider and check the link to see i f i t is bent I f so replace with a new part 3 Put the slider in its slot i n the sleeve and ver ify a loose fit over the length of the slot I f the slider binds in th...

Page 790: ...NY S U B S T I T U T E S ANYTIME A N E W F A S T E N E R IS N E E D E D R E P L A C E WITH T H E C O R R E C T F A S T E N E R S P R O V I D E D IN T H E S E R V I C E P A C K A G E O R F A S T E N E R S L I S T E D IN T H E P A R T S B O O K S B E F O R E S E R V I C I N G A S T E E R I N G C O L U M N E Q U I P P E D WITH A N AIR B A G R E F E R T O G R O U P 8M E L E C T R I C A L F O R P R O P...

Page 791: ...AIR B A G MOD U L E IS P L A C E D ON A B E N C H O R O T H E R S U R F A C E P L A S T I C C O V E R S H O U L D B E F A C E U P T O MINIMIZE MOVEMENT IN C A S E O F A C C I D E N T A L D E P L O Y M E N T 4 Remove the airbag module Fig 6 from the steering wheel The air bag is mounted to the steer ing wheel using a mounting bolt located i n each spoke of the steering wheel Access to the mounting ...

Page 792: ...es Anytime a new fastener is needed replace it only with the correct fasteners provided in service packages or with fas teners listed in the parts book 4 Install the airbag module i n steering wheel Install the 3 original or correct replacement air bag module attaching bolts Tighten the airbag mod ule attaching bolts to a torque of 10 N m 90 in lbs C A U T I O N When reconnecting battery on a vehi...

Page 793: ... THE AIR BAG MODULE WHEN CARRYING A LIVE M O D U L E T H E TRIM COVER S H O U L D B E POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF MODULE ACC3DENTLY DEPLOYS IF AIR B A G MOD ULE IS PLACED O N A BENCH OR OTHER SUR FACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE O F ACCIDENTAL DEPLOYMENT 4 Remove the airbag module Fig 10 from the steering wheel The air bag is mounted to the ste...

Page 794: ...nut to a torque of 61 N m 45 ft lbs 4 Install airbag electrical lead into the connector on the back of the airbag module Fig 11 Be sure electrical connector is securely latched into air bag module connector Connect the horn switch wire from the clockspring to the horn switch wire of the airbag module Fig 11 C A U T I O N T h e fasteners s c r e w s and bolts origi nally used for the airbag compone...

Page 795: ...flex joint to the steering column shaft 4 Rotate the steering wheel for access to the pinch bolt Fig 15 attaching the flex joint to the intermediate steering shaft Loosen but do not remove the pinch bolt Fig 15 attaching the flex joint to the intermediate steering shaft 5 Rotate the steering wheel back to its original position so that the front tires of the vehicle are i n the straight ahead posit...

Page 796: ... C O L U M N U P P E R S T E E R I N G MOUNTING B R A C K E T C O L U M N S H A F T SHIPPING PIN H O L E SHIPPING S T E E R I N G C O L U M N PIN H O L E MOUNTING F L A N G E 8 0 a 5 f 2 8 4 Fig 19 Steering Column Shipping Pin Hole S T E E R I N G COLUMN J A C K E T TIE S T R A P Fig 20 Tie Strap Installed In Steering Column TIE S T R A P S T E E R I N G C O L U M N Fig 21 Tie Strap Locked On Stee...

Page 797: ... washer Fig 24 attaching the adjustable pedal actuator to knee blocker panel Remove the adjustable pedal actuator from the knee blocker panel 15 Remove the screws attaching the fuse box Fig 24 to knee blocker panel 16 Remove the knee blocker panel Fig 25 from the lower instrument panel 17 Remove the duct for the drivers side air vent from the lower dash panel Fig 26 18 Tilt the steering column to ...

Page 798: ...nstall Puller Snap On CJ2001P or an equiv alent three point puller on the steering wheel Fig 30 Fig 29 Steering Column Shroud Fig 30 Puller Installed On Steering Wheel CAUTION Do not bump or hammer on steering wheel or steering column shaft when removing steering wheel from steering column C A U T I O N Do not apply heat to the steering wheel when removing the steering wheel from the steering colu...

Page 799: ...N G IGNITION SWITCH WIRING H A R N E S S C O N N E C T O R Fig 34 Wiring Harness Connection To Ignition Switch 29 Remove the 2 nuts Fig 35 attaching the steering column to the dash panel DASH PANEL NUTS 2 80a5f27f Fig 35 Steering Column Attachment To Dash Panel 30 Remove the 2 nuts and washers Fig 36 attaching the upper mounting bracket of the steering column to the dash panel CAUTION When steerin...

Page 800: ...80a5f281 Fig 3 8 Steering Column Wiring Trough Attachment PLASTIC C A P S U L E GROUND CLIP EERING C O L U M N Fig 89 Steering Column Ground Clip CAUTION W h e n steering c o l u m n is installed in vehicle place a c o v e r o n t h e c u s h i o n of the front seat to protect seat f r o m d a m a g e 2 Install steering column in vehicle with the steering column shaft through hole in dash panel Po...

Page 801: ...d c a u s i n g c l o c k s p r i n g a s s e m b l y to b e c o m e inoperative The y e l l o w c e n t e r i n g indicator m u s t be present in the c e n t e r i n g w i n d o w of the c l o c k s p r i n g a n d the a r r o w o n t h e c l o c k s p r i n g rotor m u s t be p o i n t i n g at the c e n t e r i n g w i n d o w 20 Center the clock spring using the following procedure Depress the...

Page 802: ...n Exit vehicle with the DRB scan tool Install the latest version of the proper diagnostic cartridge into the DRB scan tool Ensuring that their are no occupants I n the vehicle connect negative cable to negative post of the battery Using the DRB scan tool read and record active fault codes Also read and record any stored fault codes Refer to the Passive Restraint Diagnostic Test Manual i f any faul...

Page 803: ...0 Reverse Gear 2 90 IDENTIFICATION Located on the left side of the aluminum tail hous ing is a cast pad The pad has the vehicle identifica tion number stamped on i t Fig 1 This number should match the vehicle identification number located on the dash pad A bar code tag is also located on the left side of the transmission case These numbers should be used when ordering parts for this transmission O...

Page 804: ...ng above 600 RPM The PCM verified first gear speed RPM TAIL HOUSING VIPER EMBLEM TAIL HOUSING OIL SEAL 9321 117 SHIFTER LEVER Fig 2 Viper Emblem Location Throttle position sensor TPS signal is less than 0 068 volt above closed throttle 23 percent throttle opening The solenoid resets when vehicle speed drops below 2 MPH REVERSE LOCKOUT SOLENOID The reverse lockout solenoid prevents the operator fro...

Page 805: ... transmission with Dexron I I I fluid The transmission is full when the fluid level is even with the bottom of the fill hole 7 Install transmission fill plug R E M O V A L A N D I N S T A L L A T I O N TRANSMISSION REMOVAL The transmission can be removed from the vehicle without having to remove the engine The transmis sion unbolts from the bell housing 1 Disconnect battery power source 2 Lift veh...

Page 806: ...TALLATION 1 Start the seal into housing Then tap seal into place with seal installer C 3995 or C 3972 Fig 5 2 Reinstall drive shaft assembly CAUTION T h e drive shaft strap bolts u s e a Loctite patch for retention o n initial installation T h e s e s c r e w s must be replaced with new pieces whenever they are removed SPECIAL TOOL Fig 5 Seal Installation CAUTION Replace drive shaft joint straps w...

Page 807: ...2 Install shifter onto transmission Make sure that the ball on the bottom of the shifter is i n the off set lever 3 Install cover mounting bolts and tighten to 18 N m 156 in lbs 4 Shift the vehicle to ensure that the shifter operates correctly 5 Reinstall shift console D I S A S S E M B L Y A N D A S S E M B L Y INPUT SHAFT I f the input shaft splines or pilot bearing is dam aged the input shaft c...

Page 808: ...n original reading Install a thicker shim I f end play Is less than original reading install a thinner shim 6 After the correct shim has been Installed remove the adapter plate and apply Mopar Gasket Maker to the sealing surfaces Then reassemble the transmission 7 Install transmission into vehicle and fill with Dexron I I I transmission fluid CAUTION T h e drive shaft strap b o l t s u s e a Locti...

Page 809: ...ring located in the housing bore Fig 15 Speed Sensor Removal 5 Remove two tail housing nuts located at the top of the transmission tail housing Fig 16 6 Remove the six tail housing to main case bolts Fig 17 7 Gently pry tail housing off Pry only at pry points Fig 18 and pull tail housing off case TRANSMISSION 21 7 Fig 16 Tail Housing Nut Removal T A I L HOUSING Fig 18 Tail Housing Pry Points ...

Page 810: ...reverse gear bearing wave washer and brass synchronizer ring Fig 22 12 Under normal use the reverse synchronizer is forced against the snap ring This makes snap ring removal difficult Lightly tap the reverse synchro nizer forward to relieve pressure on snap ring Fig 23 This will make it easier to remove the snap ring REVERSE GEAR I THRUST WASHER SNAP RING PLIERS 9321 63 Fig 21 Reverse Gear Snap Ri...

Page 811: ...emoval _ 9321 66 Fig 24 Shift Fork Snap Ring 14 Remove synchronizer sleeve snap ring Fig 25 5 6 SHIFT FORK SNAP RING SNAP RING PLIERS Fig 25 Synchronizer Snap Ring 15 Remove shift fork and synchronizer sleeve from transmission as an assembly Fig 26 16 Remove 5 6 gear shift fork snap ring Fig 27 17 While holding 5 6 shift fork in place pull clus ter extension shaft straight out Fig 28 9421 108 g 27...

Page 812: ...Fig 32 Skip Shift Boll Pin VENT Fig 30 6th Gear Removal 20 Remove top cover plate bolts and pry off cover Fig 31 21 Remove roll pin from skip shift lever Fig 32 Then slide skip shift lever off of shaft Note the direc tion for reassembly 22 Remove shift detent assembly Fig 33 Check O ring replace i f required 9421 102 9421 99 Fig 33 Shift Detent Assembly ...

Page 813: ...ransmission Fig 36 26 Separate offset lever and guide plate to remove the roll pin that was driven down i n Step 23 of this procedure 27 Remove 5 6 driven gear using special tool 6444 puller and 6622 jaws 28 Remove two torx screws located on the top of the transmission case Fig 37 29 Remove clutch slave cylinder from transmis sion 30 Remove 11 front adapter bolts Fig 38 Leave one bolt i n temporar...

Page 814: ... bench to allow the input shaft to hang freely MAIN SHAFT TWO BENCHES 9421 105 Fig 39 Stand Transmission Upright 32 Remove the one bolt left i n the adapter Then pry transmission case upward away from front adapter and remove case Fig 40 33 Remove reverse rail assembly Fig 41 TRANSMISSION CASE 9321 82 Fig 40 Transmission Case Removal MAINSHAFT CLUSTER GEAR 9321 83 Fig 41 Reverse Rail Assembly ...

Page 815: ...il Removal 35 Remove cluster gear assembly Fig 43 36 Lift input shaft from front adapter Fig 44 A t this point the transmission has been disassem bled into subassemblies Main Shaft Cluster Extension Tail Housing Cluster Gear Input Shaft Transmission Housing To service a particular subassembly refer to the Disassembly And Assembly section that pertains to that component Fig 43 Cluster Gear Fig 44 I...

Page 816: ... 2 Remove rear main shaft tapered bearing Fig 46 MAIN SHAFT BEARING FIRST GEAR 9321 90 Fig 46 Main Shaft Bearing 3 Remove 1st gear and bearing from shaft Fig 47 4 Remove 1 2 snap ring with snap ring pliers from main shaft Fig 48 5 Remove 1 2 thrust washer and blocker ring assembly from main shaft Fig 49 MAIN SHAFT FIRST GEAR NEEDLE BEARING 9321 91 Fig 47 1st Gear and Bearing MAIN SHAFT SYNCHRONIZE...

Page 817: ... O N D G E A R SYNCHRONIZER HUB 9321 94 Fig 50 Second Gear and Synchronizer Hub 7 Remove 3 4 synchronizer snap ring Fig 51 M A I N SHAFT SNAP RING SYNCHRONIZER HUB MAIN SHAFT 9321 96 Fig 52 Third Gear and 3 4 Synchronizer 9 Clean inspect and replace parts as required To reassemble reverse procedure CLUSTER EXTENSION 1 Remove bearing spacer Fig 53 BEARING SPACER 4 fO n BEARING 9321 97 BEARING 9321 ...

Page 818: ...ING 9321 99 Fig 55 Gear and 5 6 Synchronizer Sleeve 4 Remove caged needle bearing Fig 56 5 Clean inspect and replace parts as required To reassemble reverse procedure NEEDLE BEARING BEARING 9321 100 Fig 56 Needle Bearing TAIL HOUSINi 1 Remove the idler gear bracket bolts Fig 57 Then remove the bracket TAIL HOUSING 9321 101 Fig 57 Idler Gear Bracket Bolts 2 Remove thrust washer gear and bearing Fig...

Page 819: ...RING 9321 103 Fig 59 input Shaft 2 Install main shaft and bearing 3 Install case and bolt together using all bolts 4 Install 5 6 driven gear Fig 60 A l l measure ments will be taken from this gear 5 6 DRIVEN GEAR MAIN SHAFT TRANSMISSION CASE 9321 104 Fig 60 5 6 Driven Gear 5 Oscillate the input shaft and main shaft back and forth to seat bearings 6 Set up dial indicator as shown i n Fig 61 ADAPTER...

Page 820: ... to the thickness of the shim that was i n the transmission when the end play readings were taken Record this number 10 Install a shim s behind the bearing cone i n the front adapter equal to the number recorded i n Step 9 CLUSTER iEAR 1EARIN0S 1 Remove inspection plug i n the front adapter Fig 62 Fig 62 Inspection Plug 2 Place cluster gear Into front adapter Fig 63 3 Install case onto front adapt...

Page 821: ...Install a shim s behind the bearing cone i n the front adapter equal to the number recorded i n Step 10 COUNTER SHAFT EXTENSION END PLAY 1 Assemble tail housing with original shim 2 Install special tool 6625 Fig 66 Snug down tool and then loosen two turns 3 Install dial Indicator Fig 67 4 Zero the dial indicator and record the end play reading I f there is no end play recorded a thinner shim must ...

Page 822: ... N m 16 ft lbs Inspection Plug 27 N m 20 ft lbs Interlock Bolt 27 N m 20 ft lbs Rev Idler Brkt Bolts 24 N m 18 ft lbs Rev Inhibitor Bolt 18 N m 156 in lbs Shifter Assembly 20 N m 15 ft lbs Shift Detent Ass 34 N m 25 ft lbs Skip Shift Solenoid 34 N m 25 ft lbs Trans Top Cover Bolts 20 N m 15 ft lbs Trans Crossmember Bolts 81 N m 60 ft lbs Trans Mount Bolts 41 N m 30 ft lbs Trans To Eng Bolts 3 8 41...

Page 823: ... DESCRIPTION AND OPERATION TIRE INFORMATION The tire used on both the Viper RT 10 and the GTS is the Michelin Pilot SX The Michelin Pilot SX Tires Fig 1 are designed and engineered for their specific use on these vehicles These tires will provide the best overall performance for the normal operation of this vehicle The ride and handling characteristics match the vehicle s requirements With proper ...

Page 824: ...limate Road surface temperature The road street surfaces that the tires encounter The tire traction and the heat temperature resis tance ratings follow the tread wear rating They are encoded either A B o r C A n A code represents the best rating i n either category The traction ratings are based upon a tires s ability to stop a vehicle on wet pavement when tested under controlled conditions on U S...

Page 825: ...ize tires not matching the specifi cation charts may cause interference with vehicle components Under extremes of suspension and steering travel interference with vehicle components may cause tire damage TIRE INFLATION PRESSURES WARNING OVER O R UNDER INFLATED T I R E S CAN AFFECT VEHICLE HANDLING THE TIRE CAN FAIL SUDDENLY RESULTING IN LOSS OF VEHICLE CONTROL Under inflation causes rapid shoulder...

Page 826: ...le Installation of snow tires could cause adverse han dling of the vehicle Due to the lack of the proper speed rating sudden tire failure may occur at high speed operation DIAGNOSIS AND TESTING PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure After checking the air pressure replace valve cap finger tight TIRE TREAD WEAR INDICATORS Tread wear indicators are molded ...

Page 827: ...ing and scuffing as i t moves over the street road surface A feathered tread edge that faces toward the vehi cle indicates an excessive wheel toe in position A feathered tread edge that faces away from the vehicle indicates an excessive wheel toe out position The Tread Wear Patterns direction that a feathered edge has developed can be determined by moving the tips of your fingers over the tire tre...

Page 828: ... ALIGNMENTTO PREFFERRED SPECIFICATION OK CAR LEADS OPPOSITE DIRECTION PROBABLE CAUSE TIRES INSTALL A KNOW GOOD SET OF FRONT TIRE AND WHEEL ASSEMBLIES ROAD TEST O K ROAD TEST CAR STILL LEADS ADJUST FRONT CASTER AND OR CAMBER TO COMPENSATE I 1r f LEAD CORRECTED CAR STILL LEADS REPLACETHE CONTACTTHE FRONT TIRES TIRE MANUFACTURE ROADTEST OK CAR STILL LEADS CONTACTTHE TIRE MANUFACTURER NOTE VERIFY THAT...

Page 829: ...CH MOUNTING Wheels and tires are match mounted at the factory This means that the high spot of the tire is matched to the low spot on the wheel r i m This technique is used to reduce run out i n the wheel tire assembly The high spot on the tire is marked with a paint mark or a bright colored adhesive label on the out board sidewall The low spot on the r i m is identified with a label on the outsid...

Page 830: ...C L E A N I N G A N D I N S P E C T I O N CLEANING OF TIRES Remove protective coating on tires before delivery of vehicle The coating could cause deterioration of tires Remove protective coating by Applying warm water Letting i t soak one minute Scrubbing the coating away with a soft bristle brush Fig 10 Remount Tire 90 Degrees in Direction of Arrow Steam cleaning may also be used for cleaning DO ...

Page 831: ...AND R E A R W H E E L S O F THIS V E H I C L E A R E NOT I N T E R C H A N G E A B L E DO NOT P L A C E F R O N T W H E E L S ON T H E R E A R O R V I C E V E R S A This vehicle is equipped with 10 inch wide rims on the front axle and 13 inch wide rims on the rear axle All rims are 17 inches in diameter Due to the wheel rims widths being different on the front and the rear of the vehicle the rims ...

Page 832: ...ATE WHEEL ON HUB Check the accuracy of the mounting surface on the wheel and the flange of the hub bearing assembly Drive the vehicle a short distance to eliminate any tire flat spotting that may have occurred from the vehicle being parked Verify all wheel nuts are properly tightened and torqued i n the correct sequence Fig 2 Use run out gauge D 128 TR to determine run out Fig 3 PR1951A Fig 3 Run ...

Page 833: ...face of the wheel and the hub Installing wheels without good metal to metal contact could cause loos ening of the wheel nuts This could adversely affect the safety and handling of the vehicle To install the wheel first position i t properly on the mounting surface using the hub pilot as a guide All wheel nuts should be lightly tightened Then pro gressively tightening them i n sequence Fig 7 to 122...

Page 834: ...m flange and the other half on the r i m between the outer face and the weld using tape on wheel weights Fig 9 and Fig 10 Off vehicle bal ancing is necessary Wheel balancing can be accomplished with either on or off vehicle equipment When using on vehicle balancing equipment remove the opposite wheel tire 80ab370d Fig 8 Wheel Weight Locations ADD BALANCE WEIGHTS HERE TIRE OR WHEEL TRAMP OR WHEEL H...

Page 835: ...s cracked bent dented has excessive r u n out or has broken welds The tire inflation valve should also be inspected fre quently for wear leaks cuts and looseness I t should be replaced i f defective or its condition is doubtful VALVE STEM This vehicle requires that special valve stems be used in the rims Use of other than the recommended valve stems can cause rapid air loss and tire failure SPECIF...

Page 836: ......

Page 837: ...ounds on painted sur faces Damage to finish c a n result Do not u s e harsh alkaline based cleaning solvents on painted or upholstered surfaces Damage to finish or color can result Do not hammer or pound on plastic trim panel when servicing trim plastic can break Viper uses many different types of push in fasten ers to secure the interior and exterior trim to the body Most of these fasteners can b...

Page 838: ...e touched up as soon as possible page PAINTED SURFACE TOUCH UP 2 W E T SANDING BUFFING A N D POLISHING 2 to prevent deterioration of body panels For best results use Mopar Scratch Filler Primer Touch Up Paints and Clear Top Coat TOUCH UP PROCEDURE 1 Scrape loose paint and material from inside scratch or chip 2 Clean affected area with Mopar Tar Road Oil Remover and allow to dry 3 Fill the inside o...

Page 839: ... K K E N S Viper Red Clear Coat LRN 7384 22122 B9247 45963 CHA92 LRN Viper Bright Silver Metallic Clear Coat VA9 36395 28075 B9844 54834 CHA98 VA9 Herberts Standox and Spies Hecker use the Chrysler paint code as listed on the Body Code Plate I N T E R I O R INTERIOR C O L O R S C H R Y C O D E P P G B A S F DUPONT S H E R W I N WILLIAMS M S A K Z O N O B E L S I K K E N S Black X9 9451 6329 99 460...

Page 840: ...N C O N T A C T WITH U R E T H A N E A D H E S I V E S H O U L D B E AVOIDED P E R S O N A L INJURY MAY R E S U L T A L W A Y S W E A R E Y E AND HAND P R O T E C T I O N W H E N W O R K I N G WITH G L A S S CAUTION Protect all painted and trimmed surfaces from coming in contact with urethane or primers Be careful not to damage painted surfaces when removing moldings or cutting urethane around win...

Page 841: ...3 Clean inside of windshield with Mopar Glass Cleaner and lint free cloth 4 Apply clear glass primer 25 mm 1 in wide around perimeter of windshield and wipe with clean dry lint free cloth 5 Apply black out primer 15 mm 75 in wide on top and sides of windshield and 25 mm 1 in on bot tom of windshield Allow at least three minutes dry ing time 6 Using a razor knife remove as much original urethane as...

Page 842: ...23 6 BODY REMOVAL AND INSTALLATION Continued S R Fig 5 Apply Tape to Retain Windshield Molding Fig 4 Lower Windshield Into Position ...

Page 843: ...REAR HOLD DOWN ROLLER T R A C K 14 HOOD REAR STABILIZER CATCH 15 HOOD RELEASE CABLE 13 HOOD SIDE EMBLEM 10 HOOD SLAM BUMPER 13 page INNER BELT WEATHER STRIP 21 INSIDE DOOR RELEASE BEZEL 19 INSIDE DOOR RELEASE HANDLE 19 INSIDE REAR VIEW MIRROR 25 LIFTGATE 37 LIFTGATE HINGE 37 LIFTGATE LATCH 38 LIFTGATE LATCH STRIKER 39 LIFTGATE LOCK CYLINDER 39 LIFTGATE SLAM BUMPER 38 LIFTGATE SUPPORT CYLINDER 38 L...

Page 844: ...e vehicle I f the leak occurs on right 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 I f necessary remove inte rior trim covers or panels to gain visu...

Page 845: ...trips weld seams or moldings After each length is applied drive the vehi cle I f noise goes away after a piece of tape is applied remove tape locate and repair defect POSSIBLE CAUSE OF WIND NOISE Moldings standing away from body surface can catch wind and whistle Gaps i n sealed areas behind overhanging body flanges can cause wind rushing sounds Misaligned movable components Missing or improperly ...

Page 846: ...d 2 Clean adhesive residue from hood with Mopar Super Kleen solvent or equivalent INSTALLATION VIPER GTS EMBLEM VIPER R T 1 0 EMBLEM 1 I f the original emblem is to be reused peel old adhesive tape from back of emblem 2 Clean adhesive residue from emblem with Mopar Super Kleen solvent or equivalent 3 Cover the back of emblem with two sided adhe sive tape Trim tape to fit emblem Tape can be acquire...

Page 847: ...en to hood HOOD LOUVER REMOVAL 1 Release the hood latch and open hood 2 Remove nuts holding hood louver to the hood 3 Separate louver from the hood Fig 6 Fig 6 Hood Louver INSTALLATION 1 I f necessary paint the hood louver prior to installation 2 Position louver i n opening i n the hood 3 Install the nuts to hold hood louver to the hood HOOD OUTSIDE AIR DUCT REMOVAL 1 Release hood latch and open h...

Page 848: ...op of hood hinge to hood 6 Verify that the gaps between the hood and adjacent body components conform to the gaps listed in the Specifications section of this group Adjust as necessary 7 Verify hood operation Adjust as necessary HOOD HINGE REMOVAL 1 Remove hood 2 Disconnect hood latch release cable from hood latch on hinge that must be removed 3 Remove bolts holding hood hinge to upper frame rail ...

Page 849: ...4 Verify latch operation Adjust as necessary HOOD SLAM BUMPER REMOVAL 1 Release hood latch and open hood 2 Rotate slam bumper counterclockwise 3 Separate slam bumper from hood latch INSTALLATION 1 Position slam bumper to hood latch 2 Rotate slam bumper clockwise 3 Verify hood alignment Adjust as necessary HOOD LATCH STRIKER REMOVAL 1 Release hood latch and open hood 2 Remove bolts holding hood lat...

Page 850: ... 5 on other hood latch i f cables are being replaced HOOD REAR HOLD DOWN ROLLER BRACKET REMOVAL i l Release hood latch and open hood 2 Remove bolts holding hold down roller bracket to hood Fig 14 3 Separate roller bracket from hood Fig 14 Hood Hold Down Roller Bracket INSTALLATION 1 Position roller bracket to hood 2 Install bolts holding hold down roller bracket to hood HOOD REAR HOLD DOWN ROLLER ...

Page 851: ...N 1 Position cowl cover to vehicle 2 Install screws holding cowl cover to cowl for ward of doors 3 Install screws holding cowl cover to mounting brackets 4 Install windshield wiper arms Refer to Group 8K Windshield Wipers and Washers FRONT END SPLASH SHIELDS REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove wheel and tire assembly 3 Release hood latch and open hood 4 Disengage thumbscr...

Page 852: ...nel from vehicle 80a60250 INSTALLATION 1 Position trim panel to vehicle 2 Engage lip on top edge of trim panel under the roof panel 3 Push on A pillar trim panel to engage trim panel to duo lock fastener DOOR HINGE COVER REMOVAL 1 Open hood and door 2 Remove screws holding top of door hinge cover to cowl side behind hood roller track Fig 19 Slip shims from behind cover 3 Remove screw holding hinge...

Page 853: ...lts holding door hinge to hinge pillar Fig 21 6 Remove bolts holding door hinge to door shut face 7 Separate door hinge from vehicle 80a60248 Fig 21 Door Hinge INSTALLATION 1 Position door hinge to vehicle 2 Loosely install bolts to hold door hinge to hinge pillar and door shut face 3 Align hinge to marks made on hinge pillar and tighten bolts to hold hinge to hinge pillar 4 Align door hinge to ma...

Page 854: ... 11 Remove trim panel from door 80a5f2d0 Fig 23 Door Trim Panel INSTALLATION 1 Position trim panel to door 2 Connect tweeter wiring connector to the door wiring harness 3 Holding the bottom of the trim panel out from the door connect the upper edge of trim panel to the inner belt weather strip 4 Install screws to attach trim panel to bottom of the door 5 Install screw to attach front of trim panel...

Page 855: ...cle INSTALLATION 1 Position door stanchion cover to vehicle 2 Install screw to hold stanchion cover to stan chion 3 Install outside door release handle 4 Install inner door stanchion trim panel I0DY 23 11 Fig 25 Door Stanchion Outer Cower INSIDE DOOR RELEASE 1EZEL REMOVAL 1 Release door latch and open door 2 Push rearward on inside door release bezel until hooks on bezel disengage from the tabs on...

Page 856: ...olding door release switch to outside door release button 3 Remove nut holding release button to door stanchion Fig 28 4 Separate door release button from vehicle DOOR STANCHION 80a5f2dc Fig 28 Outside Door Release Button INSTALLATION 1 Position door release button i n hole i n door stanchion outer cover and stanchion 2 Install nut to hold release button to door stan chion 3 Install door release s...

Page 857: ... and windshield portion of A pillar 3 I f necessary apply adhesive to back of weather strip to hold weather strip to flange along lower por tion of A pillar door sill and B pillar 4 Push weather strip onto flange along door sill B pillar and lower portion of A pillar INNER BELT WEATHER STRIP REMOVAL 1 Remove door trim panel 2 Remove push i n fasteners attaching the leading edge of the inner belt w...

Page 858: ...eather strip 6 Install door trim panel DOOR GLASS REMOVAL 1 Remove door trim panel 2 Remove door stanchion outer cover 3 Raise door glass to midway position 4 Remove clip attaching door glass to window regulator guide Fig 33 5 Remove door glass from window regulator guide 6 Remove door glass up stop 7 Remove door inner belt weather strip 8 Lift glass upward and out of opening i n top of door Fig 3...

Page 859: ...oor trim panel DOOR GLASS FRONT GUIDE REMOVAL 1 Remove door trim panel 2 Remove door glass 3 Remove screws holding glass front guide to the inner door panel Fig 36 4 Remove nut holding front guide to bottom of door 5 Separate front guide from vehicle INSTALLATION 1 Position glass front guide i n door 2 Install nut to hold front guide to bottom of door 80a60243 Fig 36 Door Glass Front Guide 3 Insta...

Page 860: ...t as necessary 80a6121c Fig 38 Lower Door interlock plate LOWER DOOR INTERLOCI CATCH REMOVAL 1 Remove screws holding door interlock catch to door opening sill Fig 39 2 Separate interlock catch and shims i f equipped from sill Fig 39 Lower Door Interlock Catch INSTALLATION 1 Position interlock catch and shims i f equipped to sill 2 Install screws holding door interlock catch to door opening sill 3 ...

Page 861: ...visor downward to expose fasteners 2 Remove screws attaching sun visor to roof panel Fig 42 3 Remove sun visor from headlining Fig 42 Sun Visor INSTALLATION 1 Position sun visor to headlining 2 Install screws to attach sun visor to roof panel DOOR OPENING WEATHER STRIP REMOVAL 1 Open door 2 Disengage push in fastener at base of wind shield attaching door opening weather strip to A pil lar 3 Pull w...

Page 862: ...crossmember 2 Position spacers between seat belt retractor and crossmember and install bolts to hold seat belt retractor to the rear frame top crossmember N O T E Torque for the seat belt retractor bolts i s 28 N m 250 in lbs 3 Route the seat belt trim cover seat belt latch and seat belt anchor through slot I n bulkhead trim panel 4 Position bulkhead trim panel to bulkhead 5 Install screws to atta...

Page 863: ...ru ment panel below heater control 4 Install gear shift handle 5 Install instrument panel center bezel Refer to Group 8 E Instrument Panel and Gauges for proper procedures 6 Install ash receiver BULKHEAD TRIM PANEL ROADSTER REMOVAL 1 Remove center console rear attachment screws 2 Move seats to the forward position 3 Remove speaker Fig 46 Center Console 4 Disconnect switch at alarm lock cylinder 5 ...

Page 864: ...rim to bracket at flange that extends under bulkhead trim 9 Remove quarter trim panel from vehicle 80b46bb9 Fig 49 Quarter Trim Panel INSTALLATION 1 Position quarter trim i n vehicle 2 Install screw attaching quarter trim to bracket at flange that extends under bulkhead trim 3 Install side cargo trim panel 4 Install screws attaching quarter trim panel to bulkhead 5 Install screws attaching the qua...

Page 865: ...parate carpet from vehicle INSTALLATION 1 Using a flat bladed scraper remove old adhe sive from bulkhead i f necessary 2 Paint bulkhead to avoid corrosion i f necessary 3 Apply adhesive on bulkhead panel i n pattern shown Fig 51 4 Position carpet i n vehicle 5 Push carpet to adhesive on bulkhead 6 Install center console 7 Install quarter trim panels 8 Install bulkhead trim panel 9 Install seat bel...

Page 866: ...ables to back of sport bar 15 Remove nuts attaching roof panel to trunk pan from inside rear wheelhouse Fig 55 16 Remove trunk rear t r i m panel 17 Remove trunk lining as necessary to access roof panel nuts at rear of trunk area 18 Remove nuts attaching roof panel to trunk pan at rear of trunk pan 19 Drill out rivets attaching the roof to the trunk pan extensions 20 Using a suitable cutting tool ...

Page 867: ... or equiv alent on trunk pan where roof panel edge will mate to the trunk pan Fig 55 and Fig 56 10 With aid of a helper position roof panel to vehicle Ensure that the front edge of the roof panel is positioned under the windshield molding and the studs at the rear of roof pass through the mating holes in trunk pan C A U T I O N Minimize m o v e m e n t of the roof panel o n c e it c o m e s into c...

Page 868: ...el at sides of headlining 7 Install push i n fasteners to attach headlining to roof panel at center of headlining 8 Install trunk trim panels 9 Install sun visors QUARTER PANEL ROADSTER memowAL 1 Remove rear wheelhouse splash shield 2 On right quarter panel remove fuel fill door 3 Disconnect rear lighting lamps Refer to Group 8L Lamps 4 Remove trunk lid 5 Remove rear bumper fascia Refer to Group 1...

Page 869: ...side the trunk 8 Separate quarter panel from vehicle Fig 60 Quarter Panel Coupe INSTALLATION 1 Position quarter panel to vehicle 2 Verify alignment of quarter panel to trunk pan roof panel and door surround panel Adjust position of quarter panel as necessary 3 Install bolts to hold the quarter panel to the trunk pan 4 Install rear wheelhouse splash shields 5 Install pop rivets to hold quarter pane...

Page 870: ...stall quarter panel SP01T CAP REMOVAL 1 Remove B pillar filter piece 2 Remove door weather strips 3 Remove quarter trim panels 4 Remove bulkhead trim panel 5 Remove trunk lid 6 Remove quarter panels 7 Remove rear glass i f equipped 8 Disconnect center high mounted stop lamp 9 Using a suitable drill with a 5 m m 0 187 in drill bit remove pop rivets holding sport cap to trunk pan Fig 62 10 Remove nu...

Page 871: ...runk hinge and trunk lid if necessary 4 Using previously made marks align trunk hinges to the trunk lid 5 Tighten nuts holding trunk hinge to trunk lid 6 Verify that trunk lid is properly aligned to rear deck panel and quarter panels Adjust as necessary TRUNK LID SLAM BUMPER REMOWAL 1 Release trunk latch and open trunk lid 2 Support trunk lid on prop rod 3 Rotate slam bumper counterclockwise Fig 6...

Page 872: ...rt trunk lid on prop rod 3 Remove trunk latch remote to gain access to lock cylinder fastener 4 Remove nut holding lock cylinder to trunk lid Fig 67 5 Separate lock cylinder from trunk lid INSTALLATION 1 Position lock cylinder and seal to trunk lid 2 Install nut holding lock cylinder to trunk lid 3 Install trunk latch remote Fig 67 Trunk Lock Cylinder TRUNK LID WEATHER STRIP REMOVAL 1 Release trun...

Page 873: ... s will p r o v i d e t h e correct b o d y g a p o n c e t h e s u p p o r t c y l i n d e r s are installed 6 Install support cylinders to the ball studs on liftgate 7 Verify liftgate operation Adjust as necessary LIFTGATE HINGE REMOVAL 1 Release liftgate latch and open liftgate 2 Support liftgate on a suitable prop rod 3 Place tape along roof panel near the hinge to be removed 4 Remove trunk tr...

Page 874: ...g 71 Liftgate Slam Bumper INSTALLATION 1 Position slam bumper to roof panel 2 Rotate slam bumper clockwise to achieve cor rect liftgate to quarter panel alignment LIFTGATE LATCH REMOVAL 1 Release liftgate latch and open liftgate 2 Remove trunk lining as necessary to access lift gate latch and remote 3 Using a suitable drill with a 3 mm 0 125 in drill bit remove pop rivets holding latch remote to b...

Page 875: ...pan INSTALLATION 1 Position lock cylinder and seal through opening in trunk pan and tail lamp closure panel 2 Install nut attaching lock cylinder to trunk pan and tail lamp closure panel 3 Align lock cylinder arm to slot in latch remote and insert arm into slot 4 Position latch remote bracket to the trunk pan 5 Install rivets to attach remote bracket to trunk pan 6 Install trunk lining LIFTGATE WE...

Page 876: ...e latch and open liftgate 2 Support liftgate on suitable prop rod 3 Remove support cylinder from ball stud on trunk pan bracket 4 Remove rear trunk trim panel 5 Remove screws attaching trunk trim panel to the roof panel and sport bar 6 Remove the trim panel from vehicle Fig 78 Trunk Trim Panel INSTALLATION 1 Position the trim panel i n the vehicle 2 Install screws attaching trunk trim panel to the...

Page 877: ...im spacers 4 Install lower rear splash shields 5 Install rear wheel and tire assembly FUEL TANK CL0SE0UT PANEL REMOVAL 1 Release trunk latch and open trunk lid 2 Support trunk lid on prop rod 3 Remove spare tire from trunk 4 Using a suitable drill with a 3 m m 0 125 in drill bit remove pop rivets holding fuel tank closeout panel to trunk pan Fig 81 5 Pull closeout panel rearward to separate sealed...

Page 878: ...iously removed from that location 4 Apply two part polyurethane adhesive i n areas indicated Fig 83 5 Install trunk pan 6 Locate trunk pan to frame using two 10 mm pins 7 Install bolts to attach rear of trunk pan to frame 8 Install bolts to attach trunk floor reinforcement cables to frame 9 Install roof panel TAIL LAMP CLOSURE PANEL REMOVAL 1 Remove trunk lining as necessary to access tail lamp wi...

Page 879: ...Panel 6 Install liftgate latch remote bracket to trunk pan 7 Install license plate 8 Install screws to hold tail lamp closure panel to the quarter panel at sides of closure panel 9 Install tail lamp wiring grommet to trunk pan 10 Engage tail lamp wiring connector to body wiring harness 11 Install trunk lining ...

Page 880: ...23 44 BODY S R S P E C I F I C A T I O N S N O T E All dimensions in mm W l Within 4 0 2 0 RT LTW I 1 5 F L U S H 0 0 1 0 1 5 0 75 S E C S S 80a6al5f ...

Page 881: ...U S H 2 0 IS C R O S S C A R Ii VIEW A R T L T W l 1 25 2 0 4 0 1 0 T S E C D D RT LT W l 4 0 10 5 4 5 1 5 4 5 F L U S H 1 0 3 5 1 0 F L U S H 1 0 F L U S H 5 5 1 0 S E C H H 7 0 2 0 4 0 RT LT W l 4 0 l J W l 3 0 7 0 2 0 5 0 RT LT W l 4 0 J I W 1 30 80a6a15e ...

Page 882: ...1 0 0 0 1 0 0 0 T Y P I C A L P E R I P H B O T H L A M P S 2 0 0 5 1 0 F L U S H 1 0 U N D E R F L U S H 8 0 1 0 U N D E R F L U S H 2 0 0 5 1 0 2 5 0 0 1 5 F L U S H 0 5 R T L T W I 1 0 5 0 2 0 5 0 2 0 0 0 1 0 0 0 1 0 1 0 1 5 U N D E R F L U S H 8 0 1 0 CONST W l 2 0 80a6a15c ...

Page 883: ...SPECIFICATIONS Continued BODY 23 47 80a6a15b ...

Page 884: ...tly into the lock cylinder 2 Apply a small amount of lubricant to the key 3 Insert key into lock cylinder and cycle the mechanism from the locked to the unlocked position NOTE Do n o t a d d m o r e lubricant 4 Cycle the lock cylinder mechanism several times to allow the lubricant to flow throughout the cylinder 5 Wipe all lubricant from exterior of lock cylinder and key ALL OTHER 80DY 1ECHANIS1S ...

Page 885: ...BE 26 BLOWER MOTOR 6 EXPANSION VALVE 26 COMPRESSOR CLUTCH COIL DIAGNOSIS 9 FILTER DRIER ASSEMBLY 27 COMPRESSOR NOISE DIAGNOSIS 9 HEATER A C UNIT HOUSING 27 DUAL PRESSURE CUT OFF SWITCH 11 HEATER CORE 28 EXPANSION VALVE 11 HEATER HOSES 29 HEATER PERFORMANCE TEST 11 LIQUID LINE 29 REFRIGERANT SYSTEM DIAGNOSIS 12 SUCTION LINE 30 SIGHT GLASS REFRIGERANT LEVEL TEMPERATURE CONTROL CABLE 30 INSPECTION 14...

Page 886: ...ESTED WITH COM PRESSED AIR SOME MIXTURES OF AIR and R 134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED SEEK MEDICAL ATTENTION IMMEDI ATELY IF SWALLOWED OR INHALED DO NOT STORE IN OPEN OR UNMAR...

Page 887: ...ure drops below 196 to 248 kPa 28 4 to 36 psi or exceeds 2544 to 3137 kPa 369 to 455 psi which could damage the compressor the DPCO will open The A C switch sense circuit will open to the HVAC control causing the PCM to turn off the com pressor clutch relay The DPCO is a sealed factory calibrated unit I t must be replaced i f defective ENGINE COOLING SYSTEM REQUIREMENTS To maintain adequate temper...

Page 888: ...system while the vehicle is i n forward motion SYSTEM OIL LEVEL It is important to have the correct amount of oil i n the A C system to ensure proper lubrication of the compressor Too little oil will result i n damage to the compressor Too much oil will reduce the cooling capacity of the system and consequently result i n higher discharge air temperatures N O T E The o i l used i n the c o m p r e...

Page 889: ...remove heat and humidity from the air entering the passen ger compartment The evaporator located in the heater A C unit is cooled to temperatures near the freezing point As warm damp air passes over the fins in the evaporator moisture in the air condenses to water dehumidifying the air Condensation on the evaporator fins reduces the evaporators ability to absorb heat During periods of high heat an...

Page 890: ...es the blower motor with varied voltage CAUTION Stay clear of the blower motor and resistor block Hot Do not operate the blower motor with the resistor block removed from the heater A C housing Refer to the Blower Motor Vibration Noise Chart ELECTRICAL DIAGNOSIS Refer to the Blower Motor Electrical System Diag nosis Chart Also refer to Group 8W Wiring Dia grams for more information 5 Insert a ther...

Page 891: ...FCSSIBLT RADIATOR FAN OR COMPRESSOR NOISE LOOSE MOUNTING OK TIGHTEN LEAVE E N G I N E ON SHUT BLOWER MOTOR OFF RE CHECK NOISE STILL PRESENT NOISE GONE OK PROBLEM NOT IN SLOWER SYSTEM VIBRATION STILL PRESENT CHECK BLOWER SCROLL AREA FOREIGN MATERIAL IN FAN OR SCROLL YES REMOVE FOREIGN MATERIAL FAN RUBBING HOUSING NO REPLACE MOTOR RE CHECK r REPLACE AND ASSE MOTOR WHEEL MBLY RE CHECK YES A TO DJUST ...

Page 892: ... E R E P L A C E M O T O R V O L T A G E P R E S E N T N O V O L T A G E C H E C K F O R O P E N C I R C U I T F U S E B L O C K T O M O T O R C H E C K F O R B A D C O N N E C T I O N A T M O T O R T E S T C O N T I N U I T Y F U S E L I N K T O I G N S W I T C H T O F U S E B L O C K R E P A I R T E S T F O R B A D G R O U N D A T M O T O R R E P A I R G R O U N D C I R C U I T S E E W I R I N G...

Page 893: ...a volt meter 0 20 volt scale with clip leads measuring voltage across the battery and A C clutch 3 With A C control i n A C mode and blower at low speed start the engine and r u n at normal idle 4 The A C clutch should engage immediately and the clutch voltage should be within two volts of the battery voltage I f the A C clutch does not engage test the fusible link 5 The A C clutch coil is accepta...

Page 894: ...BELT INTERFERENCE KNOCKING OR GRINDING NOISE FROM COMPRESSOR REPLACE COMPRESSOR COMPRESSOR WON T TURN PROPERLY CLUTCH ENGAGES BUT SLIPS OR SMOKES CLUTCH SLIPPING LOW VOLTAGE AT CLUTCH CHECK WIRING SWITCHES CLUTCH AMPERAGE AND GROUND AMPERAGE GREATER THAN 5 AMPS CLUTCH COIL PARTIALLY SHORTED REPLACE COIL OIL GREASE O N FRICTION SURFACES REPLACE COMPRESSOR FRONT COVER CHECK SHAFT SEAL FELT NOTE APPL...

Page 895: ...wer 5 Start the engine and allow to idle 1000 rpm After the engine has reached running temperature allow the passenger compartment to heat up This will create the need for maximum refrigerant flow into the evaporator 6 I f the refrigerant charge is sufficient discharge high pressure gauge should read 965 to 1655 kPa 140 to 240 psi Suction low pressure gauge should read 140 kPa to 207 kPa 20 psi to...

Page 896: ...ruction i n heater system POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW 1 Pinched or kinked heater hoses 2 Improper heater hose routing 3 Plugged heater hoses or supply and return ports at cooling system connections refer to Group 7 Cooling System 4 Plugged heater core 5 Air locked heater core 6 Water valve sticking or inoperative 7 I f coolant flow is verified and outlet tempera ture is ...

Page 897: ...WITH P A R K B R A K E S E T C O R R E C T E V A P O R A T O R SUCTION G A U G E P R E S S U R E 20 35 PSI 140 240 kPa C O R R E C T C O M P R E S S O R D I S C H A R G E G A U G E P R E S S U R E 140 240 PSI 966 T O 1656 kPa P R E S S U R E S O K C O R R E C T E V A P O R A T O R SUCTION G A U G E P R E S S U R E 20 35 PSI 140 240 kPa C O R R E C T C O M P R E S S O R D I S C H A R G E G A U G E ...

Page 898: ...S The actuators i n this system are operated by vac uum Inside each actuator is a rubber diaphragm Attached to the rubber diaphragm is the actuator arm When vacuum is applied to the vacuum cham ber the diaphragm collapses causing the actuator arm to move Depending on which side of the dia phragm vacuum is applied will determine which way the actuator arm moves All ports on the actuators should hol...

Page 899: ...compressor and connect refrigerant lines Then evacuate and charge refrigerant system 7 Most recovery recycling equipment will mea sure the lubricant being removed This is the amount of lubricant to be added back to the system I f a new compressor is being installed drain lubricant from old compressor measure the amount drained and dis card old lubricant Drain the lubricant from the new compressor ...

Page 900: ...ng the instructions provided with the charging equipment being used charge through the suction side of the system Add enough refriger ant to clear the sight glass i n the filter drier 7 A t the point when the sight glass clears note the weight of the refrigerant supply drum or the level i n the charging cylinder Add an additional 227 g 8 oz of refrigerant to the system Remove the jumper wire from ...

Page 901: ...and replaced with new oil or a new compres sor be used This will eliminate the possibility of con taminating the refrigerant system I f the refrigerant system has been open to the atmosphere i t 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...

Page 902: ...s in a R 134a refrigerant s y s t e m 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 I ...

Page 903: ... engine cylinder head or alternator WARNING REFRIGERANT PRESSURES REMAIN HIGH E V E N T H O U G H T H E ENGINE MAY B E T U R N E D O F F B E F O R E REMOVING A F U L L Y C H A R G E D COMPRESSOR REVIEW T H E SAFETY P R E C A U T I O N S AND WARNINGS S E C T I O N IN THIS G R O U P DO NOT TWIST O R KINK T H E R E F R I G E R ANT LINES W H E N REMOVING A F U L L Y C H A R G E D C O M P R E S S O R S...

Page 904: ...ld coil onto com pressor housing Fig 15 Slide field coil off of com pressor housing 6 Examine frictional faces of the clutch pulley and front plate for wear The pulley and front plate should be replaced i f there is excessive wear or scor ing I f the friction surfaces are oily inspect the shaft nose area of the compressor for oil and remove the felt from the front cover I f the compressor felt is ...

Page 905: ...e assembly tight against the shim s measure the air gap between front plate and pulley face with feeler gauges The air gap should be between 0 35 and 0 65 m m 0 014 and 0 026 inch I f proper air gap is not obtained add or subtract shims until desired air gap is obtained 8 Install compressor shaft bolt Tighten to 17 5 2 N m 155 20 in lbs NOTE S h i m s m a y c o m p r e s s after t i g h t e n i n ...

Page 906: ...ver Fig 19 Removing Steel Valve Plate Gasket Fig 20 Removing O Ring 7 Pry out the felt retainer and remove felt from front cover Fig 21 8 Remove seal snap ring Fig 22 9 Place compressor front cover on a flat surface with neck of cover facing up Using a brass drift press out seal assembly Fig 23 10 Remove dowel pins valve plates Fig 24 FELT FELT 9124 23 Fig 21 Removing Felt Retainer and Feit INSTAL...

Page 907: ...install lip seal in front cover using a socket that contacts the outer diameter of the lip seal Fig 25 and Fig 26 SOCKET FRONT COVER SEAL SEAT 9224 50 Fig 25 Match Socket to Outer Seal Diameter HAMMER FRONT COVER 9224 51 Fig 26 Installing Seal Fig 24 Disassembling Compressor Front End 7 Install seal snap ring Fig 27 8 Lubricate front cover O ring with refrigeration oil and carefully place it in se...

Page 908: ...ll revolutions 15 Check front housing clutch coil alignment pin for proper installation 16 Install clutch assembly 17 Install compressor 18 Evacuate and charge refrigerant system 9124 23 Fig 29 Felt Retainer and Felt COMPRESSOR HIGH PRESSURE RELIEF VALVE REMOVAL 1 Using a refrigerant recovery machine remove the refrigerant from the A C system 2 Rotate the high pressure relief valve counter clockwi...

Page 909: ... remove and will c a u s e a reliability problem with the compressor REMOVAL 1 Disconnect negative battery cable from battery 2 Remove hood and hood support Refer to Group 23 Body for procedure 3 Remove air ducts located i n front of the air cleaner assembly and air cleaner assembly Refer to Group 25 Emission Systems for procedure 4 Remove bolt retaining condenser inlet line to condenser Fig 31 5 ...

Page 910: ... line from vehicle Fig 34 Discharge Line Location INSTALLATION For installation reverse the above procedures Tighten the Discharge Line bolt at the Compressor to 20 to 30 N m 15 to 22 ft lbs torque Tighten the Discharge Line bolt at the Condenser to 15 to 22 N m 11 to 16 ft lbs torque DUAL PRESSURE CUT OFF SWITCH REMOVAL 1 Open the vehicle hood 2 Disconnect the negative battery cable 3 Using a ref...

Page 911: ...lter drier and remove filter drier from clamp 5 Cover the open ends of the refrigerant lines to minimize refrigerant system contamination INSTALLATION For installation 1 Replace O rings on both refrigerant line go to the filter drier 2 Reverse the above procedures Tighten Filter Drier Attaching Nuts to 5 to 6 N m 40 to 50 in lbs torque 3 Evacuate and Charge A C system SIGHT GLASS AND EVAPORATOR IN...

Page 912: ...op heater core Fig 39 4 Remove heater core retaining screws Fig 40 5 Note the position of the heater core The heater hose tubes are offset and can only be installed i n the proper direction 6 Lift heater core straight up and out of heater housing Fig 41 INSULATION SEAL DASH PANEL 9324 4 MOUNTING SCREW Fig 38 Heater Housing HEATER CORE The heater housing must be removed from the vehicle to service ...

Page 913: ... clamps at each end of hose to be removed 3 Carefully rotate hose back and forth while tug ging slightly away from connector nipple CAUTION When removing h o s e s from heater core inlet or outlet nipples do not u s e e x c e s s i v e force Heater core may become damaged and leak engine coolant into heater unit INSTALLATION For installation reverse the above procedures LIQUID LINE CONDENSER TO FI...

Page 914: ... Filter Drier to 4 to 5 N m 35 to 45 in lbs torque and the Liquid Line Nut at the Evaporator to 12 to 15 N m 9 to 11 ft lbs torque SUCTION LINE REMOVAL 1 Remove refrigerant from the A C system using a refrigerant recovery machine 2 Remove suction line bolt and line from A C compressor Fig 44 3 Remove suction line bolt and line from evapo rator Fig 35 4 Raise vehicle on a hoist 5 Remove the two suc...

Page 915: ... Position cable housing on water valve clamp and engage clamp 7 Verify proper Heater A C control cable opera tion WACUUi ACTUATORS MODE DOOR REMOVAL 1 Remove right side knee bolster and steel plate assembly 2 Remove Heater A C air ducts 3 Remove actuator cover Fig 45 4 Label vacuum lines and then disconnect Fig 46 5 Remove C clip from actuator arm Fig 47 A C HEATER HOUSING VACUUM ACTUATOR ACTUATOR...

Page 916: ...installation 4 Remove water valve mounting bolts INSTALLATION For installation reverse the above procedures Hose s must be fully seated on control valve within VMn of base Assure that hose and nipple on water control valve are clean and dry Never use oil or sil icone when installing hose Use new clamps Refer to Temperature Control Cable for cable adjustment pro cedure Fig 50 Water Controi Valve DI...

Page 917: ...s Fig 56 Fig 54 A C Heater Housing Retaining Screws HEATING ANtJ All CONDITIONING 24 33 Fig 55 A C Heater Housing Retaining Clips EVAPORATOR HOUSING HALVES PROBE 9424 153 Fig 56 A C Heater Housing Halves 6 Remove evaporator sensing probe from the cen ter of the evaporator and remove probe from housing Fig 57 and Fig 58 7 Remove evaporator from housing Fig 59 Fig 57 Evaporator Sensing Probe ...

Page 918: ...emove the vacuum actuator cover Fig 60 A C HEATER HOUSING 9424 146 Fig 62 Went Door Actuator Lever HEAT DEFROST DOOR ACTUATOR LEVER HEAT DEFROST DOOR ACTUATOR ACTUATOR COVER 9424 134 Fig 60 Vacuum Actuator Cover 10 Mark the vent actuator bracket and the vent door shaft for assembly identification The vent door Fig 63 Heat Defrost Door Actuator Lever ...

Page 919: ...Actuator 9424 133 Fig 65 Heat Defrost Door Actuator 14 Remove the vent door from the housing Fig 66 15 Remove the heat defrost door from the hous ing Fig 67 SUBASSEMBLY RECONDITION The thermostatic expansion valve TXV is located at the evaporator inlet Fig 68 VENT DOOR Fig 66 Vent Door HEAT DEFROST DOOR 9424 159 Fig 67 Heat Defrost Door THERMOSTATIC ms k EXPANSION JmmL EVAPORATOR 9424 161 Fig 68 T...

Page 920: ...emove capillary tube from clip at the evapo rator outlet Fig 70 THERMOSTATIC EXPANSION VALVE TXV OUTLET 9424 164 9424 160 n Z__ Fig 70 Capillary Tube 3 Remove evaporator inlet line from TXV Fig 71 4 Remove flange nut at TXV outlet Fig 72 Fig 72 TKV Outlet ASSEMBLY To assemble the Heater A C housing reverse the above procedures The heater core tubes are offset and must be installed i n the proper m...

Page 921: ...tem Description Notes V E H I C L E Viper coupe and roadster S Y S T E M R134a w expansion valve COMPRESSOR Nippondenso 10PA15 ND 8 PAG O Freeze up Control mechanical clutch cycling switch internal near evaporator Off 34 F resets On 40 F D O A L FUNCTION PRESSURE SWITCH D F P S mounts on receiver drier Item Description Notes Low psi Control opens 20 4 2 84 psi resets 36 7 psi High psi Control open...

Page 922: ......

Page 923: ...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 page LOAD VALUE 9 MALFUNCTION INDICATOR LAMP MIL 2 MONITORED SYSTEMS 6 NON MONITORED CIRCUITS 8 STATE DISPLAY TEST MODE 2 TRIP DEFINITION 8 circuit has not been met For example assume th...

Page 924: ...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 attempts to activate these outputs and allow an observer to verify proper operation Most of the tests provide an audib...

Page 925: ... Control Circuit Injector 3 output driver does not respond properly to the control signal 14 P0202 Injector 2 Control Circuit Injector 2 output driver does not respond properly to the control signal 15 P0201 Injector 1 Control Circuit Injector 1 output driver does not respond properly to the control signal 19 P0505 Idle Air Control Motor Circuits A shorted or open condition detected in one or more...

Page 926: ...t below the maximum acceptable voltage 3A P0113 Intake Air Temp Sensor Voltage High Intake air temperature sensor input above the minimum acceptable voltage 3D P0204 Injector 4 Control Circuit Injector 4 output driver does not respond properly to the control signal 3 E P0132 Right Rear or just Upstream 0 2 S Shorted to Voltage Oxygen sensor input voltage maintained above the normal operating range...

Page 927: ...r or just Fuel System Rich A rich air fuel mixture has been indicated by an abnormally lean correction factor 77 P0171 Right Rear or just Fuel System Lean A lean air fuel mixture has been indicated by an abnormally rich correction factor 78 P0175 Left Front Fuel System Rich A rich air fuel mixture has been indicated by an abnormally lean correction factor 79 P0174 Left Front Fuel System Lean A lea...

Page 928: ...Front Catalyst Efficiency Failure Catalyst efficiency below requried level B5 B6 P0151 P0157 Left Up 0 2 S Shorted to Ground Left Down 0 2 S Shorted to Ground 0 2 sensor voltage too low tested after cold start 0 2 sensor voltage too low tested after cold start BA P1398 Mis fire Adaptive Numerator at Limit CKP sensor target windows have too much variation MONITORED SYSTEMS There are new electronic ...

Page 929: ...oller to shift to closed loop control as soon as possible The heating element used to heat the 02S sensor must be tested to ensure that i t is heating the sensor properly The 02S sensor circuit is monitored for a drop i n voltage during warmup of the sensor The sensor out put is used to test the heater by isolating the effect of the heater element on the 02S sensor output volt age from the other e...

Page 930: ...nd passing the monitor is considered to be a Good Trip I f any other Emission DTC is set not an OBDII Monitor a Good Trip is considered to be when the Oxygen Sensor Monitor and Catalyst Monitor have been completed or 2 Minutes of engine r u n time i f the Oxygen Sensor Monitor or Catalyst Monitor have been stopped from running It can take up to 2 Failures i n a row to turn on the MIL After the M I...

Page 931: ...em is i n closed loop it cannot determine excessive oil consumption T H R O T T L E BODY AIR FLOW The PCM cannot detect a clogged or restricted air cleaner inlet or filter element VACUUM ASSIST The PCM cannot detect leaks or restrictions i n the vacuum circuits of vacuum assisted engine control system devices However these could cause the PCM to store a MAP sensor diagnostic trouble code and cause...

Page 932: ...wertrain Control Module PCM allows intake manifold vacuum to draw vapors into the combustion chambers during certain operating conditions All engines use a duty cycle purge system The PCM controls vapor flow by operating the duty cycle EVAP purge solenoid Eefer to Duty Cycle EVAP Purge Solenoid i n this section NOTE T h e evaporative s y s t e m uses specially m a n ufactured h o s e s t h e y nee...

Page 933: ... The solenoid is energized with a fixed duration pulse Subsequent fixed pulses occur when the diaphragm reaches the switch closure point The spring i n the pump is set so that the system will achieve an equalized pressure of about 7 5 inches of water When the pump starts the cycle rate is quite high As the system becomes pressurized pump rate drops I f there is no leak the pump will quit I f there...

Page 934: ...ugh the fitting A strong vacuum should also be felt when a finger is placed over the fitting inlet 2 Install the fixed orifice fitting Remove the make up air hose from the grommet on the engine valve cover Hold a piece of stiff paper parts tag loosely over grommet 3 After allowing approximately 1 minute for crankcase pressure to reduce the paper should draw up against the grommet with noticeable f...

Page 935: ... connec tor to solenoid 2 Install solenoid into the rubber mounting 3 Install front fascia Refer to Group 13 EVAP CANISTER The EVAP purge canister mounts to the radiator support behind the front fascia Fig 4 EVAP and LDP Pump REMOVAL 1 Remove the front fascia Refer to Group 13 2 Disconnect vacuum harness and electrical con nector 3 From inside of the left front wheel well remove EVAP purge caniste...

Page 936: ...to Group 13 2 Disconnect vacuum harness and electrical con nector 3 From inside of the left front wheel well remove EVAP purge canister and LDP Pump bracket mount ing bolts Fig 5 4 Remove hoses from the top of EVAP canister 5 Remove 3 nuts from EVAP canister and bracket Fig 6 6 Remove canister Fig 7 7 Remove 3 screws from LDP and bracket Fig 9 80b3c59e Fig 8 EVAP and LDP Pump LDP P U M P M O U N T...

Page 937: ...D A L 5 5 0 A S S E M B L Y C O M P R E S S O R C L U T C H C O I L 24 20 A S S E M B L Y C O N D E N S E R 24 25 A S S E M B L Y D I F F E R E N T I A L 3 2 7 A S S E M B L Y E N G I N E 9 2 0 A S S E M B L Y F I L T E R D R I E R 24 27 A S S E M B L Y F I N A L 3 17 A T T A C H I N G LINK S T A B I L I Z E R B A R 2 43 A T T A C H I N G LINKS S T A B I L I Z E R B A R 2 26 2 64 2 84 A U D I O D ...

Page 938: ... E N T E R H I G H M O U N T E D S T O P L A M P B U L B 8 L 1 0 C E N T E R H I G H M O U N T E D S T O P L A M P C H M S L 8 L 1 3 C E N T E R M E S S A G E 8 E 2 C E N T E R T E S T M E S S A G E 8 E 5 C E N T E R I N G C L O C K S P R I N G 8 M 8 C E N T E R L A M P S M E S S A G E 8 E 1 1 C E R T I F I C A T I O N L A B E L V E H I C L E S A F E T Y lntro 1 C H A I N A N D S P R O C K E T TIM...

Page 939: ... R REAR S T E E R I N G W H E E L 19 39 C O V E R R O C K E R P A N E L 23 17 C O V E R TIMING C H A I N 9 22 C O W L C O V E R 23 15 C R A N K C A S E V E N T I L A T I O N S Y S T E M 25 11 C R A N K C A S E V E N T I L A T I O N S Y S T E M I N S P E C T I O N 25 12 C R A N K S H A F T 9 32 9 44 C R A N K S H A F T D A M P E R 9 37 C R A N K S H A F T E N D P L A Y 9 17 C R A N K S H A F T OIL ...

Page 940: ...MODULE EEM ELECTRONIC POWER DOOR LOCKS 8P 2 ENTRY MODULE EEM ELECTRONIC VEHICLE THEFT SECURITY SYSTEM 8Q 2 ENTRY REMOTE KEYLESS 8P 3 ENTRY TRANSMITTER PROGRAM REMOTE KEYLESS 8P 4 EVACUATING REFRIGERANT SYSTEM 24 17 EVAP CANISTER 25 13 EVAP CANISTER AND LEAK DETECTION PUMP 25 10 EVAP PURGE SOLENOID DUTY CYCLE 25 11 25 13 EVAP PURGE SOLENOID VALVE DUTY CYCLE 14 35 EVAP PURGE SOLENOID PCM OUTPUT 14 2...

Page 941: ...M 14 36 HEATER A C UNIT HOUSING 24 27 HEATER A C UNIT RECONDITION 24 32 HEATER BLOWER MOTOR SWITCH 8E 9 HEATER CONTROL 8E 9 HEATER CONTROL LAMP 8E 9 HEATER CONTROL SWITCH 8E 10 HEATER CORE 24 28 HEATER HOSES 24 29 HEATER PERFORMANCE TEST 24 11 HEIGHT ADJUSTMENT VEHICLE 2 3 HEIGHT ALIGNMENT SPECIFICATIONS WITH VEHICLE AT CURB 2 19 HEIGHT CHECKING AND SETTING CURB 2 3 HEIGHT SETTING DESIGN 2 7 HEIGH...

Page 942: ...I N D E R I G N I T I O N S W I T C H 8D 15 K E Y C Y L I N D E R L O C K 8D 6 K E Y L O C K C Y L I N D E R IGNITION S W I T C H 8D 9 K E Y L E S S E N T R Y R E M O T E 8P 3 K E Y L E S S E N T R Y T R A N S M I T T E R P R O G R A M R E M O T E 8P 4 K N O C K A T L O W S P E E D S 3 3 K N U C K L E 2 61 2 64 2 75 K N U C K L E S T E E R I N G 2 23 2 26 2 38 L A B E L VECI F U E L S Y S T E M 14...

Page 943: ...N T R Y H O R N S 8 G 4 M O D U L E EEM E L E C T R O N I C E N T R Y P O W E R D O O R L O C K S 8P 2 M O D U L E EEM E L E C T R O N I C E N T R Y V E H I C L E T H E F T S E C U R I T Y S Y S T E M 8 Q 2 M O D U L E F A N 7 18 M O D U L E F U E L P U M P 14 3 M O D U L E H E A D L A M P 8L 12 M O D U L E PCM P O W E R T R A I N C O N T R O L 8D 1 8D 9 M O D U L E P O W E R T R A I N C O N T R O...

Page 944: ...R N H O S E 19 15 P O W E R S T E E R I N G G E A R 19 24 P O W E R S T E E R I N G OIL C O O L E R 19 16 P O W E R S T E E R I N G P U M P 19 10 19 17 19 23 P O W E R S T E E R I N G P U M P F A S T E N E R T O R Q U E SPECIFICATIONS 19 22 P O W E R S T E E R I N G P U M P F L O W S P E C I F I C A T I O N S 19 22 P O W E R S T E E R I N G P U M P F L U I D R E S E R V O I R 19 21 P O W E R S T E...

Page 945: ... E C T O R 8 11 R E P A I R T H O M A S A N D B E T T S C O N N E C T O R S T E R M I N A L C O N N E C T O R 8 12 R E Q U I R E D C H A R G I N G TIME 8A 3 R E Q U I R E M E N T S E N G I N E C O O L I N G S Y S T E M 24 3 R E Q U I R E M E N T S F U E L 14 1 R E Q U I R I N G N O L U B R I C A T I O N P A R T S 0 2 R E S E R V O I R B R A K E F L U I D 5 62 R E S E R V O I R P O W E R S T E E R ...

Page 946: ...2 4 S O L E N O I D D U T Y C Y C L E E V A P P U R G E 25 11 25 13 S O L E N O I D R E V E R S E L O C K O U T F U E L S Y S T E M 1 4 2 8 S O L E N O I D R E V E R S E L O C K O U T T R A N S M I S S I O N 2 1 2 S O L E N O I D S K I P S H I F T 21 1 S O L E N O I D T E S T S T A R T E R 8 B 5 S O L E N O I D V A L V E D U T Y C Y C L E E V A P P U R G E 1 4 3 5 S O L E N O I D P C M O U T P U T...

Page 947: ...S Y S T E M D I A G N O S I S C H A R T S S T E E R I N G 19 1 S Y S T E M D I A G N O S I S C H I M E 8U 1 S Y S T E M D I A G N O S I S E X H A U S T 11 3 S Y S T E M D I A G N O S I S R E F R I G E R A N T 24 12 S Y S T E M E N G I N E L U B R I C A T I O N 9 11 S Y S T E M E V A C U A T I N G R E F R I G E R A N T 24 17 S Y S T E M E V A P O R A T I O N C O N T R O L 25 10 S Y S T E M E X H A ...

Page 948: ... Q U A R T E R 23 28 TRIM P A N E L R O A D S T E R Q U A R T E R 23 28 TRIM P A N E L T R U N K 23 40 TRIM P A N E L T R U N K R E A R 23 40 TRIM P A N E L R O A D S T E R B U L K H E A D 23 27 TRIP D E F I N I T I O N 25 8 T R O U B L E C O D E S D I A G N O S T I C 25 2 T R O U B L E S H O O T I N G T E S T S 8 9 T R O U B L E S H O O T I N G T O O L S 8 8 T R O U B L E S H O O T I N G W I R I ...

Page 949: ... I N G A N D P O L I S H I N G 23 2 W H E E L A L I G N M E N T 2 10 W H E E L A L I G N M E N T C H E C K A N D A D J U S T M E N T 2 13 W H E E L A L I G N M E N T I N S P E C T I O N P R E 2 13 W H E E L B A L A N C E TIRE 22 11 W H E E L B E A R I N G N O I S E F R O N T 3 3 W H E E L B L O W E R M O T O R 24 18 24 19 W H E E L C O V E R REAR S T E E R I N G 19 39 W H E E L I N F O R M A T I O...

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Page 951: ...se include page number What topics are hard to locate confusing or not covered completely What comments or suggestions do you have Your Name Dealership Address M a n u a l N a m e Y e a r a n d N u m b e r All comments become property of Chrysler Corporation and may be used without compensation ...

Page 952: ...Fold Here Place Stamp Here Chrysler Corporation CIMS 424 81 55 25999 Lawrence Ave Center Line Ml 48015 Fold Here ...

Page 953: ......

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